Full on RTDI build up.

mtbr297

Vendor
Joined
Nov 3, 2002
Location
Ft. Worth, TX., USA
TDI
2015 Golf TDI, Seat Leon FR PD 150 6 speed.
Starting with a 2004 R32 and building 300 hp engine. Will be building engine with BHW block bored to 81.5. I'm using a pd 150 crank, rosten rods, pd 150 head, BEW injectors with 80% nozzles. 2260VK turbo, S3 intercooler modified to fit pd 150 euro radiator carrier. Will be porting head and using stage 3 colt cam. Trans is a euro 4 motion tdi trans and installing wavetrac locker, with steel shifter forks. Cryogenic treatment applied to all engine parts including head and block before machining. Plus cryogenic treated trans gears, shafts and syncro hubs. Cryogenic treatment supplied by 300below in Decatur IL. I would recommend them to anyone, very helpful and fast turn around. This is what we started with.
 

rspring

Veteran Member
Joined
Sep 13, 2009
Location
Florida
TDI
09 Jetta CR; 2011 BMW 335D
Thanks to RyanP, Frans, Steve, Kerma, 300 Below, and all others that are participating in this build!
 

rspring

Veteran Member
Joined
Sep 13, 2009
Location
Florida
TDI
09 Jetta CR; 2011 BMW 335D
This is how it started:
Car:
- 2004 Volkswagen R32 in Reflex Silver, leather, 52,338 miles

Engine/Performance:
- HPA FT450 Turbo kit with competition intercoolers
- HPA Race Grade Connecting Rod Bearings
- HPA Dual High-Flow catalysts
- HPA Lengthened Gear set
- Swain Tech Thermal coating on all pipes and turbine housing
- HKS EVC 6 with EasyWriter PC interface
- Raceware head stud kit
- EVOMS V-Flow intake
- TT valve cover with Black powder coated
- DLI-Teknik engine mounts
- 034Motorsport Track Density dog bone
- EIP Competition Exhaust system with custom resonator
- Bosch 044 Motorsport inline fuel pump
- Lightweight Alloy standard size pulleys (Crank, Water pump, PS, tensioner)
- Low profile Mk5 oil pan and matching oil pump (high ground clearance)
- Intercooler mister (installed but not wired yet)
- Aeromotive Ajustable fuel pressure regulator
- Bigger oil cooler from 3.6L VR6
- Samco Blue Silicon cooler hoses
- VAD Mobile scanning tool with Palm TX
- Aquamist HFS-5 water injection system with dual injectors

Suspension:
- KW V3 Coilover Kit
- KW sport camber plates with competition alloy top mounts
- CPP Rear adjustable control arms, Stainless steel, TOP&BOTTOM
- Tomas Sport Tuning Rear Stress Brace
- Front Autotech ClubSport 25mm hollow sway bar
- Rear Neuspeed Race Series 25mm hollow anti-sway bar
- S3 Front strut tower brace
- BBS 18x8.5 CH wheels
- Continental ExtremeContact DWS 235/40/18 all season
- Compact spare tire
- new LCAs with spherical joints

Brakes:
- Brembo GT Front Big Brake kit 355x32 6 piston with slotted rotors
- ECS Tuning Rear Stage 1 Upgrade kit 308x22 with slotted rotors

Driveline:
- HPA/Sach sport clutch
- Front AND Rear Peloquin Differentials
- HPA Competition Haldex controller (Orange)
- HPA short shifter

Audio
- Lots of changes since I bought it- the installed stuff was blown or corroded

Lights:
- Genuine VW European HID headlight w/clear shield
- Black out W8 Overhead console
- European headlight switch with Foglight LED mod
- Hella Micro DE HID driving light
- Rear Fog light Mod

Interior:
- Defi D-link System electronic gauges and controller (boost, water temp, oil temp, oil pressure, fuel pressure) with warning, recording and play back capabilities
- Defi VSD Concept Heads up display for above gauges
- Gorilla trunk mat
- Extra VW Monster mat set
- Extra VW All Weather mat set
- Extra Audi TT pedals
- Aluminum Safecraft Fire Extinguisher and Custom Mounting Bracket

Exterior:
- Seat Cupra R Front Splitter (New in the bag, NOT installed yet)
- Rear Aero wiper
- Phaeton shark fin antenna


This is the starting point for the build at Steve's. Since then, the front drivetrain has been sold. He is now building a new drivetrain using a trans from Denmark that Frans sourced, with all the goodies that can be had: Ryan's turbos and piping, Kerma tunes, MattW head bolts a new wavetrac, and on and on....
 
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mtbr297

Vendor
Joined
Nov 3, 2002
Location
Ft. Worth, TX., USA
TDI
2015 Golf TDI, Seat Leon FR PD 150 6 speed.
We have the cryo treated trans put back together with wave trac diff. Here are some pics of the trans with steel shifter forks replacing the brass forks and the wavetrac diff installed. If you look closely you'll see the steel forks have a third finger in the middle to give some extra strength to the shifter. They also have poly tips for smooth engagement and long service life. These forks replace 1-2 and 3-4. Made by USP racing.

 

rspring

Veteran Member
Joined
Sep 13, 2009
Location
Florida
TDI
09 Jetta CR; 2011 BMW 335D
We anticipate being right about 450ft/lbs at peak when this is done. I am torn between an SBC Stage two endurance and a Stage three endurance. I live in the city and do not want a heavy pedal. On the other hand, with a wavetrac up front, a Peloquin in the back and the modified haldex, wheel spin will not be a clutch saver. SBC says the Stage two is conservatively rated for 450ft/lbs.. Oh, and I have significant arthritis in my knees.... Thoughts? Thanks!
 
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spartan

Veteran Member
Joined
Aug 25, 2011
Location
MI
TDI
05 Passat Wagon
Granted we were not really in the same scenario, but I had a stage 3 endurance in my PD wagon. I had no problems with the pedal pressure, in fact, I found it to be rather light compared to other performance clutches I had driven in the past.
 

isonic

Veteran Member
Joined
Aug 11, 2009
Location
St. Paul, MN
TDI
2003 Golf 4door 5spd
This is how it started:
Car:
- 2004 Volkswagen R32 in Reflex Silver, leather, 52,338 miles

Engine/Performance:
- HPA FT450 Turbo kit with competition intercoolers
- HPA Race Grade Connecting Rod Bearings
- HPA Dual High-Flow catalysts
- HPA Lengthened Gear set
- Swain Tech Thermal coating on all pipes and turbine housing
- HKS EVC 6 with EasyWriter PC interface
- Raceware head stud kit
- EVOMS V-Flow intake
- TT valve cover with Black powder coated
- DLI-Teknik engine mounts
- 034Motorsport Track Density dog bone
- EIP Competition Exhaust system with custom resonator
- Bosch 044 Motorsport inline fuel pump
- Lightweight Alloy standard size pulleys (Crank, Water pump, PS, tensioner)
- Low profile Mk5 oil pan and matching oil pump (high ground clearance)
- Intercooler mister (installed but not wired yet)
- Aeromotive Ajustable fuel pressure regulator
- Bigger oil cooler from 3.6L VR6
- Samco Blue Silicon cooler hoses
- VAD Mobile scanning tool with Palm TX
- Aquamist HFS-5 water injection system with dual injectors
Not to hate on what you are doing here...because I fully support 4motion swapped TDI's. BUT, if you already have an .:R32 (specifically an HPA VR6) built to this level why would you use it to start this project? How could you give up that exhaust note?
 

rspring

Veteran Member
Joined
Sep 13, 2009
Location
Florida
TDI
09 Jetta CR; 2011 BMW 335D
Isonic, the HPA setup was super quick, hard to drive gently when you wanted to, heavy on premium fuel consumption and worth a good chunk for financing part of the swap. It was awesome, but just not for me. With everything else that was on the car, it seemed like an ideal candidate for my desires. The exhaust tone was cool though.

TdiMeister, I don't think anything non-ferrous was cryoed. Steve had to separate pretty much everything.
 

rspring

Veteran Member
Joined
Sep 13, 2009
Location
Florida
TDI
09 Jetta CR; 2011 BMW 335D
Marin,

Yes, it is. We spoke several months ago about it.

Thanks!
 
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rspring

Veteran Member
Joined
Sep 13, 2009
Location
Florida
TDI
09 Jetta CR; 2011 BMW 335D
Going with a stage three endurance, -OFE. Anyone have one of these?
 

CharlieT

Veteran Member
Joined
Dec 10, 2008
Location
Houston, Tx
TDI
Audi TTqTDI, B4V, B5.5V, '12 NMS SEL
Going with a stage three endurance, -OFE. Anyone have one of these?
Yes, but mine isn't fitted yet either. Going into my TTqTDI with my new engine, similar numbers, very similar build actually. Lets see who strips their clutch first !
 

rspring

Veteran Member
Joined
Sep 13, 2009
Location
Florida
TDI
09 Jetta CR; 2011 BMW 335D
Charlie, can you confirm the p/n for the STG3E with the OFE pressure plate? I called SBC earlier, but Steve just informed me I had a 5speed p/n.

I think both cars should do the Texas Mile!

:)
 

CharlieT

Veteran Member
Joined
Dec 10, 2008
Location
Houston, Tx
TDI
Audi TTqTDI, B4V, B5.5V, '12 NMS SEL
Mine was K70287 SS TZ PD (SS plate and OFE disc)
And SBC0503 TDI (240mm heavy smf for 02M)
 
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mtbr297

Vendor
Joined
Nov 3, 2002
Location
Ft. Worth, TX., USA
TDI
2015 Golf TDI, Seat Leon FR PD 150 6 speed.
Here is an update of what has been going on lately. Machine work is done, head is ported. Only thing left for the machine shop is balancing then we can start assembly of the engine. Trans is built and ready to go. Received large shipment of parts for the engine build.


Crazy looking 4 motion down pipe.

Off subject but these are the ice blocks that slid off our local Walgreens last week.

Close up of machining of head for stage 3 colt cam.

Block and head, block had the deck just cleaned up. We will be cleaning up block and applying fresh paint. We're using a BHW block, 81.5 mm pistons and pd 150 crank.
 

Nash_TDI

Veteran Member -TDIClub Enthusiast
Joined
Sep 3, 2002
Location
Louisville, ky
TDI
2000 Silver Jetta TDI
I was thinking you didn't need to clearance for stg3 colt cam or is it just to be safe?

Awesome build btw. Get it done and bring it to the R32 gtg at Tail of the dragon.
 

Nash_TDI

Veteran Member -TDIClub Enthusiast
Joined
Sep 3, 2002
Location
Louisville, ky
TDI
2000 Silver Jetta TDI
Is the darkside manifold different for awd or just the downpipe?

Edit: Ryan got back with me. Apparently it is just the down pipe that is different.
 
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