Long overdue update!
I sang the praises of epytec too soon! i got a new flywheel down which was still incorrectly machined. the friction surface was too small for the gti 220mm clutch. So if anyone ordered one be prepared to have it machined down.
A few updates have happened since the last update:
A new ebay afh manifold was fitted, as expected this too a fair bit of bending the clear the gti sump. This gave a few ft/lbs in the mid range of increase over the stock item
I 3d printed a Carbon fibre Nylon inlet manifold for the ITBS, the alloy one purchased didnt have very smooth gas flow and pretty poor port matching. 3d printing one enabled me to port match it perfectly. Along with this i 3d printed some trumpets. This along gave a massive increase in power and torque. dyno runs showed a consistent 170-172bhp. This is for all intensive purposes a 10bhp upgrade from the manifold and trumpets alone. A very worthwhile exercise
I dropped the 6 speed out to refresh it with new bearings and fitted a 4.53 final drive, at the same time fitted a helix sprung paddle clutch. the final drive made a nice difference, in hindsight a 5.08 final drive would be better for my application but is a fair chunk of change. For anyone wandering the helix clutch is still very driveable!
SInce the last update we have done a few rallies down in the quarry. Car ran flawlessly for all events!
We entered the 2021 L'etacq attack rally, coming 1st in class out of 5 and beat some very quick cars.
The 2021 Jersey rally came around very quickly (8th & 9th) and although the car was thoroughly prepared we had multiple issues all weekend
The first came on SS4, we were battling for 1st in class when we bent a lower arm which lost us a lot of him. this wasnt from hitting anything and we due to the amount of grip the tyres had on an off camber hairpin right. We were gutted as this pushed us right down the standings. This for swapped out at service and started the push to make up the lost time.
The night stages came around and an electrical issue left us stranded on the side of a road section, luckily we managed to fix it with a pair of snips and duct tape!
The Saturday went great until the penultimate stage (25 out of 26) where we sheared the stub on the RHS cv joint, this put us out of the rally as we lost all drive. upon inspection the cv joint fitted wasnt a JR cv joint, maybe this is why...
Lessons learnt/to do:
Lightly reinforce lower arms and dont buy cheap arms. there are reinforcement plates available for mk2 golf arms, ill do a similar exercise. however i don't want to make the arms so strong that the chassis is now the weak point
Only use quality cv joints, a lad on the polo forums upgraded to r32 cv joints however this requires a full custom front suspension set up which is abit out of my skill set. Ill just use quality CV's from now on and inspect them once a year
Here's some photos of whats happened since the last update (in no order)