*** MK2 Rally Build with ALH TDI ***

We need a video

Bczuk said:

We need a video

Click to expand...

When i get back from Turkey....

The fancy clutch we installed doesn't hold even with the stock tune & nozzles sot that is one order of business we will have to attend to sooner than later.

A couple videos from last weekend at Sandblast Rally in South Carolina

https://youtu.be/Lh6RyXrt7IA


Sandblast Rally 2015 Hairpin Car Compilation
Sometimes, fast looks slow.

https://youtu.be/ZegFVOIgGeo


A couple of notes:
We finished 5th overall out of 50ish entrants and 3rd in 2wd behind an SRT4 and a turbo Escort.

This is the first time we have driven the car at speed and intended to use Sandblast as a shakedown for the car running a stock 90hp ALH tune. The engine was rock solid all weekend and felt great --- but slow --- in the deep sand.

Learned that we may actually be making less than 90hp as we are using the stock mk2 in-tank lift pump (for gas cars) and that may actually be a bottleneck to the injection pump at higher rpm. The car felt really weak above 3500rpm. Anyone ever use an mk2 lift pump? The mk4 lift pump will not fit in the tank but I would like to have it setup with a lift pump that flows adequately for say a 175hp tune in the near future. Any advice appreciated.

Have you considered an in-line fuel pump? Somewhere between the tank and fuel filter.

QuantumRallySport said:

Learned that we may actually be making less than 90hp as we are using the stock mk2 in-tank lift pump (for gas cars) and that may actually be a bottleneck to the injection pump at higher rpm. The car felt really weak above 3500rpm. Anyone ever use an mk2 lift pump? The mk4 lift pump will not fit in the tank but I would like to have it setup with a lift pump that flows adequately for say a 175hp tune in the near future. Any advice appreciated.

Click to expand...

You're right, a stock TDI is sloooow. I fit a old PD lift pump in my Corrado.
http://forums.tdiclub.com/showpost.php?p=4029896&postcount=2

http://forums.tdiclub.com/showpost.php?p=4029897&postcount=3

You can get the shorter and new pump from DG-TDI but I would call his shop. Appalachian Diesel Works, 2893 New Leicester Highway
Leicester, NC 28748



Be sure to add a second 90 degree elbow or you may bust a hose. http://forums.tdiclub.com/showpost.php?p=4204315&postcount=28 No problems for years now.

Houpty GT said:

You're right, a stock TDI is sloooow. I fit a old PD lift pump in my Corrado.
http://forums.tdiclub.com/showpost.php?p=4029896&postcount=2

http://forums.tdiclub.com/showpost.php?p=4029897&postcount=3

You can get the shorter and new pump from DG-TDI but I would call his shop. Appalachian Diesel Works, 2893 New Leicester Highway
Leicester, NC 28748

Be sure to add a second 90 degree elbow or you may bust a hose. http://forums.tdiclub.com/showpost.php?p=4204315&postcount=28 No problems for years now.

Click to expand...

Thanks for the links but I think I need something much more resilient than that for rally. The abuse the cars take is pretty epic and I doubt something like that would hold up for long.

More video footage.

This is of a long uphill in deep sand through a series of 3-4 turns.
https://youtu.be/Opfhxq7rl_4?t=4m1s

Looks like lots of fun and will be more so with a good tune/upgrades

A lot of great shots from Sandblast over here: http://photos.nasarallysport.com/Event/2015-Sandblast-Rally/New-Jordan-Apgar-Media/i-ffh5Cmd




Vidoe here: we come by at 35-seconds in after a bunch of EVOs. Yes, that really is flat out for 250 into left 6 without lifting. The car really is that slow. I know there were some worries we were sandbagging but they are not true at all. Should be fixed soon enough though -- PP520s arrived yesterday.
http://photos.nasarallysport.com/Event/2015-Sandblast-Rally/New-Guthrie-Vol-Marshal/i-KLnT96T
Another short video
http://photos.nasarallysport.com/Event/2015-Sandblast-Rally/RoadMarshalChrisSkorlinski/i-CfdVGwv

I love this car!

Quantum Rally Sport's TDI is no longer slow. Went to RocketChip Performance Tuning today and got a little tune up

Easily churns snow tires on dry pavement in 3rd gear.
Be warned 2wd ralliests.

THanks
New German Performance
US Rally Team

Yessssssss!

Impatiently waiting for the next outing, what's the next event for you guys?

eldar11 said:

Impatiently waiting for the next outing, what's the next event for you guys?

Click to expand...

Right now, here is the schedule we are working on:
--I am remodeling our kitchen myself while working full time and traveling so it is taking some time
--I am working as a spotter/coach at the Red Bull Global RallyCross this weekend in DC
--We plan to do some testing the first week of September.
--We are signed up for Black River Stages in NY september 19th http://blackriverstages.com/ but may choose to do LSPR instead depending on whether I have to travel for work and how much $$ gets consumed by this kitchen.

Subbed! This is my type of fun!

Nice build. I love the expression of surprise a Mk II has. That second pic, I see a bit of C3po with the slot below the bumper.
My neighbor wants the 225HP 20V I will have left over for a MK II build. Need to find a good starter car.

EDIT: I found a couple but boy, they don't look as nice as that rally with the round headlights. That would have to get changed.

Headed to Black River Stages Rally in Harrisville NY this coming weekend if anyone is in the area and wants to see some rally action or hang out in the service area.

www.blackriverstages.com

Volunteers are needed as well. Learn more here:
http://www.nasarallysport.com/main/volunteering


http://blackriverstages.com/register-to-volunteer/

We only got one in-car video this weekend and the spot-metering was off so it is a bit washed out. But, we tied for the overall win on this stage even with a minor hiccup

We retired from the event late that night after breaking an axle and having the wheel-bearing come apart so we could not continue.

More details later.

https://www.youtube.com/watch?v=k4GB_YuYvRA&feature=youtu.be

https://www.facebook.com/Quantum-Rally-Sport-281129179600/timeline/?ref=nf

QuantumRallySport said:

More details later.

Click to expand...

Thursday Sept 17. Find worn left front wheel bearing during loading process and frantically try to find replacement. Rally community comes through and delivers two spares to the event Friday afternoon.

Friday Sept 18. Arrive just south of Ontario Canada for rally and install new upright/hub/wheel bearing assembly and re-align car. Test drive reveals that replacement parts also fixed the darting steering and soft initial brake pedal as the wobbling bearing was kicking the brake pads back into the caliper. Bonus!

Saturday Sept 19. Attempt to drive car in a swift but (mostly) controlled manner. Learn that you are actually going really fast. Eventually go a bit too fast in the dark & rain and end up cleaning a ditch. This leads to a broken axle at the stub. The stub holds the wheel bearing together. Yes, the same wheel bearing you just replaced. But this time it really comes apart and car is undriveable… Stand in the cold rain and the very dark woods with dedicated spectators for 2 hours waiting for the trailer to come. We even managed to get it onto the trailer somehow without a come-along.

Sunday Sept 20. Decide to head home rather than thrash all night and morning with no service crew as we had to drive home immediately after the rally anyway and planned to drive shifts through the night. This was a good plan as about 7 hours into my drive, the trailer had a braked-axle bearing failure that quickly turned into a brake fire. Even with a Good Samaritan’s assistance, it took nearly 3 hours to get back going. Spent a lot of time with a small hammer, a cold-chisel, and a hacksaw blade wrapped in tape getting the axle stub ready to accept the replacement bearings…. In the dark. By myself. Again…

Besides the curse of 3 damaged wheel bearings we learned a few other important things:

1) The TDI is competitive. We set the fastest stage time (tied with Gary Donoghue in his Evo9) on the very first stage and set a bunch of fast times on the remaining stages as well.

2) The TDI is easy to drive. We had worried that the torque would cause issues with putting down power in a controlled manner on gravel. The car makes approximately 160hp and 300 lb-ft with the torque available from 1800rpm to 4500rpm. Wheel-spin could prove a challenge but was not an issue. I am sure it would be awful on snow and ice but on hard packed dirt, gravel and sand, each with and without heavy rain, it proved to be no problem at all.

3) It is hard to tell how fast you are going in the TDI. Unlike the 7300rpm gas motor, the TDI does not give you the visceral experience of screaming speed. It makes nearly the same chugging noises and pulling feelings at 2500rpm as it does at 5000rpm but you are going twice as fast. And the car feels about the same too. So, in 4th gear, you can be running anywhere between about 52mph (at 2500 rpm) and 104mph (5000 rpm) and not feel much difference. I have been calibrated to the gas motor so I never have to think about this but found myself approaching corners quite a lot faster than I had expected in the TDI. I will probably acclimate quickly and sub-consciously to this.

4) There is still a mystery source of water intrusion (beyond the water coming in the roof vent seen in the video). Multiple garden-hose and pressure washer tests of the firewall and outside of the car have failed to turn up a substantial leak. Water still fills the floors during even modest rain events…

5) Don’t clean ditches. You will break stuff.

6) Charge camera battery & adjust settings before event... Only got one stage of footage.

Park expose interview
www.youtube.com/watch?v=pHsSj24x5X4&feature=youtu.be


Stage 1 (the stage referenced in point #1 above)
www.youtube.com/watch?v=k4GB_YuYvRA

In case the original offending bearing was one from when you built the car, rolling it around without axles in will destroy bearings quick, and to that extent. Keep a spare set of outer joints to bolt in if you have to roll the shell around sans drive train.

You're only making 160 whp? I'll have to re-read your build thread.

Awesome car, keep up the good work!

Thanks.

We keep old CVs with stubs for just that purpose. Both these bearing failures were mechanical. The first due to wear, the second due to a failure of the support (axle stub).

I need to get the car on a dyno, it should be around 160hp.

VNT17/22 witn PP520 injectors running a conservative tune from RocketChip that does not come close to maxing out the hardware. Full throttle and max load for several minutes produces EGTs under 1400 degrees and only get a tiny amount of smoke and only under 2500rpm...

https://youtu.be/676wOPQ8A-Y

Really quiet even with a 2.5" straight pipe all the way out...

Had some more axle issues at New England Forest Rally (NEFR) a couple weeks ago. Snapped 3 more axles all on the splines inside the wheel bearing/hub. However, all was not lost, we set competitive times with a rookie co-driver reading (most of) the notes.

Upgrade plans:
1) Axles/outer CVs
2) PD130 intake manifold
3) Gas 5th gear to bring it down to a reasonable top speed for gravel. Currently geared for about 145mph, should bring it down to about 125.

One pair of axles snapped simultaneously That is some crusty mud on the one on the left as they both shot out into the woods about 30 feet from the start line on stage 8.





Stub and nuts should be in here....

Can we get an edit on the pics, can barely see anything they're huge!

Steve Addy said:

Can we get an edit on the pics, can barely see anything they're huge!

Click to expand...

Ah, fixed.

Upgrade to VR6 outer CVs and hubs maybe? The VR6 outer joint will fit in place of the stock one, and the hubs are the same dimensions, just needing re-drilling for the 4x100 pcd.

Also, maybe worth investigating TT/mk4 outer joints as they use a bolt rather than a nut to hold them in to the hub. I've never played with those though so couldn't say whether they would swap or not.

Anyone make chromoly axles yet?