st.:Reet project - just another 550+ hp R32

[zlos]

So I've sold my mk6 R20 and stepped back into a juicy .:R32 world

Here are some details:

MY2009 Mk5 VW Golf R32 DSG
Motorsport Seats
RNS 510
Blue Shadow



Engine:

3,2 VR6 24V BUB

Air intake

-Intercooler Precision
-Alu pipes
-DV Stock 710N

Exhaust:

-Turbo Borg Warner S200G TwinScroll
-Wastegate Tial
-complete exhaust, full 3,25" MG Mtorsport

Fuel system:

- 6x Bosch 550cc EV14
- Bosch 044 fuel pump

Electronics:

1. Motronic ME7.1.1 ST10 programmed by CompSport.pl
- left foot braking
- no rear lambdas
- no SAI
- no EVAP
- bigger MAFu calibration

2. Factory DSG Temic CompSport
- Launch Control at 4100rpm
- shortened gear shifts
- manual - no kickdown
- manual - possible driving at max rpms
- gear change depending on the gearbox mode (D/S/M) between 6500-7000rpm

3. Numbers
- Defi (Boost,EGT)
- E-MFA Kufatec

4. Turbo intelligence: HKS EVC ver. 6

Drivetrain:

- 6g DSG
- stronger clutches 7-pieces (650Nm)
- Haldex Performance with radio controller (stock,Sport,Race)

Suspension:
- lowered 20mm's
- Bilstein B16 PSS10 Kit
- front brakes Forge 6 pistons, 356/32mm, EBC YellowStuff

Others:
- Rear camera from Golf Mk6
- Phone BT connection
- Ultraleggera 18x8, Contisport 5 225/40/R18


TO BE DONE:
- stronger rear brakes (I've heard Forge's gonna release rear brakes set for mk5 R32)
- some misterious changes withing the engine, still trying to pack more power

Results with old turbo setup:


Results with new setup:


Woerthersee 2012:





A bit of fire:


A bit of noise





Project's running thanks to Pat & Simon from CompSport.pl (thumbs up!). And my dearest wife, who is not following my bank account status

Hope to see you on the Woethersee 2013 and grab a beer

[rhcp4life]

[sjparker]

nice

love the seats, love the color

[Swapped6n]

Very cool

[JC@DouglasVW]

This is an awesome pic

[SKYdude]

Very nice and very fast!

[abeR]

"stepped bank" indeed!

[tWiStEd-tORqUe]

😭 nice R32


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[skaven-R32]

Welcome! Not much left to do on that beast.

[Uncle Wiggley]

😭 nice R32


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X2

[zevion]

Awesome. R32T's taking over the world!!

[r32grrl]

sick

[KurtCav]

that color.

no engine pics?

[BetaOp9]

Glorious!

[mk5_R32#3828]

hopefully someday mine will be that fast

[batman25]

I'm going to need to see a race....

[Stylist07]

Drivetrain:

- 6g DSG
- stronger clutches 7-pieces (650Nm)

Where did u get these better Clutches from??????

I thought no body made better and bigger clutches for the R32????

[zlos]

no engine pics?

I am still working on engine bay look. Last months I was focused more on mechanics & parameters that a look. Give me some weeks to clean it up

"stepped bank" indeed!

Oooops

Drivetrain:

- 6g DSG
- stronger clutches 7-pieces (650Nm)

Where did u get these better Clutches from??????

I thought no body made better and bigger clutches for the R32????

The 650Nm clutches are on the market for some time already. In Poland www.compsport.pl distributes them. as far as I know you can get them from a canadian company: http://www.hpamotorsport.com/contact.htm as well.

[kidplatinum]

180mph and some change, pretty impressive...did not take all day either.

[zlos]

How it sounds from the outside - old exhaust set up (now is louder)


New exhaust set up (car's dirty, forgive me pls):

[zevion]

The 650Nm clutches are on the market for some time already. In Poland www.compsport.pl distributes them. as far as I know you can get them from a canadian company: http://www.hpamotorsport.com/contact.htm as well.

IMO, they're not worth the money. I tried other clutches but ended up putting 745 Nm through stock clutches using United Motorsport DSG software that increases clutch pressure. No slip at all and it handles it all day long. I've pulled clutches after a few thousand miles to check wear and there was none. If you ever have to replace clutches, I highly recommend going stock and using UM software.

[simple_man]

+1 on UM Code.
17PSI on OEM clutch pack and holding fine, no slip. That is also on clutch that is 100,000km OLD

[zlos]

IMO, they're not worth the money. I tried other clutches but ended up putting 745 Nm through stock clutches using United Motorsport DSG software that increases clutch pressure. No slip at all and it handles it all day long. I've pulled clutches after a few thousand miles to check wear and there was none. If you ever have to replace clutches, I highly recommend going stock and using UM software.

+1 on UM Code.
17PSI on OEM clutch pack and holding fine, no slip. That is also on clutch that is 100,000km OLD

What about oil pump? Pumping 17psi all day long might be dengerous for a pump, right?

EDIT: UM has no representative outside North America

[Mr_Peach]

http://unitedmotorsport.co.uk/

[zevion]

What about oil pump? Pumping 17psi all day long might be dengerous for a pump, right?

EDIT: UM has no representative outside North America

I'm running 27lbs boost. No oil pump issues yet (and it's the primary coolant for the turbo. It's a 6766 precision turbo with ceramic center section). Obviously I don't actually run 27lbs more than in short bursts of a seconds or minutes at a time (you run out of road quickly). Done a couple of 2500 mile road trips without mechanical issues, including some hard driving on 'The Dragon'. Runs great and is reliable.

As for clutch pressure, it's a little over 19 bar on mine (stock is 13.5 bar). No slip at 27lbs. Over 650WHP. As I mentioned, stock clutches.

Anyways, your car looks awesome dude. Love the sound, the color, the seats, the flames, the whole thing.

[zlos]

I'm running 27lbs boost. No oil pump issues yet (and it's the primary coolant for the turbo. It's a 6766 precision turbo with ceramic center section). Obviously I don't actually run 27lbs more than in short bursts of a seconds or minutes at a time (you run out of road quickly). Done a couple of 2500 mile road trips without mechanical issues, including some hard driving on 'The Dragon'. Runs great and is reliable.

As for clutch pressure, it's a little over 19 bar on mine (stock is 13.5 bar). No slip at 27lbs. Over 650WHP. As I mentioned, stock clutches.

Anyways, your car looks awesome dude. Love the sound, the color, the seats, the flames, the whole thing.

Sounds really interesting, I will contact the UK dealer and try to get it for me.


650WHP/745Nm is way more impressive than mine 450WHP/620Nm. Have you measured with haldex on or off?
What level of torque you have at the LC rpms? Launch controll goes smoothly, no slips on the clutches?

[S-V-K]

Sounds really interesting, I will contact the UK dealer and try to get it for me.


650WHP/745Nm is way more impressive than mine 450WHP/620Nm. Have you measured with haldex on or off?
What level of torque you have at the LC rpms? Launch controll goes smoothly, no slips on the clutches?

Beautiful car and goes like mental

Good luck contacting UK dealer - my e-mail isn't answered for 10 months +
At the show they even didn't wanted to talk to me and kept walking away.

They don't need business - arrogant people.

On other hand US based United motorsports has very good reputation contact them.

[zevion]

650WHP/745Nm is way more impressive than mine 450WHP/620Nm. Have you measured with haldex on or off?
What level of torque you have at the LC rpms? Launch controll goes smoothly, no slips on the clutches?

Dude, yours is very impressive. In that vid to 300kph it's QUICK!

I did dyno pulls on both front wheel (with haldex fuse pulled) and all-wheel dynos.

Here is a 654WHP front wheel pull:

http://www.youtube.com/watch?v=r0vfZ...layer_embedded

I don't use launch control right now because I fear breaking something in the drive train. I'm not drag racing, it's a street car, so I tend to roll of the line with everything loaded up, then plant it.

[zlos]

Dude, yours is very impressive. In that vid to 300kph it's QUICK!

I did dyno pulls on both front wheel (with haldex fuse pulled) and all-wheel dynos.

Here is a 654WHP front wheel pull:

http://www.youtube.com/watch?v=r0vfZ...layer_embedded

I don't use launch control right now because I fear breaking something in the drive train. I'm not drag racing, it's a street car, so I tend to roll of the line with everything loaded up, then plant it.

I'd love to have your numbers, but mine toy is too "rocky" to be dynoed with FWD only. Tried with different stickers to glue the gums to the rolls, but always failed.

Alhtough EU's dynos are two rolls pew wheel mine turbo is too agressive for two rolls only. Checked on semislick and contisport 5 - both rubbers are too slicky to be dynoed on FWD only.

So my dyno's are 4WD only.

Mine max turbo load is 1.3psi. What's yours?

[zevion]

I'd love to have your numbers, but mine toy is too "rocky" to be dynoed with FWD only. Tried with different stickers to glue the gums to the rolls, but always failed.

Alhtough EU's dynos are two rolls pew wheel mine turbo is too agressive for two rolls only. Checked on semislick and contisport 5 - both rubbers are too slicky to be dynoed on FWD only.

So my dyno's are 4WD only.

Mine max turbo load is 1.3psi. What's yours?

Actually we had a bad time trying to get the car not to slip the rollers. We got it in the end though. You can see it almost wanting to torque off as well. We really had to tighten the straps down.

In this dyno run we hit 654, but ran out of fuel. I'd go for more power, but it's enough for me. I'm just enjoying the driving now and less of the building process. Getting over 550 requires internals (rods etc). Getting over 650 requires big injectors and a different fuel system with a surge tank and huge pump. Also a bigger turbo. I did this and it was a big investment for another 100hp. Probably not worth it. Unless you're crazy.

Not quite sure what you mean by max turbo load.

[simple_man]

Dude, yours is very impressive. In that vid to 300kph it's QUICK!


I don't use launch control right now because I fear breaking something in the drive train. I'm not drag racing, it's a street car, so I tend to roll of the line with everything loaded up, then plant it.

I know the feeling
But turbo do not really produce much boost in first gear during LC, regardless RPM at Launch. So, it's pretty much OEM level stress.

On the other hand if you run Jeff's BOOST LC mode, this may brake few drive-shafts
Don't you love Porsche style LC with Boost @ about 5-6PSI ? I am still to get mine.

[simple_man]

ZLOS, 300km/h run looks amassing. I love how 0-100 comes so incredably fast
What gearing do you run in DSG? You mentioned custom gearset, who's set is it? Any noise over OEM?

What is your RPM in 6th gear at 100km/h?
I need higher 6th gear for high speed cruising

EDIT:

Your injectors: - 6x Bosch 550cc EV14

Mine are the same and run 120% IDC @ 17 PSI. Watch your 1.3Bar, your IDS will be sky high

[PSU]

Looks wicked.

[zlos]

Actually we had a bad time trying to get the car not to slip the rollers. We got it in the end though. You can see it almost wanting to torque off as well. We really had to tighten the straps down.

In this dyno run we hit 654, but ran out of fuel. I'd go for more power, but it's enough for me. I'm just enjoying the driving now and less of the building process. Getting over 550 requires internals (rods etc). Getting over 650 requires big injectors and a different fuel system with a surge tank and huge pump. Also a bigger turbo. I did this and it was a big investment for another 100hp. Probably not worth it. Unless you're crazy.

Not quite sure what you mean by max turbo load.

Yeah, mine dynoing was also a nightmare. We ended up on 4x4 and only thank to haldex performance we were able to measure the car. With factory haldex settings front axle was still slipping

We have one or two ideas how to get closer to 600ps without changing turbo. We'll see

Turbo boost I meant, sorry for my English.

I know the feeling
But turbo do not really produce much boost in first gear during LC, regardless RPM at Launch. So, it's pretty much OEM level stress.

Don't you love Porsche style LC with Boost @ about 5-6PSI ? I am still to get mine.

Mine LC produces lots of stress for clutches, unfortunately.
Porsche LC is crazy

ZLOS, 300km/h run looks amassing. I love how 0-100 comes so incredably fast
What gearing do you run in DSG? You mentioned custom gearset, who's set is it? Any noise over OEM?

What is your RPM in 6th gear at 100km/h?
I need higher 6th gear for high speed cruising

EDIT:

Your injectors: - 6x Bosch 550cc EV14

Mine are the same and run 120% IDC @ 17 PSI. Watch your 1.3Bar, your IDS will be sky high

I have OEM gearings, simply software is corrected so gear changes faster. Apart of clutches & software DSG remains pretty OEM.

Some months ago I had opportunity to check my engine @ approc 500hp with a Passat R36 gearbox prepared by HGP. Well, this a is looooong gearbox 6th gear, 5.000 rpms and 270 km/h. But the car felt like it lost over a 100hp.

Mine injectors are pretty busy, that's true I don't know the IDC out of my head.

[zevion]

We have one or two ideas how to get closer to 600ps without changing turbo. We'll see

It's the rods that will break at 600hp on the VR6. You must do the rods at these power levels. You are already pushing the limit now. Aside from that, the VR6 is very strong.

Mine injectors are pretty busy, that's true I don't know the IDC out of my head.

I run 910cc injectors and they are at nearly 100% duty at 654WHP. Nice and rich at full boost (27 psi).