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RTDI Part 2

3L3M3NT

Veteran Member
Joined
Jun 16, 2008
Location
Sturgeon Bay, WI
TDI
04 Jetta GLS TDI, 04 RTDI
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As some of you know I purchased the Silver R32 to TDI swap from rspring at the end of May.

I've always wanted one after seeing this thread.
http://forums.tdiclub.com/showthread.php?t=370877

The story about picking up the car.
Well, I was the one that ended up buying the RTDI from rspring.

Dealing with Rick(rspring) has been phenomenal and would definitely buy anything from him again.

Picking up the car was a bit of an ordeal though...since I was unable to go get the car due to being in a wheelchair, so I had a friend fly to Dallas to pick up the RTDI.
Fran was supposed to be picked up at 9 am from the hotel...needless to say he did get picked up till 10:30 and then when he got to shop the car wasn't even there. The car was at one of the mechanics homes. Apparently the mechanic didn't even know the car was getting picked yesterday Saturday May 30th,2015. So when Fran first saw the car there were wires every where and half of the dash was apart. The glove box was out, the wires were every hanging loose, the door sills weren't on, and the Borla exhaust that was supposed to be installed wasn't.

This is after I called down this past Wednesday May 27th, 2015 to confirm that the car would be ready for the 1200 mile trip back to Wisconsin and was told it would be ready to go.

Fran called me to see if I still wanted to buy the car, because he couldn't imagine the car was going to be able to be driven back. After explaining things to me, I figured the interior could be put back in at least, so the mechanic put everything together.

Then the extra parts had to get loaded in the car before Fran could leave, so that added more time.

Here is the real kicker...is that Fran went to fill up the car and couldn't, because come to find out the original R32 filler neck was still in the car.:mad: Fran headed back to the shop and asked how they filled the car and was handed a foot long funnel to fill the tank on the car.

When he had to use the funnel to fill up the car it was a huge pita and the regular gas vent was leaking fuel, when he got near to top and luckily a bystander noticed and mentioned it to Fran after nearly a gallon had leaked out. The whole car wreaked of diesel and because of this, Fran had to stop for the night, because the fumes were getting to him. If not for that he thought he could have made the trip in a day.

Luckily Fran has helped me with my car, otherwise he never would have known where to look for the hood release under the hood because there's no grill in place for the hood pull to go through.:rolleyes:

The drive back went pretty smooth, minus running out of fuel, because the fuel gauge isn't working and showed 3/4 when he ran out. Luckily a police officer stopped and stayed with him till the tow truck got there with diesel. Good thing for a lift pump.

Fran did say that the car ran great once up to temp and made good time by following a group of bikers at 90 mph and had to catch up once, because they got away when a few semis got in the way, so he did a quick 120 mph sprint to catch up. He also really likes the responsiveness of the brakes.

I'll have to go through the car over the next couple of days and see what parts are in the car...hopefully a MKIV Golf TDI filler neck.

Any idea Steve if it's in the car?

Well there's mine and Fran's experience on getting the car from Fort Worth Texas to Sturgeon Bay, Wisconsin in 2 days.

Stolen from this thread. http://forums.tdiclub.com/showthread.php?t=338097

Here is Part 1 of the build process.
http://forums.tdiclub.com/showthread.php?t=399613

How the car started it's life. The original FS Thread on VWVortex.
http://forums.vwvortex.com/showthread.php?5790842-FS-2004-Reflex-Silver-R32-w-HPA-Turbo-FT450-and-lots-of-mods-(52K-in-MA)

Right now my plan it to get the car running a lot better by hopefully clearing all the codes that are on the car to get it to stop going into limp mode right off the bat. It took 2 cycles of the key when I went for a ride and my brother-in-law said it took 5 tries before he go out of limp mode.:mad:
Even after swapping 4 BAR MAP Sensors(I thought that may have been the problem, since my Jetta had a faulty 3 BAR MAP Sensor that caused limp mode on start up) it still started in limp mode.

Install +120% Injectors to try and clear up the smoke with a shorter injection window. On the track, they'll only tolerate soooo much rolling of coal.

Another issue is the horrible job done with the wiring harness...so that more than likely is going to get replaced over winter.:rolleyes:

The plan for the interior is to pretty much strip it down to the bare essentials, then install an Autopower Roll cage, Recaro Sporster CS seats, and Schroth Quick-Fit harnesses. It's going to be my HPDE car:D

The plan for the exterior is to replace both bumpers with new ones. An OEM R front bumper will replace the beat up one that is on the car. The rear is getting replaced with an OptikWerks rear bumper that has no exhaust cutouts. Like so.http://www.optikwerks.com/Golf4/RLineWithout/index.html

Since I'm going with a no exhaust cutout bumper, I'm going to install a single turn down exhaust that is on the drivers side and angled to the side 30 degrees or so. Weigh savings and the other drivers on the track won't get pissed as they get passed by RTDI.
I just need to figure out if 3" will fit or if I have to run 2.5" exhaust past the diff and then go 3" muffler and turn down tip

I've already installed this grille.http://www.kamei.co.uk/scripts/rbvehsel4.php?emulate=whycar&query=6087&vptype=265184&brand=KAMEI&prodid=13638
With an ECS Billet hood pull.http://www.ecstuning.com/Volkswagen-R32_MKIV--3.2/Exterior/Body/Hood/Release/ES2748122/

I'll end up deleting the rear wiper arm at some point and time...low priority.:p

I plan on painting the car too over winter, but the color is going to be a surprise:p I'll have the rub strips shaved along with the marker lights and more than likely the door handles and go with door poppers(aerodynamics) and it'll look BA

I'll install a Full FIS TDI cluster, instead of the R cluster.

I'm in the process of selling the wheels and tires, since they're curb rashed and not my style, so I got a set of 18" OZ Racing Ultraleggera's in black going on when 3 of the 4 wheels get back from the powdercoater. I found 3 silver ones for sale on Vortex for a good price, so I bought those and ordered the 4th black one with 4 tires on Tirerack and had them shipped to me with the one rim with the tire on it and 3 tires loose to install after the other 3 get back from the powdercoater matching them to black one I sent with.

The Brembo brakes won't clear 17" wheels, so brakes are getting sold and swapped for a Racing Brake setup, so I can run my 17" OZ Racing Superleggeras I had for my Jetta when I went to the track. The price difference in 18s vs 17s is about $60/tire so $240/set, which adds up when we might go through 2-3 sets a season.:eek:
The RB Setup, I'm going with the Special Order Blue.
Fronts
http://www.racingbrake.com/Big-Brake-Kit-4-pot-MK4-FRONT-2004-p/2187-k.htm

Rears, I'm getting the rear caliper powdercoated to match the fronts, by emailing RB and asking for the color code on the fronts, so I can get the rears powdercoated to match. Yes I'm that anal retentive /Detail oriented lol
http://www.racingbrake.com/Two-piece-rotor-open-slot-VW-Golf-Audi-TT-Re-p/2172.htm
Incase you're wondering it's Cardinal Blue http://www.lowvolumepowder.com/Cardinal-T009-BL01-Blue-90-Percent-Gloss-Touch-Up-Paint-2-Oz-Bottle

An awesome review of the front RB setup.
http://forums.vwvortex.com/showthread.php?5642289-Racingbrake-Big-Brake-Kit-%28BBK%29

Down the road plans are girdle, CAE Shifter, USRT Parts(They've got a lot of great performance parts for VWs and I'm sure a few other models. http://www.usrallyteam.com/ ) Go check'em out and tell Scott Eric Murrock sent you.;)
A FluidAmpr from Isaam @ INA I'm sure he'll turn me onto a few other goodies I forgot about, again tell him you saw my thread. He's a great guy to work with:D http://forums.tdiclub.com/showthread.php?t=404646
Enclosed trailer to haul my wheelchair, tools, jack, cooler, track wheels, event tent, etc. A 5x9x5 tall all aluminum by Blizzard Mfg. would be perfect.
http://www.blizzardmfg.com/

That's all I can think of at the moment.

I'd like to Thank:
Rick(rspring) for being awesome to deal with throughout this whole endeavor.

Fran for going through the ordeal of picking up the car and driving it back 1200 miles.

Jon Fettig(JFettig) for helping me figure out what I needed for the car injectors wise and picking up that the harness leaves a lot to be desired.

Darkside Developments for the +120% injectors, 4 BAR MAP Sensor with the reducer, R32 Airbox, DSG Snorkel, R32 MAF Housing, and small end bushing for the dogbone mount.

Recaro for when I get the Sporster CS Seats

Autopower for the 6-point weld in Roll Cage.http://www.autopowerindustries.com/Roll-Bars-Cages/

Luis (nkgneto) for the RB Setup and wheel stud conversion

300 Below for treating my new RB Rotors.
http://www.300below.com/

Chris, Louis, Mike, Thor for the help removing and installing parts.

My Parents and Grandparents for their support. Being in my position I sadly can only own 1 vehicle and that's my Jetta.

My friend Collin at Just In Time(JIT) for helping me get parts shipped out.
http://www.justintimecorp.com/

Blake @ 3ZERO3 Motorsports
http://www.3zero3motorsports.com/

Rennline for their tow hook and the awesome GoPro mount, that goes right on their tow hook.
http://www.rennline.com/

Eurogear for an awesome looking Notchless Carbon Fiber Hood.
http://www.eurogearusa.com/index.html

Sorry if I forgot anyone, send me a pm and I'll add you to the list.
 
Last edited:

Nash_TDI

Veteran Member -TDIClub Enthusiast
Joined
Sep 3, 2002
Location
Louisville, ky
TDI
2000 Silver Jetta TDI
Look forward to the build. Have you been down to WITW before? I know I have seen your Jetta before.
 

3L3M3NT

Veteran Member
Joined
Jun 16, 2008
Location
Sturgeon Bay, WI
TDI
04 Jetta GLS TDI, 04 RTDI
Look forward to the build. Have you been down to WITW before? I know I have seen your Jetta before.
Nope never been to WITW before, but I'm going to try to make it next year. So hopefully I'll see you at the 2016 WITW ;)
 

Nash_TDI

Veteran Member -TDIClub Enthusiast
Joined
Sep 3, 2002
Location
Louisville, ky
TDI
2000 Silver Jetta TDI
Sounds good hopefully 2 awd tdis then.

Was eyeing your injectors I need some for my passat build. I know big injectors short duration are the new thing.
 

3L3M3NT

Veteran Member
Joined
Jun 16, 2008
Location
Sturgeon Bay, WI
TDI
04 Jetta GLS TDI, 04 RTDI
Sounds good hopefully 2 awd tdis then.

Was eyeing your injectors I need some for my passat build. I know big injectors short duration are the new thing.
That would be cool and maybe we could convince FUB, who bought CharlieT's Audi TT to attend as well.

Let me know on the injectors, I'm to get help swapping them within the next month or so.
 

3L3M3NT

Veteran Member
Joined
Jun 16, 2008
Location
Sturgeon Bay, WI
TDI
04 Jetta GLS TDI, 04 RTDI
Shots of the underside, since we have a nice 2-post lift.:)











Pictures of the inside portion of the brakes




Talk about a tight squeeze between the rotor and the rear knuckles.


 

3L3M3NT

Veteran Member
Joined
Jun 16, 2008
Location
Sturgeon Bay, WI
TDI
04 Jetta GLS TDI, 04 RTDI
I've got a few picture to post up. Right now it's mostly going to be pictures of parts getting removed. lol

The car on the lift.








The front bumper that was on the car was removed and Sold.:D





A few engine bay shots after JFettig cleaned up a few things to get the IC Piping to fit better around the oil filter housing.



 

3L3M3NT

Veteran Member
Joined
Jun 16, 2008
Location
Sturgeon Bay, WI
TDI
04 Jetta GLS TDI, 04 RTDI
Blizzard Trailer Ordered

Well I went ahead and ordered a nice Blizzard Mfg Trailer.

I was emailing with Blizzard and they sponsor a Snow Show in Monrosville, PA October 17th and 18th and with me not being in a huge hurry to get the trailer, they are going to use it in the show as a display model and then at the end of the show on Sunday my friend who grew up in the Pittsburgh area is going to pick it up from the show and tow it back to Sturgeon Bay for me.

So it all worked out in the end.

Here is a picture of my Jetta towing my parents 5x12 enclosed trailer. It also helps it's only 5' tall on the inside, so it helps with aerodynamics. The trailer Blizzard is making for me is 5x9 and 5' 6" tall on the inside, so I can wheel right in the trailer to stay out of the sun and inclement weather if need be.





Here is an example of the trailer I'll be getting exempt mine will be Indigo Blue, like in the picture further down.





The super nice single cam style closure.


Nicely finished on the inside and I'm having them add an Aluminum flap that'll fill in the gap between the ramp door and floor of the trailer, so I can roll right in.


The color I'm going with, that looks to be a very close match to my Galactic Blue.



I can't wait till I get it.
 

3L3M3NT

Veteran Member
Joined
Jun 16, 2008
Location
Sturgeon Bay, WI
TDI
04 Jetta GLS TDI, 04 RTDI
Onto more car related matters the seats are all out of the car now.





Time to order the Recaro Sporster CS seats.

When I went on a test drive with some friends we kept on noticing a clunk when we accelerated, so immediately my thought went to dogbone mount. Once we had it up on the lift I saw the reason for the clunking.





Well that's not going to work.

The dogbone got replaced with a nice Billet Aluminum unit from 034 Motorsport. The great part about the design is that you can adjust the length between the part that bolts to your subframe and the small end bushing by bolting the big end to the subframe and turning the billet arm to the proper length you need and then bolting the small bushing to the trans, then they were thinking and put a jam nut to lock everything down.

Thanks Blake at 3Zero3 Motorsports for getting it to me so fast. Even though it wasn't listed on their site he was able to get me one asap.

Here is a link to it on 034 Motorsport site.
http://store.034motorsport.com/034motorsport-billet-dogbone-mount-mkiv-volkswagen-8n-8l-audi-motorsport-18t-vr6-tdi-20l-8v-mk4.html

On with the pictures.
You can see the jam nut really well in this picture.




Here's a pic of the faulty dogbone mount.



I'll put a nice new Vibra Tech small end bushing in to replace the faulty small end bushing that was in there.

Like so. It's the small guy on the right side.


So a fairly productive week.
 

3L3M3NT

Veteran Member
Joined
Jun 16, 2008
Location
Sturgeon Bay, WI
TDI
04 Jetta GLS TDI, 04 RTDI
Nothing major to post up, but I got excited when I received my New Rennline Tow Hook and GoPro mount for really either car, since both take the same tow hook :D

Let Shawn know you saw it in my build thread and he might be willing to give you a small discount if you tell him Eric Murrock recommended the tow hook and GoPro Mount.;)

Here are the links to the tow hook and GoPro mount for those interested.
http://www.rennline.com/Rennline-Folding-Tow-Hook-Screw-Type/productinfo/E13.102/

GoPro Mount
http://www.rennline.com/Rennline-GoPro-Camera-Tow-Hook-Mount/productinfo/PH01/

Here are some pictures of it when I first got it.


They include this little rubber nub that you stick to the backside of the tow hook to save your bumper from getting beat up.


Here are pictures of it mocked up on the car, since I couldn't wait to see what it looked like on the car.






Rennline includes 5 nylon washers and an O-ring to adjust how far the tow hook goes on and helps you to remove a washer if the tow hook isn't lined up and make it so the loop is hanging correctly. In my case to make sure the GoPro mount is aligned to take a correct video.


 

duwem

Veteran Member
Joined
Apr 11, 2012
Location
Wi
TDI
2002 Golf GLS TDI 5 Speed
Wow quite the machine!

Is the rear part of the exhaust with the mufflers stock R parts? not super keen on how the pipe just goes in the middle and hits a hard 90 each way, but I guess it works. If its R exhaust does it have a flapper still in it?
 

3L3M3NT

Veteran Member
Joined
Jun 16, 2008
Location
Sturgeon Bay, WI
TDI
04 Jetta GLS TDI, 04 RTDI
Wow quite the machine!

Is the rear part of the exhaust with the mufflers stock R parts? not super keen on how the pipe just goes in the middle and hits a hard 90 each way, but I guess it works. If its R exhaust does it have a flapper still in it?
Thanks. That exhaust isn't staying on the car. ;) I have no idea what the current exhaust has on it as far as flappers, etc.

The plan is to remove the exhaust that is on there and replace it with a 2.5 or 3" SS exhaust.

Depending on where it'll fit I plan on adding an Aeroturbine muffler and since I'll be putting a different bumper on, I'll be going with a turn down tip right before the lip on the bumper.

Now I just need to remove rear bumper and exhaust that is on there and replace it with the new bumper that is tehere and find someone to help me build the SS exhaust for the RTDI.

So if there is any one who is able to help me install a SS exhaust, that would be great. :cool:
 

3L3M3NT

Veteran Member
Joined
Jun 16, 2008
Location
Sturgeon Bay, WI
TDI
04 Jetta GLS TDI, 04 RTDI
I'm all set to put the brakes on the car now that I got the rear calipers back from Espos Powdercoating, who color matched them to the special order blue that the fronts are. All I have to say is they turned out phenomenally!
Check him out at: http://espospowdercoating.com/

Here are a few pictures of the calipers to show you the quality of his work.






With some help of a few friends, hopefully the brakes, wheel studs, and wheels will be on the car so it can be rolled around, since there's no seats in it. lol
 

3L3M3NT

Veteran Member
Joined
Jun 16, 2008
Location
Sturgeon Bay, WI
TDI
04 Jetta GLS TDI, 04 RTDI
Looks good, did you or the PC guy take apart the rears?
Since I'm unable to take them apart I had a friend take the calipers apart. He's actually going to be re-assembling the rear calipers over the next few days, so I really want to get the brakes on. :)
 

Nash_TDI

Veteran Member -TDIClub Enthusiast
Joined
Sep 3, 2002
Location
Louisville, ky
TDI
2000 Silver Jetta TDI
Nice, the rears always scared me with the integrated ebrake. I've popped a few fronts apart.

Some S4 brakes I did for my passat:



I have my Front and Rear Brembos to rebuild next. 20 pistons of fun.
 

3L3M3NT

Veteran Member
Joined
Jun 16, 2008
Location
Sturgeon Bay, WI
TDI
04 Jetta GLS TDI, 04 RTDI
Nice, the rears always scared me with the integrated ebrake. I've popped a few fronts apart.

Some S4 brakes I did for my passat:



I have my Front and Rear Brembos to rebuild next. 20 pistons of fun.
Espos Powder coating would have done it, but it was an extra $50/caliper. So I figured I would ask a friend if he could help with the rear calipers.

Looks like you've got quite the project in front of you. ;)
 

3L3M3NT

Veteran Member
Joined
Jun 16, 2008
Location
Sturgeon Bay, WI
TDI
04 Jetta GLS TDI, 04 RTDI
With the help of a friend, the rear bumper was removed from the car in preparation for the new R-Line rear bumper without the exhaust cutout.

Factory bumper.




End result.




To the this :D






Should look pretty good.:cool:
 

3L3M3NT

Veteran Member
Joined
Jun 16, 2008
Location
Sturgeon Bay, WI
TDI
04 Jetta GLS TDI, 04 RTDI
So, what are you doing with the exhaust? Turndown?
Yep, a single turn down on the drivers side.

If you watch the dyno video you can see how much it smokes and they frown upon that at the track ;)
https://www.youtube.com/watch?v=KxtVaL7ning

Hopefully with the new Race PD injectors and +120% Firad nozzles and the turn down exhaust, I won't have as much smoke :D

I'll find out in a month or so.
 

Nash_TDI

Veteran Member -TDIClub Enthusiast
Joined
Sep 3, 2002
Location
Louisville, ky
TDI
2000 Silver Jetta TDI
Thanks to you I ordered the Rennline tow hook and gopro mount. :) Lucky my buddy is a dealer.
 

3L3M3NT

Veteran Member
Joined
Jun 16, 2008
Location
Sturgeon Bay, WI
TDI
04 Jetta GLS TDI, 04 RTDI
Smoke = wasted fuel. Hopefully you can get it dialed in. Good luck and keep us posted.
I guess I didn't think of it that way, but yes, that is a fair amount of wasted fuel going out the exhaust :(

Once I get it on the ground and plates for it, along with the +120% Firad injectors in the car it should hopefully be quite a bit less smokey :)
 

3L3M3NT

Veteran Member
Joined
Jun 16, 2008
Location
Sturgeon Bay, WI
TDI
04 Jetta GLS TDI, 04 RTDI
With the help of a friend, the rear brake kit from Racing Brake got installed last night and so did the amazing Racing Brake wheel stud conversion kit.

The links to both items, encase you're interested ;)
Rear Brake Kit that works for any MKIV car and I believe a MKI Audi TT:)
http://www.racingbrake.com/Two-piece-rotor-open-slot-VW-Golf-Audi-TT-Re-p/2172.htm
Wheel Stud Conversion Kit. The reason I went with these over others is that they put a super nice 8mm bolt head on the end of the wheel stud, so you can snug them up :thumbup:
They're 80 mm in length, so they are perfect if you wanna add spacers to your setup, either to clear the calipers or to get that perfect stance.
http://www.racingbrake.com/RB-Wheel-Studs-Nuts-80mm-for-Audi-VW-10-pc-Axl-p/vw-80.htm
Here are the pictures from RB Site on the wheel studs.
The super nice 8mm hex head :thumbup:




You can get either Cone seat or Ball seat lug bolts. Sadly in my case I need both cone and ball seat lug nuts, since the OZ Racing Ultraleggeras are Ball Seat


Pics of the brake install.
Here's how great a job Espos Powdercoating did to match the caliper to the special order Blue without having the front caliper in hand. I think the only reason the rear looks different is the rear is cast, compared to the front caliper that's machined.


 

3L3M3NT

Veteran Member
Joined
Jun 16, 2008
Location
Sturgeon Bay, WI
TDI
04 Jetta GLS TDI, 04 RTDI
On the car with the wheel in place and I might be a little biased, but I think it looks Awesome!


This is how close the fronts would have been.


Actually the drivers side front has the wheel weights rubbing on the calipers, that's how snug it is with those Brembo 6 piston calipers and 355mm rotors.






That's it for today and hopefully the fronts can go on tomorrow.:beer:
 
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