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    Thread: ToeBall's R Build Thread (Scalawag)

    1. Member
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      05-29-2012 06:54 PM #1
      Welcome to my build thread. This is my R. There are, well, not many, but a few like it, but this one is mine. Ok, done channeling Stanley Kubrick, I swear.

      I've done some of the OEM+ type mods, such as LED tails, but enough people have done those that there's plenty of info on it. Instead, I'll cover some of the more unique stuff.


      _MG_1291 by Toe_Ball, on Flickr

      So far my mods include:


      Upcoming mods include:
      • OEM aluminum glove box handle
      • OEM Rain and Light Sensor with Anti-Dazzle Rear-View Mirror
      • H2Sport Rear Bearing Kit
      • H2Sport Fuel Pump Drive Upgrade
      • STaSIS 370mm Mono4 front brake kit
      • Racing Brake rear rotors
      • StopTech Street Performance rear brake pads
      • PODI TrueColor Match Gauges
      • Bluewater Performance Valve Cover
      • JE 9.5:1 pistons, ceramic top, teflon skirt coatings, 20mm wrist pins
      • Integrated Engineering Tuscan 144x20 connecting rods
      • Integrated Engineering Block Girdle and Balance Shaft Delete Kit
      • DLI Teknik Motor Mounts
      • Innovate Motorsports OT-2 Data Logger
      • HEP Stage 1 Intake with Direct Port Meth Nozzles
      • USP Low Pressure Fuel Pump Module
      • Fluidamper
      • RS4 Injectors
      • INA External Oil Cooler
        [*}CAT Stage 2 camshafts
      • INA 70mm MED9/17 Throttle Body
      • SSP Port and Polish head job
      • Eurodyne Boost Manager Plus+ Boost and Water Methanol Injection Controller
      • Graf Brass Impeller Water Pump
      • Precision Turbo 5830
      • HPA 4-piston rear brake kit


      DieselGeek skid plate removed from the list of modification because of clearance issues with transmission cooling duct. Ground Control camber plates removed because they can't be safely used with the Eibach coilovers, replaced with a custom pair of camber plates from Vorshlag Engineering.


      _MG_7858 by Toe_Ball, on Flickr
      Last edited by ToeBall; 06-07-2013 at 10:46 AM.

    2. Member hussdog426's Avatar
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      05-29-2012 07:35 PM #2
      Quote Originally Posted by johnnyR32 View Post
      IMO the best place for mounting a euro plate is in the trash.

    3. Member GTI Fanboy's Avatar
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      05-29-2012 07:42 PM #3
      Looking good! Great start to a build.

    4. Member pierovw's Avatar
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      05-29-2012 07:44 PM #4
      I want to see your car in person

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      05-29-2012 07:53 PM #5


      So whats in the APR box?

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      05-29-2012 08:19 PM #6
      I picked my car up at the Port of Houston.


      _MG_1134 by Toe_Ball, on Flickr


      _MG_1133 by Toe_Ball, on Flickr


      _MG_1136 by Toe_Ball, on Flickr

      Pretty much the first mod I did was an AWE intake and a Neuspeed engine cover. And of course, a Diesel Geek Sigma-6 short shift kit.


      _MG_1300 by Toe_Ball, on Flickr

      It took a fair bit of dissassembly of the engine compartment to get to where I could install everything.


      _MG_1302 by Toe_Ball, on Flickr

      _MG_1305 by Toe_Ball, on Flickr

      _MG_1307 by Toe_Ball, on Flickr

      The first thing to install was the heat shield from the AWE intake along with the holding strap.

      _MG_1309 by Toe_Ball, on Flickr

      I could also install the Sigma-6 and adjust it.

      _MG_1310 by Toe_Ball, on Flickr

      Next the battery tray, battery, and intake tube could all go in.

      _MG_1311 by Toe_Ball, on Flickr

      Followed by the bottom of the airbox and the rest of the intake plumbing.

      _MG_1312 by Toe_Ball, on Flickr

      At this point, I noticed that they also provided a very nice machined bracket instead of the cheaper looking one.

      _MG_1315 by Toe_Ball, on Flickr

      Finally fitted the engine cover and airbox lid.

      _MG_1314 by Toe_Ball, on Flickr

      And the parts I didn't reinstall.

      _MG_1317 by Toe_Ball, on Flickr
      Last edited by ToeBall; 05-29-2012 at 08:23 PM.

    7. Member
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      05-29-2012 08:21 PM #7
      Next up, Milltek exhaust.

      _MG_1351 by Toe_Ball, on Flickr

      Sorry, didn't stop for photos, was a pain to install, especially the downpipe. The drive-shaft has to come out to get everything in. At least it sounds good when done.


    8. Member
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      05-29-2012 08:24 PM #8
      Since I was under the car anyway, I added a Unibrace UB.


      _MG_1394 by Toe_Ball, on Flickr

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      05-29-2012 08:30 PM #9
      Since this is the older FSI engine, a catch can was in order. I went with the 42 Draft Designs Ultimate can. I adapted the provided bracket to fit it behind the right headlight. For plumbing, instead of using the provided hoses, which would never fit with the Neuspeed cover, I picked up a couple of 90 degree heater hoses from NAPA (9820) as well as a 90-degree heater hose connector. I took the can apart and rotated the top relative to the base. This allows me to have the inlet on one side and the outlet on the other. The inlet pipe runs down through the intake manifold runners and then connects using the 90 degree connector and a straight piece to the can. The return line runs under the engine cover brackets and under the fuel lines for the engine.


      _MG_1945 by Toe_Ball, on Flickr


      _MG_1943 by Toe_Ball, on Flickr

      I still haven't routed the drain hose. I'll do that when I need to drain the can or for the next oil change.
      Last edited by ToeBall; 02-25-2013 at 06:24 PM.

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      05-29-2012 08:33 PM #10
      Are you running VTA on your bpv after removing the recirc tubing?

    11. Member
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      05-29-2012 08:36 PM #11
      Quote Originally Posted by endrswrd View Post
      Are you running VTA on your bpv after removing the recirc tubing?
      Yes. The AWE kit provides a small filter for the N75 outlet. There's no real change in lag and no CEL.

    12. Member 1.8turboB5's Avatar
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      05-29-2012 09:05 PM #12
      i was looking at the unibrace. let me know how you feel about it if you have driven it since the install yet.
      2013 CW Golf [R] 4dr / GIAC Stage 1 93oct / Evolution Motorsport CAI / B&G Coilovers / 18x8 et41 Polished Interlagos

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      05-29-2012 09:16 PM #13
      You Aint About That Life | ETYolo

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      05-29-2012 09:28 PM #14
      Exhaust sounds great

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      05-29-2012 10:25 PM #15
      Quote Originally Posted by 1.8turboB5 View Post
      i was looking at the unibrace. let me know how you feel about it if you have driven it since the install yet.
      Can't really tell the difference. I didn't exactly push the car very much pre-install, nor since, yet. Supposedly the XB makes a big difference while the UB less so.

      Quote Originally Posted by slidemx5 View Post
      Exhaust sounds great
      Thanks. I'm pretty happy with it, though I'm planning a variation of the flapper mod to allow me to shut it up on demand.

      Since I'm already replying, I'll move some stuff down here.


      _MG_1948 by Toe_Ball, on Flickr

      The next batch of mods is:
      • APR Intercooler
      • Racing Brake rotors, front and rear
      • StopTech Street Performance brake pads
      • Unibrace XB
      • Eibach Multi-Pro R2 coilovers
      • Ground Control camber plates
      • Soundaktor delete
      Last edited by ToeBall; 05-29-2012 at 10:29 PM.

    16. Junior Member
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      05-29-2012 10:55 PM #16
      Awesome job so far, can't wait to hear how the rest of install goes. We have the UB and XB on the way, should be hear tomorrow. Was wondering if you had any issues with the front heat shields as they protrude around the front mounting bolts. Did you cut them, bend them, or just bolt the UB right over the heat shield extensions?

      How do you like the intake, and is that a regular paper cone filter? Does it seal up with the front end air intake of the grill?

      Killer job on the catch can install. Looks much better than the double hoses coming out from under the engine cover. Those 90 degree heater hoses were brilliant. Maybe 42DD will update their kit to reflect some of your work, since follows the spirit and design philosophy of how the build things.

      If ever in Dallas, wouldn't mind seeing your car and comparing how each drives.

    17. Member
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      05-29-2012 11:14 PM #17
      Quote Originally Posted by takmanR View Post
      Awesome job so far, can't wait to hear how the rest of install goes. We have the UB and XB on the way, should be hear tomorrow. Was wondering if you had any issues with the front heat shields as they protrude around the front mounting bolts. Did you cut them, bend them, or just bolt the UB right over the heat shield extensions?
      Thanks. I tried to just bolt the UB on first, but there wasn't enough stud sticking out for the nuts to catch thread so I trimmed the shield around the studs with some sheet metal sheers.

      How do you like the intake, and is that a regular paper cone filter? Does it seal up with the front end air intake of the grill?
      The intake's ok. I like the sound. It's not paper, it's some waxy coating. There's a foam rubber seal on the front of the airbox but it doesn't really seal on the front of the car. It's still significantly better than the open scoop thing of the stock snorkel though, and I'm ok with it.

      Killer job on the catch can install. Looks much better than the double hoses coming out from under the engine cover. Those 90 degree heater hoses were brilliant. Maybe 42DD will update their kit to reflect some of your work, since follows the spirit and design philosophy of how the build things.
      Yeah, the hoses and stuff were about $50 at NAPA. I can't see them adding that much to the price of the kit. 42DD does sell 90 degree fittings and stuff.

      If ever in Dallas, wouldn't mind seeing your car and comparing how each drives.
      Definitely. Or if you make it out to Houston, lemme know. We can go grab a beer. I'm sure TLud would be up for it too.

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      05-30-2012 12:04 AM #18
      cant wait to see your review on the coils....see you got the rotors

    19. Member Icer Jo's Avatar
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      05-30-2012 02:50 AM #19
      Looking forward to seeing Scalawag in person once done

      Sent from my SGS2 E4GT

    20. Member
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      05-30-2012 07:41 AM #20
      Quote Originally Posted by 1stmsig View Post
      cant wait to see your review on the coils....see you got the rotors
      Yeah. Thanks for that. USPS marked them as delivered on the 25th but didn't actually drop them off until the 29th. I was going nuts trying to figure out where they could have been. LOL

      Quote Originally Posted by Icer Jo View Post
      Looking forward to seeing Scalawag in person once done
      Can't wait to see what you do with yours either. You coming to the EAG meet on Friday?

    21. 05-30-2012 07:58 AM #21
      Nice build thread! Some pretty nice modifications so far.

    22. Member nectar13's Avatar
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      05-30-2012 12:09 PM #22
      i like what you are doing with your car.

      looking forward to a review of the coils.

    23. Member mikeh6's Avatar
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      05-30-2012 02:42 PM #23
      nice build so far

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      05-30-2012 06:33 PM #24
      The Ground Control camber plates do not fit the Eibachs. Talked some with Ground Control about this and they made them more generic (basically to fit Koni), but since these coilovers are quite a bit beefier, the plates don't fit. They asked for a couple of photos so I went ahead and put a micrometer to the shock shafts.


      Untitled by Toe_Ball, on Flickr

      7/8" diameter on the shock shaft


      Untitled by Toe_Ball, on Flickr

      14mm thread

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      05-30-2012 06:52 PM #25
      That sucks about the camber plates.

      You already know I'm a big fan of your car and what you have done/will do to it. We need to meet up again soon for pictures and updates.
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      05-30-2012 10:32 PM #26
      Thanks all for the kind words. I'm really enjoying researching, spec'ing and wrenching on the car. A lot of that research comes from everyone here, so in addition to the kind words, I'd also like to thank everyone for the help. You make a great knowledge base on which I depend.

      Quote Originally Posted by TLud View Post
      That sucks about the camber plates.

      You already know I'm a big fan of your car and what you have done/will do to it. We need to meet up again soon for pictures and updates.
      That's funny. I actually consider your car one of my favorite builds. I mean Teff's car is awesome, but a bit over the top. Yours is a great blend of enhancing the car without sacrificing it's nature. I've borrowed a few of your ideas on my build as well, and I'm seriously considering some of your points on wheel weight and cost/benefit. I'll be at the EAG meet and C&C. Let me know if you're going to either.

    27. Member Icer Jo's Avatar
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      05-30-2012 10:51 PM #27
      I'll be in Dallas :/ though I'll try to attend next months

      Sent from my SGS2 E4GT

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      05-31-2012 01:19 AM #28
      Thanks for the tips in your reply. We just got our UB and XB today. Nice quality parts. Now have to find the time to put them on. Hope all goes well as you get the rest of your parts on the car. We'll have to get together some day for that beer.

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      05-31-2012 08:00 PM #29
      Quote Originally Posted by ToeBall View Post
      Thanks all for the kind words. I'm really enjoying researching, spec'ing and wrenching on the car. A lot of that research comes from everyone here, so in addition to the kind words, I'd also like to thank everyone for the help. You make a great knowledge base on which I depend.



      That's funny. I actually consider your car one of my favorite builds. I mean Teff's car is awesome, but a bit over the top. Yours is a great blend of enhancing the car without sacrificing it's nature. I've borrowed a few of your ideas on my build as well, and I'm seriously considering some of your points on wheel weight and cost/benefit. I'll be at the EAG meet and C&C. Let me know if you're going to either.
      You're too kind.

      Depending on what you're looking for in terms of style and size, there are definitely some nice wheel options out there that will save a substantial amount of weight and make a noticeable difference withoutgoing overboard like I did. I got the new brake setup installed today. It made a noticeable difference - not as major as the wheels did, but noticeable.

      I won't be able to make it to C&C. I may make it to the EAG meet...
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      06-01-2012 08:54 AM #30
      Quote Originally Posted by TLud View Post
      You're too kind.

      Depending on what you're looking for in terms of style and size, there are definitely some nice wheel options out there that will save a substantial amount of weight and make a noticeable difference withoutgoing overboard like I did. I got the new brake setup installed today. It made a noticeable difference - not as major as the wheels did, but noticeable.

      I won't be able to make it to C&C. I may make it to the EAG meet...
      LOL, hardly. I just really appreciate a good build, and yours is well reasoned out and well executed.

      To be honest, as far as wheels go, I've more or less fallen in love with the OZ Superforgiata 5 Fori. It's very slender, has very good lines, and being 16 lbs in a 19x8.5 doesn't hurt either. As an added bonus, since it's an ET48 wheel, I don't have to mess around with shaving mounting flanges to get 245's to fit. Course the downside is I'd be paying HRE money for an OZ wheel.



      Anyway, as an update, which is the real reason I was posting. I got all the measurements to Ground Control yesterday (they were a bit slow sending me what dimensions they were looking for) and they're pretty sure they'll have all the parts to convert my plates over in the mail today. They told me to expect them on Tuesday. Very cool, if it works out. Then I get to take apart a car with not much over 3k miles on the clock.

    31. Member
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      06-01-2012 04:58 PM #31
      So got off the phone with Ground Control. Based on the dimensions I sent and them getting in touch with Eibach directly, there's no way the plates will work with the coilovers. They're sending me a call tag and I'll ship them back on Monday. I'm researching other options now. A call to APR turned up that the VWR camber plates only work with VWR coilovers. Next call will be to Vorshlag Motorsports. These guys do quite a bit of custom stuff so maybe.

    32. Member
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      06-03-2012 09:56 PM #32
      I spent a good deal of time outside today working on the R. I used this DIY as a reference http://www.golfmk6.com/forums/showthread.php?t=8956. For clarification, the screws that hold the intercooler's side mounts are on the front face. I also wound up taking apart a bit more of the car than was needed, strictly speaking, but the end result is still the same. I've got the APR intercooler in.


      _MG_2042 by Toe_Ball, on Flickr

      I went for a drive after the install. There is definitely less lag, more sound, and a bit better throttle response. There doesn't seem to be more power, but I didn't expect there to be until the car gets tuned. It's now ready for a 2+, however.

    33. Member GTI Fanboy's Avatar
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      06-03-2012 10:53 PM #33
      Welcome to the club, love my APR Intercooler.

    34. Member
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      06-06-2012 08:50 PM #34
      So now that I've got all my parts in, time to put them to work making more power. I've spent several hours over the last couple of days working with South Side Performance to come up with a custom tuning option for the R. Most of the out of the box tunes on the market are conservative out of necessity because they need to be able to cover a large range of parts, climates, and so on.

      The solution we worked out was Eurodyne Maestro 7 software. They became a dealer and my car is going to be the first production implementation on a car (they did beta code on one R already so the flashing ability is proven). The car will be flashed, hopefully in the next couple of days, with their level 2.5 maps (about the same as everyone's 2+ tune) even though I'm buying the level 3 license (this paves the way for a future big turbo build if I decided to ever go that route), and immediately allows for a full on dyno tune. A good dyno tune should be able to show a significant improvement over out of the box tunes. As an added bonus, they're pretty confidant of being able to allow ESP disable and getting rid of the speed limiter, plus a few other bells and whistles.

      The first step needed in this process was done today. A full dump of my stock ECU. This is needed to validate that the ECU in my car is fully identical with the ECU of the beta R. The part numbers match, but I'm glad they're being so through. Speaks well for the shop. The dump was emailed back to Eurodyne and as soon as they give the go ahead, my car goes in for the initial flash. After that, when we're sure everything went perfectly, we'll set up an appointment for my car to spend half a day or so on a Mustang dyno taking pulls and getting tweaked to functional perfection. Graphs to follow.
      Last edited by ToeBall; 06-06-2012 at 08:55 PM.

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      06-07-2012 10:31 PM #35
      Well, the new software is in. Basically, my car is now at "Stage 2.5" which is 2+ for everyone else. This is actually just a base map, and, like any other canned tune is very conservative. It's about on par with the Unitronic tune but is already a night and day difference from pre-tuned. Basically, I get to drive around on this tune for a few days and see what I do and don't like about it, and then the car gets to go on the rollers and get the custom tune done. The Eurodyne base map is pretty solid, but SSP really has no interest in just flashing these onto the computers. They really want to put the engine through its paces and deliver a finely tuned product. Which is good, since I fully expect to pull out another 30-40 hp over where it is now. Video and dyno charts to follow as soon as the car gets to play on the Mustang dyno.

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