Frank | .:R32 HGP460

[WestR32]

Hi all,

Some time ago I posted a quick vid of my new R32, but still didnt make a proper thread. So here goes.

I had my previous R32 from 2008 till 2012. It was a great car (and know it still is for its new owner) but I got used to the power and with just a catback, intake and a remap its not the quickest out there. So Beginning this year I started looking for some more power and took a testdrive in an E46 M3 SMG. Great car and found the power I was missing in the R32 so put my car up for sale. While it was for sale I got news of a somewhat more powerfull R32 and that the owner didnt have it for sale yet but would part with it for the right offer. Needless to say I quickly jumped in the car and drove over to take a look. Few months later and I was the owner of a R32 again but his time with some HGP power!

The specs:
Model - VW Golf MKIV R32 3drs
Year - 2003
Engine - 3200cc V6 24V
Color - Moonlight Blue Pearl Effect

Standard factory options:
Xenon
Climatronic
Rainsensor
6 CD-changer
Sunroof
Heated seats
Headlight washers
Leather armrest
Heated windows
Electric windows and mirrors
Black leather König seats
Volkswagen DSP
Volkswagen Navigation
Automatic dimming rearview mirror

Engine:
HGP 460 Turbo Kit (460PS/630NM)
- HGP R30 Garret Ball Bearing based hybrid turbo
- Custom exhaust housing with integrated wastegate
- Flowbenched Cast Exhaust manifold with external oxygen sensors
- Custom Stainless Steel Heat Shield
- Short runner cast intake manifold
- Head Spacer Plate lowering compression to (8.5:1)
- Uprated Injectors
- Custom Silicone Hoses, Piping, Stainless steel oil lines & brackets
- High flow fuel pump x 2
- Race grade con rod bearings
- HGP software mapping

Gearbox:
- Sachs 4 Paddle Sintered Racing Clutch & Single Mass Flywheel
- Lenghtened O2M Gear Set
- HPA Short Shifter
- HPA Dogbone Mount

Exhaust:
- Custom HGP 70mm downpipe
- Custom 2x 200 cells cats
- Custom 3.5inch exhaustsystem (4 silencers)

Brakes:
- Motul RBF660 Racing Brake Fluid
Front
- Porsche Cayenne 6-piston calipers
- 360mm Audi RS4 drilled discs
Rear
- OEM calipers
- OEM discs

Exterior:
- OEM R-line bra
- Open bumper vents (3x)
- OEM short antenna

Interior:
- OEM full leather König seats
- OEM PoloR lightswitch

Suspension:
- Wiechers steel strutbrace
- OEM Bilstein dampers
- OEM H&R springs
- Audi TT jacking points

Wheels and tires:
- OEM OZ Aristo 18'' ET38 7.5J
225/40/18 Michelin Pilot Sport
- spacers: 5mm front

Audio and Multimedia:
- OEM MFD with cd-changer and VW amplifier/soundsystem

When I bought the car there was a problem with the gearbox. It needed a new clutch and since the car was already standing still for over 1.5years it would also need a big service. The car was also fitted with ugly LSD Doors (Lambo style) so quickly removed those and replaced them with the originals.

Two pics from when I bought it:




The new parts:










Then the fun started. When getting the car up on the bridge we found out that the gearbox needed a bit more work then just a new clutch. Needless to say I was not happy but the previous owner and me made a deal splitting the costs of a new gearbox. Since I needed a new gearbox I also got a lenghtened O2M Gear Set fitted while it was out. The longer gears give it a higher topspeed and a bit more relaxed driving. I can also reach 65mph in 2nd gear now





The new Sachs setup:






In the end it took two months to get the car on the road again but the result is a big grin from ear to ear every time I drive it!

For now I only have some phonepics to share with you and a quick vid I made. Hope you enjoy!

[BOUDAH]

Wellp, u just sold me on that very clutch u have. I was looking into it haha. Car looksgreat!

[vr6fanatic]

[graeme86]

[gmoneyR32]

[Slapbladder]

Wellp, u just sold me on that very clutch u have. I was looking into it haha. Car looksgreat!

Depends how you want the take up to be.... 4 paddle will be very on and off....5 paddle less so and 6 puk even less.

[BOUDAH]

does sachs make a 6 puck? as far as i know they only have the 4 or full faced. frankly im not too worried about it. im more concerned with holding power

[WestR32]

they do make a 6 puck but tbh the 4 is proving to be very driveable. I gave it about 1000kilometers to run in before giving it some power. Ofcourse, it does pick up quite fast but you only notice that when in heavy traffic. The rest of the time I can drive it around without problems.

[jmh2002]

Hello again Frank Pleased to see you have made good progress with the car

[GTItraveler]

Beautiful car Frank! Especially the color

Looks like you're missing one item.........................(see sig)

[jmh2002]

Beautiful car Frank! Especially the color

Looks like you're missing one item.........................(see sig)

Cant be the most beautiful, its not Jazz Blue (runs and hides from the R32 guys...)

However yes, a Unibrace is a definite, worthwhile, and noticeable upgrade and improvement Frank, especially with the added power of a turbo .:R

PM me if you want direct info (or, you already have my email).

And, see this thread for any non believers: http://forums.vwvortex.com/showthrea...r-the-UNIbrace

[WestR32]

Unibrace is a certain upgrade for the future! Already have a strutbrace on the front so want to tighten things up in the rear aswell

[jcstomper]

Wellp, u just sold me on that very clutch u have. I was looking into it haha. Car looksgreat!

what clutch is that? and what power can it hold?

[BOUDAH]

Joe, its the 4 puck that was on that link i sent u. its is rated conservatively at 600 NM which is like 442 FTLBS of TQ. Sachs underrates their clutches, so i dont see it not atleast holding 450 easy.. now thats FT LBS, NOT HP.. im sure HP will be a bit more

I am going to get this one, I just need to see if i can use it with the OEM flywheel so i know it will be compatible with my Singlemass i already have- mainly the 6 bolts it uses etc. if not ill be dishing out the extra coin for the flywheel.

This clutch out the door will cost u 1300 dollars or so as opposed to the 700 for the other Sachs full faced clutch w/o SMF.

SORRy To highjack thread.

[WestR32]

no problem. What you are saying is 100% true. Should hold that amount of torque with ease. Horsepower is not really the killer of our clutches, the torque is so you should be good to go with that clutch

[WestR32]

Little update. Gave the car a polish, went to a car show and put it on a 4wd dyno

Car was running pretty good but the fuel was not optimal so I have to mix it with E85 now to get that sorted. I still have some upgrades planned and want to increase boost to 1.1/1.2bar. Should be at around 500hp and well over 600nm when all of that is sorted

First modification I want to make is the exhaust. 3,5" is fine as far as im concerned but I feel 4 big silencers is a bit overkill. I want to hear that V6 noise some more so next year after wintersleep I will remove a few of those silencers including a special bypass flapper system

[jmh2002]

Hi Frank Great progress!

Power seems to be right around where you should be, although Im a bit surprised to see the torque dropping off so early at only 5000rpm.

Maybe just that exhaust system even though its large diameter, is still quite restrictive with all those mufflers?

The shape of the torque curve looks very similar to the HGP kit when used with an oem R32 exhaust and modified bypass (which is obviously still more restrictive than a proper free flowing system)

And, you have PM

[WestR32]

Well the silencers are free flowing meaning the damping is outside the tubing so it cant interfere with the flow. The cats are 2x 200cells though, maybe thats the problem. Only other causes I can think off are bad fuel on which it was pinging more and more in higher rpms, small turbo (R30) or the fact that its on the normal HGP software when the kit was fitted. I dont have other software for the kit now that I have the 3.5" exhaust.

You think I should call HGP to ask if I have to perform a software update to make more use of the 3.5" exhaust?

[Slapbladder]

Well the silencers are free flowing meaning the damping is outside the tubing so it cant interfere with the flow. The cats are 2x 200cells though, maybe thats the problem. Only other causes I can think off are bad fuel on which it was pinging more and more in higher rpms, small turbo (R30) or the fact that its on the normal HGP software when the kit was fitted. I dont have other software for the kit now that I have the 3.5" exhaust.

You think I should call HGP to ask if I have to perform a software update to make more use of the 3.5" exhaust?

i would say heat soak, turbo and fuelling....you can see it spits some unburnt/rich fuel in before the end of the run which might explain a few things....
Don't worry he is obsessed with exhausts

[Swapped6n]

West! Where are you based ?

maybe we meet up some time or so!

(Mijn R32 is wel snel, maar helaas minder snel dan die van jouw)

Cool videos

[WestR32]

i would say heat soak, turbo and fuelling....you can see it spits some unburnt/rich fuel in before the end of the run which might explain a few things....
Don't worry he is obsessed with exhausts

1. heat soak: Will try look into something I read about a sharan radiator upgrade? Cooler thermostat? Maybe those bigger HPA intercoolers?

2. turbo: Will only replace this R30 when it goes. When it does I will look what option is best for me at that time, HGP R35 or 2x HGP R28

3. fueling: Already sorted now. Was running on RON98 and by mixing in some ethanol I now run on RON100 ish.

Thanks for those pointers Slap, these type of posts really help me to get this beast running like it should

[WestR32]

West! Where are you based ?

maybe we meet up some time or so!

(Mijn R32 is wel snel, maar helaas minder snel dan die van jouw)

Cool videos

I live near Rotterdam. Sounds great to meet up. I have contact with lots of R32 owners in the Netherlands and I am looking to organise a .:R-models only meet somewhere in 2013. Would be great to have you there aswell

[jmh2002]

Frank, I only mentioned the exhaust because of your continued concerns about it which you have mentioned to me by PM and email.

If you are confident there is no problem there, then yes you need to look at other things, which yes could include, fueling, timing pull, tune, etc (which are all kind of inter-related)

I dont think its because of the smaller turbo (unless its damaged). You can see on my dyno pull (on standard 98 euro pump fuel - no E85) with the exact same turbo as yours, I dont start losing torque until after 6000rpm.

Also, do you have the page from the Dyno showing boost vs rpm? Any abnormalities there?

[WestR32]

Frank, I only mentioned the exhaust because of your continued concerns about it which you have mentioned to me by PM and email.

If you are confident there is no problem there, then yes you need to look at other things, which yes could include, fueling, timing pull, tune, etc (which are all kind of inter-related)

Its not because its a smaller turbo (unless its damaged). You can see on my dyno pull (on standard 98 euro pump fuel) with the same turbo as yours, I dont start losing torque until after 6000rpm.

Also, do you have the page from the Dyno showing boost vs rpm? Any abnormalities there?

Thanks. As far as tested, the turbo is still strong. No problems there that I know off.

Dont have a boost vs rpm graph. They were not able to record that at the time of rolling. Maybe in the future I can get a new reading done at a different rolling road. Will invest in a boost gauge aswell since at this moment I have no clue what sort of boost im at

[WestR32]

Right, lets give this thread a little update now. A while ago I bought a set of H&R 20mm spacers for the rear axle. I like it for now though I might even go for 25mm's when I lowered the car.

As for the lowering, since the car is still on stock R32 suspension, I was looking on upgrading it. My eyes fell on a nice set from Bilstein. So today I bought some Bilstein B16 PSS9's.



A while back I also found out the tires were becoming slicks so tomorrow I have 4 new 'Michelin Pilot Sport 3' tires fitted allong with a new allignment because that still hadnt been done since the subframe was removed to fit the new gearbox

While all that helps handling, I wanted to hear my car a bit more aswell. Currently I have a 3,5" exhaust fitted with 4 silencers. At the moment I am still waiting for the valves from Germany but I already have the parts now to extend the vacuumsystem at the rear of the car.

At the moment I have 2 silencers on the midpipe and 2 silencers as the rearbox. In the new setup I will have a single midpipe silencer and a single larger rearbox silencer with a dual bypass system to go around the rear silencer. So when open, the car will have 1 instead of 4 silencers

The exhaust will behave like OEM where the flaps will open at around 3000rpm to calm it down when cruising but to roar when having fun with the car. To control the flaps I will also install something called "MFA XP" so I can put them on stock mode or always open mode. The MFA module will also have the advantage of being able to watch oil temps, boost etc etc etc





Coming winter I will look into upgrading my rear brakes to 312mm rotors and I will purchase an external oilcooler.

[Jonnymooshoo]

Car looks brilliant!

[Skela]

Great thread. Love the videos and all the pics. Half the fun of owning these cars is modding them, and you seem to be having a lot of fun!

[WestR32]

Sure am Brett. Thanks again for the help regarding the vacuumline. I got it figured out so soon I can route the vacuumline for the other side of the exhaust over the heatshield like you explained to me on R32oc

[AustinVaughan]

nice setup

[itouch]

Nice build and beautiful car. You have pm.

[GinsterDub]

Great progress and looking/sounding R!

[WestR32]

Today I removed the tacho-unit to send it to Germany for the adjustments in the scales and HGP logo, I installed the bright side indicators in the front wings because I had basic VW Golf ones untill now, installed the aero rear wiper, placed the custom HGP logo in the front grill, placed the carbon OZ hubcaps and tried to install the USA rear lights. Installing the rear lights didnt work out today since I didnt have the proper tools with me but I will go back to the car soon to finish the job

Also I have a Porsche 'turbo' emblem to go on the rear of the car but for that I need to degrease it first so I will fit that badge in the spring when I have picked up the car from storage.

Quick pic from a dirty car (went out for a drive previous time and didnt have a chance to properly clean it after )





The to-do list for coming spring:
- Bilstein PSS9 (installing)
- Gruvenparts adjustable tie-arms (installing)
- strutbrace behind the rear seat (installing)
- USA rear lights (installing)
- Porsche turbo logo (installing)
- HGP tacho (installing)
- small/big service
- 360mm brakediscs front axle replacing
- 312mm brakediscs upgrade rear axle
- painting rear calipers red to match the front
- LED numberplate lights (installing)
- LED sidelights (installing)
- adjusting undertray for more airflow under the engine
- adjusting airfilterbox
- adjusting exhaustsystem
- polishing and waxing the entire beast

[vr6fanatic]

Great setup Frank! You prefer Our tail lights vs European? It's nice to see our fellow R brothers from across the pond! Keep us posted as well with your R32 get together!

[WestR32]

haha yeah I like the USA ones more then the euro ones. Maybe in time I will swap the euro ones in again but all golf here drive with the euro ones, even the 1.4L's haha

[c0peXXX]

I read you put a lengthened gear set? Which gearing did you go with? I'm guessing finals and a diff case and ring from a TDI but which gear box were they sourced from (ERR, EHF, FRZ etc..)? Teeth count (ie.. 62/16/20)?

Great looking car