Our Golf GTI Stage 3+ build thread - WORLDS FASTEST

[Guy_H]

Thought I would share some build info on our latest project - we have been working with APR for over 13 years & have built many stage 3 cars, including Audi A4's, GTI's S3's & Golf R's. We have a great working relationship with APR for over 13 years & are very lucky to have the opportunity to work closely with their engineering team.

This is our second TSI build on our own cars, our previous MK6 (a red 4 door 6MT) ran the "regular" stage 3 kit on a stock engine. This vehicle saw a lot of track use and magazine testing. To date, its still the fastest FWD car ever circuit tested by Motor Magazine (Australia).

http://goapr.com.au/media/mm-june2011.pdf





It ran 12 second 1/4 miles pretty easily (at ~ 114mph), but never really impressed in straight line acceleration (to journalists) because of the 6 speed manual transmission.

So it came time to build our next car, so we had to work out how to build a better car than our little red beast, we came up with a plan:

DSG
APR Stage 3+
More front end grip

So we purchased a new 3 door DSG and went to work.

Here it is, unmodified, being run on our dyno & then with APR stage 1:



And the results:

[Guy_H]

Engine build:

We secured a good low mile stock CCZB engine & spare DSG box for the car, as it's my daily driver, I didn't want it off the road whilst we built stuff. Good choice in the end because it became an issue to get correct pistons for this particular engine code (completely different to the US spec engines) and it took months....



We are very lucky to have a really good engine builder on staff, and Mark worked with the APR team to build the engine with all the assistance of the APR team & their experience with the TSI race cars.

Cylinder head was left completely stock, the combustion chambers were all cc'd, the bore is stock, it was a fairly low mile block & was just re-honed.

[Guy_H]

Now with the DSG, we run SSP 600 pro clutch packs & oil, we have our own DSG software in place, and our friends at Volkswagen Racing UK helped us source a DSG plate differential. We have used many quife's, Peloquins & Wavetracs over the time, but when seconds a lap count, only a clutch plate version cuts the mustard. This was quite a task as it required machining & modification to fit the MK6 box.

Clutch pack build



The heart



Checking the ramp settings & preload



Setting the backlash



screwing it back in



Because the car sees a fair bit of circuit work, we wanted the assurance of the Accusump, so decided a relocate of the battery to the boot was the best method of getting us the space we require in the engine bay. Machined the Accucsump adapter in house. We also run the APR Motorsport recommended catch can setup which took extensive modification for RHD.

[Guy_H]

Intercooler - standard fare - the car runs the off the shelf APR RSC with 200 cell catalyst.



You will see in the suspension dept, the car run's Ohlins dampers, It now has VWR springs, it wears our own alloy control arms & sway bars.



To get more rubber on the road, my grand plan was a wider front end. We went with the Kersher German guards that gave us an extra inch internally with no protrusions. At the moment we had hoped to run VWR Scirocco 9" rims, but the offset has proved not ideal. at least it gives us fantastic clearance for 245 width tyres, but not the 275's I had hoped for.







Brakes are the VWR 6 pots - getting excellent results on the street & on the circuit. The VWR rims fit nicely under there with the poor tortured tyres.

Time for some warpaint: Insipired by the WRC Polo



With a customers "regular" stage 3



This is a place where it has spent a lot of time recently:



And here is where we are at today - running Sunoco GT260 plus - vs standard.

[Deadpool]

Great write up, Guy.

Really interesting to see how all this stuff comes together.

[Eddy]

Hoyhoy.

Seems like Ya-self, James & Mark have been working hard, looking very impressive & very serious.
Me like.

[Guy_H]

Thanks Deadpool - it's an absolute weapon.

Eddy - as an owner of a well sorted FWD, you can imagine what this is like. One thing we did prove recently on a photoshoot - we can leave 50 metres of rubber on the road (2 wheels in a dead straight line) so we have worked out how to "warm up the tyres" now

[Umai Naa!!]

Good to see an Australian workshop game enough tear one of these down for a thorough workover.

[BrashDaniels]

Thanks Deadpool - it's an absolute weapon.

Eddy - as an owner of a well sorted FWD, you can imagine what this is like. One thing we did prove recently on a photoshoot - we can leave 50 metres of rubber on the road (2 wheels in a dead straight line) so we have worked out how to "warm up the tyres" now

Awesome way to show the quality in your work. Now do a SKODA :p (I can ask can't I ?) :p

Sent from my ASUS Transformer Pad TF300T using Tapatalk HD

[Guy_H]

Awesome way to show the quality in your work. Now do a SKODA :p (I can ask can't I ?) :p

Sent from my ASUS Transformer Pad TF300T using Tapatalk HD

My wife has banned me from touching her Octavia VRS