White "Lion" Cupra - DSG converted track car

[teo_parvu]

Yes Mike, it is a Li Ion.

[Tfsi_Mike]

Very nice

[teo_parvu]

Unfortunately, I cannot use the TT alloy rear hubs with Federal FZ-201 235/40/18 and TD 8J ET45. The tyres touch the wheel arch. :(

[Shoduchi]

Unfortunately, I cannot use the TT alloy rear hubs with Federal FZ-201 235/40/18 and TD 8J ET45. The tyres touch the wheel arch. :(

What about rolling or extending the wheel arches a bit? I don't know if there are already wider front wings like SRS-Tec sells for Golfs mk5.

[teo_parvu]

They are intended for the rear axle, it is very complicated to extend the wheel arches there and I'm not allowed in my racing class. I'll sell them.

[Shoduchi]

Oh, right!  My mistake reading since at the rear there's more space I assumed you had troubles on the front...

[teo_parvu]

Long time since I've posted any updates here and a lot has happened. 

The car lost a lot of weight and has become more track oriented, i think I'm doing not more than 2000 miles per year now.

I've done the 1.8T oil pump conversion and balance shaft delete, installed a new custom clutch from Atix Racing Solutions, Turn-One 6 point race harnesses, quick release for the racing OMP steering wheel, redesigned the brake ducts  and bought new Team Dynamics 9J front wheels to use racing slicks. 







Had also a bad situation which cost me my top part of the engine and a HPFP, this chain broke. I had to buy a new Autotech pump which feels no different than APR.
I think this happened because I was to lazy to change gears. I was returning from the race track, tired and had to overtake a very slow lorry. I did that in sixth gear from 30-35 mph, when I put my foot down I believe I've forced the turbo into overboost. 
It was a big set-back, but at least it's like new now:





I've used for a short time some "not so cheap" AP Racing replacement discs from Reyland with custom bells which obviously failed:





So back to AP Racing now, there is no other way:





I'm still to solve a problem, the car was not making the same boost near the redline.
So I've changed the DV, did a PCV delete and looked for boost leaks everywhere.
I installed a new Forge actuator because I thought that the springs are worn. In the end I've rebuilt my turbo because there was shaft play and marks on the housing and blades. At the moment the turbo is working good at high rpm, boost is ok, over 17 psi. But now it seems that the Forge actuator is not working perfectly with Revo and It makes the ECU to reduce the load in the mid range. I think this is an overboost protection.   
Last ting I did is to buy a GFB boost controller which I still have to install, hopefully it will be the key. 






I think this has not affected too much my car's behavior on track because it is never under 4500 rpm so I've achieved a new personal best and FWD track record:

Now I've gathered everything for a DSG conversion:

New Quaife DSG LSD --- my Wavetrac will be posted up for sale
KNC gearbox
driveshafts
DSG wiring loom
DSG cooling radiator
flywheel
engine starter

I will also remap the box Revo stage 2. I hope the stock DSG clutch pack will handle Revo stage 2+ remap and track abuse. Any info will be appreciated. 

I've bought some race oriented coilovers, they are on the way. I'll say goodbye to my Bilsteins PSS10, which I believe are the best road/track compromise for the money but they are too soft for what i need.
So if anyone needs them or the LSD (Wavetrac is the best out there - I choose Quaife because after all the DSG parts, a new Wavetrac was a bit above my current budget) give me a buzz.

[teo_parvu]

Update: All the DSG conversion parts are here, the gearbox, engine starter, flywheel, LSD, driveshafts, wiring loom, gear selector:






At first seemed that the mechatronic was dead because it didn't respond to our first attempt to connect to it. So I was already looking for a new one everywhere. Yesterday I got the good news that a connection was established:



I will probably go with MRC for the coding.

Also my new AST 5300, 3 way addjustable coliovers arrived. Really hope they will help to improve my laptimes, Bilstein B16 is already a very good kit: 




And something that I should've done long ago, before i started using slicks, polyurethane bushings from Strongflex. They are a cheaper alternative to Powerflex or Superpro, but I see no reason why they wouldn't do the job just as good:



The only thing that concerns me right now is whether the Quaife LSD will fit my DSG gearbox. It seems that they are 2 types, QDF19R - 20 Tooth Parking Ring and QDF28R - 25 Tooth Parking Ring.
Early DSG gearboxes, until 2008 had 20 Tooth diffs, from 2008 onward they have 25. My gearbox is from January 2008, KNC code and I got the 25 tooth parking ring diff, hopefully it will fit. Otherwise I'll have to pay the shipping from Bucharest to UK and back and I'll have to wait for the replacement. Or use the old manual parking brake, mount the LSD without that ring and save 1-2 kgs. 
If anyone knows if KNC DSG gearbox has 20 or 25 tooth ring pls share, since Quaife didn't bothered to find out. 

[teo_parvu]

This will be the front mounted DSG cooler:



Hopefully it will do the job on track because i see the really expensive kits come with an oil pump which i believe moves the oil faster between the DSG and the cooler.
Don’t know much about it or where should it be mounted. If it replaces the stock pump or works along with it.

[Christiank]

Awesome work mate!

I'm also thinking of doing a DSG conversion for my MK5 tdi.

Waiting to get back my engine top from the workshop that will level it and make new valve seats and all that. Then it'll be ready to have all the good parts installed :)

Anyway, back to your DSG job.
Why do you change the driveshafts? - heard this wasn't needed to swap when you're doing the conversion?

[teo_parvu]

Thanks man! 

I've bought new driveshafts using a friend's VIN from his DSG ED30 even before my gearbox arrived but with the option to return them at my expense in case they will not fit.
I was hoping that mine will fit and get the money back. When the gearbox arrived, we tested them, but mine were different and the new ones were ok.

I don't know if this is a rule but in my case the 02Q driveshafts were different than the 02E ones. 
 

[Christiank]

Thanks man! 

I've bought new driveshafts using a friend's VIN from his DSG ED30 even before my gearbox arrived but with the option to return them at my expense in case they will not fit.
I was hoping that mine will fit and get the money back. When the gearbox arrived, we tested them, but mine were different and the new ones were ok.

I don't know if this is a rule but in my case the 02Q driveshafts were different than the 02E ones.

All right, well then you should be sorted if you used a VIN matching a car that was "born" with the DSG.
What about the ECU, wire harness and all this?

I also have the 02Q 6-speed manual gearbox in my 2.0tdi which hopefully someday will have th DSG running smooth :D Replacing my engine with a freshbuild one along with new exhaust system, so if I should do the conversion it would be same with these jobs. Guess it would make the job alot easier when everything is off the car anyway.

Will also install new subframe, anti roll bars, end links, brakes etc etc.

But guess it'll make my job easier to find same model as mine and use that VIN to shop the correct parts.

What about the fram the holds the pedals? Do you change this or can you use the manuel frame that holds 3 pedals to the 2 pedals from DSG?

[teo_parvu]

The ECU will have to be adapted I believe, MRC will take care of that.
I've bought a complete wiring loom from a 2013 Passat CC TSI which should be ok, we'll use the parts we need, apart from the DSG connector which is different, but we'll modify it.
At first I will use the old pedals, they will work, no problem. I will only remove the clutch pedal for weight saving. Maybe later I'll buy a DSG brake pedal.

[Shoduchi]

I went for the 20 teeth parking brake LSD version. My Ed. 30 was built in February of 2008 and the gearbox code is KNB. Hope we both got it right. 

Loving all the new bits you bought. I've read that the external oil pump for the DSG cooler is advised. The stock pump is too weak. Hope others can help you with that upgrade too. 

[teo_parvu]

I went for the 20 teeth parking brake LSD version. My Ed. 30 was built in February of 2008 and the gearbox code is KNB. Hope we both got it right. 

Loving all the new bits you bought. I've read that the external oil pump for the DSG cooler is advised. The stock pump is too weak. Hope others can help you with that upgrade too. 

That’s valuable information for me, Joaquim. Thanks bro!

Since your gearbox is KNB and mine KNC, for sure I too have 20T. I will have to get the LSD changed.
I will not take the chance to overheat the gearbox, I’m going to buy an external oil pump then. :/

LE:

Ordered:
 - DSG Oil Cooler Auxiliary Pump
 - Auxiliary Oil Pump Temperature Switch