APR Presents The BFGoodrich MaxR! -- Build Thread --

[Arin@APR]

Those intake flap deletes are pure genius!

Thank you. Our engineers made them quite some time ago and we've tested them on several projects and I've even sent some to a few of my customers. We'll work these into the catalog.

[jsausley]

Watching that Centroid video is like watching machine porn.

[Arin@APR]

Here are the ports in our CAD software.

[nectar13]

We got a completely pre production FSI engine and drivetrain in 2003.

touche' sir






digging the CAD shots.

[Resolute]

More than half a decade ago we began working with the basic 2.0T engine found within the new Golf R. There were updates along the way, but some of the basics still hold true. One of the biggest restrictions we found was in the design of the head and intake manifold. The new 2.0 TSI engine found in the Golf MK6 has a great improvement in both of these areas. Firstly, the intake manifold's runner flaps lay flat and out of the way, only leaving the port dividers as a restriction. Secondly, the entire head flows better. This results in less of a restriction meaning higher air flow levels at lower boost pressures. Intake air temperature is lower and ignition advance is far better which is absolutely critical for making big power.

The solution was simple, an APR high flow head for the FSI. Experimentation at APR was on going for years testing different porting options and testing the results. Earlier this year we purchased a Centroid 5 axis Head Porting Machine that allows our engineering team to recreate identically ported heads each and every time we load one onto the machine.

The machine can move the head around the cutting blade to increase the size of the ports as quickly as possible. It's cut down on development time significantly. Currently APR uses CFD software to test the port design and ultimately testing will take place on our super flow engine dyno and super flow flow bench.

Here are a few shots of the finished product. You'll notice the ports are smooth all the way around with no transition points where the port dividers once sat. After years of testing "upgraded" valve trains, off the shelf upgraded camshafts, and our own grinds, we've opted to stick with the stock hardware.

Next up is the factory intake manifold. As mentioned before the manifold has port flaps which sit directly in the center, blocking airflow. They are extremely restrictive. Proper removal of the flaps is a bit tricky as you're left with holes between the ports so APR's Engineers made intake manifold runner flap deletes to take care of that issue!

Will APR market this head work and tumbler/flap delete, or is this all a one-off for the project car? I think you'd have serious interest for this work.

Also, the Al LCA with offset bushing and reduced anti-lift/dive mount, the one sourced from your partners in Australia, please tell us this will also come to market. Cast iron LCAs on the R is absurd. A package with everything necessary for TT-RS spindles would be nice, too, and would probably be a good seller considering the shear mass we could dump off the front suspension with such a conversion.

Will

[styling5030]

the LCA from superpro australia

http://www.superpro.com.au/supaloy-vag-vw-alloy-arm

[Arin@APR]

Will APR market this head work and tumbler/flap delete, or is this all a one-off for the project car? I think you'd have serious interest for this work.

Yes. We've tested head porting for years now and with the purchase of the new machine are getting close to releasing a tried and true product. There's still some work to be done on our part, including a few other features we'd like to offer before this becomes a product we sell to the public.

Also, the Al LCA with offset bushing and reduced anti-lift/dive mount, the one sourced from your partners in Australia, please tell us this will also come to market. Cast iron LCAs on the R is absurd. A package with everything necessary for TT-RS spindles would be nice, too, and would probably be a good seller considering the shear mass we could dump off the front suspension with such a conversion.

This is another thing we would like to look into as well.

I think you'll see several nice new products coming from this build.

[Arin@APR]

No engine build would be complete without upgrading the factory rods and pistons. The rod design on the new Golf R and MK6 GTI TSI are much stronger than those found in the original MK5 GTI 2.0T FSI, however they still represent a weak point in the build.

Stock Rods and Pistons:





When going beyond Stage 3 pump fuel power levels, we suggest upgrading the rods. We are currently in development of a new rod design that will have several desirable features we're not seeing in development today. When the time comes, Max will be torn down and upgraded once again, but for now we are using an solution we've used in the past.

Strengthened Rods (Upgraded Rod Bearings not Shown):


With big power goals planed for the future, we've also taken this opportunity to upgrade the pistons with a solution we've used in the past. These pistons don't alter the stock compression ratio found int he Golf R. We've tested different compression ratios in the past, but found the stock compression ratio worked well, so that's what the MaxR will utilize.The pistons are also coated with a heat resistant material that's said to protect against knock however some are skeptical of these claims and analysis on our engine dyno will take place in the future. We are also in the process of testing a new piston design on other internal builds and we plan to test the results against these pistons in the future.

Coated Pistons, Rings and wrist pins:





Installed!



Another item to add to the list of modifications is the APR Balance Shaft Delete. This frees up some of the rotating mass to gain a few more HP and since every bit counts, this is a welcomed addition to the build. We've also seen quite a few of these fail in racing applications, so we've tested their removal with years of continued success.




Also, in the process of upgrading the internals, the entire rotating assembly is balanced to ensure smooth operation for years to come. Here's the crank shaft with material removed for balancing.





And part of our build includes cleaning and honing the original block as well as painting it with our trademark red color. It's all starting to come together nicely!

[BlackRabbit34]

<3

[BlackRabbit34]

I am in love.

[peruski]

Pacing back and forth with hands on hips... Mind blown.

Gotta walk this off.

[BRSomm]

Oh for an unlimited budget. And all in the name of research!

[zbeasty]

Arin

I noticed that the new pistons don't have a dish like the factory ones. Does that mean they also have a shorter pin to crown height to keep the factory CR or have you enlarged the combustion chamber?

[cloors]

We got a completely pre production FSI engine and drivetrain in 2003.

Jeez, you guys really are hooked up.

[Arin@APR]

The BFGoodrich MaxR is at SOWO this weekend. Here's a sneak peek of some testing we did on the BFGoodrich Tires G-Force Sport Comp 2s.

[TLud]

That AWOLnation song is so played out, but that video is still so bad@$$. I wish I could see the beast in action in person.

[droopy1592]

The BFGoodrich MaxR is at SOWO this weekend. Here's a sneak peek of some testing we did on the BFGoodrich Tires G-Force Sport Comp 2s.

Which method did you guys use for esc defeat? That R gets a bit loose

[batman25]

Are the GTI lighst a direct bolt-on?

[kevin160]

This must be what interns are for at APR. They get hands on experience when they lay out all the parts for the build thread picture. lol

[eurolife]

This must be what interns are for at APR. They get hands on experience when they lay out all the parts for the build thread picture. lol

I'd love an internship at APR..

[jsausley]

The BFGoodrich MaxR is at SOWO this weekend. Here's a sneak peek of some testing we did on the BFGoodrich Tires G-Force Sport Comp 2s.

video

WOW!!!

That was amazing. In what state of tune was the R in this video? The pictures we've been getting have been of the car all apart and bits at a time but here, suddenly, it's all back together and screaming around a track beautifully! Also... wow, it sounds amazing. I assume you're using the RSC exhaust?

[RBGolfR]

WOW!

[webcrawlr]

Looking good and sounding mean!

[BigmountainVMD]

I never thought you could film a car on a track like a snowboarder on a mountain... When they add the water all I could think of was big powder slashes after a few feet of snow.

Very cool.

[Arin@APR]

WOW!!!

That was amazing. In what state of tune was the R in this video? The pictures we've been getting have been of the car all apart and bits at a time but here, suddenly, it's all back together and screaming around a track beautifully! Also... wow, it sounds amazing. I assume you're using the RSC exhaust?

One evening of late night tuning before the car was shipped up north for testing at the LPG.

We're not finished yet.

[ToeBall]

That AWOLnation song is so played out, but that video is still so bad@$$. I wish I could see the beast in action in person.

I did see it today. Will snap some photos tomorrow.

Are the GTI lighst a direct bolt-on?

They're not OEM lights, and looking at the harness, they're not a direct bolt on.

[brandonekingatl]

This car is as hot sitting still in person as it is in this video! Seeing the exhaust tips alone gave me partial wood. What are the wheels this thing is sporting? The red barrels on them were sick!!

[2xtrms]

Is the exhaust on this car the same thats avail for purchase, it sounds so much meaner than the video put out by apr for the turbo back

[ToeBall]

Snapped a few detail shots today. As an added bonus, some random guy in a BFGoodrich shirts walked up and stared talking to me... turned out to be one of the drivers from the video. Very cool.


_MG_1849 by Toe_Ball, on Flickr

_MG_1850 by Toe_Ball, on Flickr

_MG_1851 by Toe_Ball, on Flickr

_MG_1853 by Toe_Ball, on Flickr

_MG_1854 by Toe_Ball, on Flickr

By the looks of the parts of the harness I could see, it took a fair bit of work to make the aftermarket headlights work. They adapted the bi-xenon to halogen for the connectors, and added the DRL signal back in from the LED circuit. I couldn't be sure, but I think they added aftermarket HID to the projector housing as well, though I didn't see any ballasts.

[BigmountainVMD]

Any info on that intake? Prototype Carbonio?

[BlackRabbit34]

Any info on that intake? Prototype Carbonio?

I think it's going to be part of the stage 3/4 kit they will be releasing for the R late summer. Count me in though

[.:RTime]

Only has 444hp......

[BigmountainVMD]

I think it's going to be part of the stage 3/4 kit they will be releasing for the R late summer. Count me in though

Yeah, I was wondering why the VWR intake was not part of the build...

[BlackRabbit34]

Yeah, I was wondering why the VWR intake was not part of the build...

Probably doesn't pull enough air, and is also designed for the stock turbo so an extra adapter would be needed.

[JedTI]

Only has 444hp......

Yeah, but from the sound of it the car is meant to be a daily driver or atleast not a track car. Either way its a very "useable" 444hp, which I think alot of R drivers are interested in. I'm sure if they wanted to pull more hp from this engine they could.