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My LCR 225 - Badger 5 edition. PIC Heavy first page.

Discussion in 'The Project Room' started by Dan1720v, Mar 12, 2012.

  1. Dan1720v
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    Dan1720v Member

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    [Mar 12, 2012]
    Copied direct from other forums.

    18th November 2011, made the 350 mile round trip to go and collect it. Bought it from a very loving owner, who also gave me alot of other bits and pieces i wasnt expecting, like 5l of mobil 1 oil, tailor fitted car cover and a few others.
    Well here it is...
    [​IMG]
    Basic spec:
    225PS – 1.8, 20v Turbo – Running the standard map
    • K&N 57i Cone filter – freshly cleaned and re-oiled red
    • Jabbasport polished stainless heat shield
    • Autobahn88 Silicone Turbo intake pipe, in red
    • Newsouth phenolic intake manifold spacer gasket
    • Forge Motorsport closed loop diverter valve
    • N249 Bypass mod
    • Various replacement vacuum/boost hoses in red silicone hose
    Wheels/Tyres:
    • Standard Leon Cupra R 18” wheels – minor scuffs and discolouration, but no buckling
    • Toyo Proxes T1-R’s - All 4 newly fitted in February this year, with less than 5,000 miles covered
    Brakes:
    • EBC Ultimax Discs front and rear
    • EBC Yellow stuff pads front and rear – rears have plenty of life left, but the fronts are due for replacement. A set of OEM spec Ferodo pads will be fitted prior to sale.
    • New O/S/R calliper, lacquered red to match, fitted at time of brake overhaul (approx 35k ago), plus new brake fluid
    Chassis:
    • Superpro Polybushes - fitted to Wishbones, Dogbone Torque mount and Anti-roll bar
    • Audi S3 upper strut brace
    • Original Stock LCR spec springs and shocks – Firm and stiff, but not harsh
    • N/S/F Wheel bearing replaced – January 2010
    One thing I didn't realise, was how slow these are in standard trim!! Soo...
    [​IMG]
    FMIC
    Milltek exhaust, non res, with sports cat.
    this shall be fitted next week and hopefully in for mapping at P-Torque at the weekend...
    Today gave it a winter protection, using :-
    Auto glym SRP
    Jetseal 901
    Supernatural Hybrid Sealant
    Dodo Juice Purple Haze wax
    [​IMG]


    20/11/11


    Soo...
    Stealth
    Before,
    [​IMG]
    During,
    [​IMG]
    After.
    [​IMG]

    21/11/11


    Update again..
    [​IMG]
    Love it!
    Then I got lazy and got someone else argue with the seized cat bolts
    [​IMG]
    Already pulls so much better than the standard down pipe back system. Hopefully it'll be in for mapping on Saturday.

    24/11/11

    More pictures with another wax coat:
    [​IMG]
    [​IMG]
    [​IMG]
    Some pictures to show how (in)visible the intercooler is:
    [​IMG]
    [​IMG]

    27/11/11
    Well, took the trip up to p-torque yesterday.
    Arrived there will was tied up with another car but took the time to come and explain he was running slightly behind, but would be with me shortly.
    After he finished, onto my car it was. Strapped down and ran up on the rollers. Then, on the power run, disaster!! Down to 3 cylinders. Gutted. Especially as the previous lever had only just replaced the coils before I bought it. Will took off the. Engine cover off and found cyl 4 cool had come unplugged. Due to a broken look clip. I think he was relieved as I was!
    After a few runs, he unclipped it and took it out. Came back and handed me the keys, I took it out, and at first, a little disappointed, but i think this is due to how smooth it is. However, when I drove away, it felt ALOT better, I'm guessing it was down to the heat soak.
    Results were:
    Std 224bhp/fly
    P-torque 278.0/fly
    Std 175bhp/wheels
    P-Torque 242/wheels
    Std 219lb/ft
    P-torque 302lb/ft
    Will did say it made 315lb/ft at one point but was getting vibration from the flywheel do knocked it back :)
    The drive home, as expected, fun. Apart from pulling out from strensham services, giving it a boot full and BANG. I initially thought, well, rods did well lol. But it was the dump valve being blown out the charge pipe :) so a 2 mile walk back to get a screwdriver and all was sorted.
    Pics/vid
    [​IMG]
    Graph
    [​IMG]
    Vid:
    http://i432.photobucket.com/albums/qq49/dunlop172/d2135c8b.mp4

    (All was not as it seemed as you shall read further on...)


    12/12/11

    [​IMG]
    **** just got real y0.
    KW V3's.

    5/1/12
    Quick detail using New products and camera

    quick clean and playing about with my new 350d :)
    [​IMG]
    [​IMG]
    [​IMG]
    [​IMG]
    [​IMG]
    [​IMG]
    [​IMG]
    #1
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  3. Dan1720v
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    Dan1720v Member

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    [Mar 12, 2012]
    Clean:
    [​IMG]
    [​IMG]
    [​IMG]
    [​IMG]
    [​IMG]
    [​IMG]
    [​IMG]
    [​IMG]
    [​IMG]
    [​IMG]

    17/1/12
    One of a few packages has arrived ;)
    [​IMG]
    [​IMG]
    Delivery 2/5
    [​IMG]
    Delivery 3/5
    [​IMG]
    And 4/5
    [​IMG]
    Final delivery is here, many thanks to Russ, my mate who works for VW as a parts manager..
    [​IMG]
    All genuine:
    Cambelt kit
    Water pump with metal impellor
    Head gasket
    Head bolts
    Thermostat
    4/2/12
    A few pics.
    Managed to get the rounded bolt out, so its now at the stage of removeing the oil pump and strainer to remove the rods.
    I am also waiting on a delivery from the us of a..
    Some pics of today and yesterday.
    [​IMG]
    [​IMG]
    [​IMG]
    [​IMG]

    Loose from the factory? I've no evidence of the turbo ever being removed.
    [​IMG]
    [​IMG]
    [​IMG]
    Cleaned the pickup...
    [​IMG]
    Rod installation
    [​IMG]
    [​IMG]
    [​IMG]
    More parts
    [​IMG]
    [​IMG]
    Rocker gasket
    Turbo gaskets
    Manifold gaskets
    Updated 'sputter' big end bearings
    Tubular manifold
    3" down pipe
    3" sports cat
    #2
  4. Dan1720v
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    Dan1720v Member

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    [Mar 12, 2012]
    17/2/12
    Well, due to problems at home(gf...) Meant the rebuild pics are kind of non existant.
    Apart from this one.
    [​IMG]
    Heres a pic of the badger 5 tip:
    [​IMG]
    and the manifold:
    [​IMG]
    My rear arb also arrived today :)
    Here's 3 videos.

    Noise(with ESP intervention)
    http://i432.photobucket.com/albums/qq49/dunlop172/2ef8c02c.mp4

    Spool up
    http://i432.photobucket.com/albums/qq49/dunlop172/5a37b840.mp4

    And speedo.
    http://i432.photobucket.com/albums/qq49/dunlop172/b2d68bba.mp4[/QUOTE]

    24/2/12
    Well, a LONG overdue update. Not really been in the frame of mind to update due to becoming single again
    Anyway

    A new bit arrived..

    A Neuspeed 28mm Rear Anti roll bar. Decided i didnt like the red it was powedercoated so keyed it up and painted it matt black, in keeping with the car's stealthy appearence

    Fitting was a doddle, took all of 20 minutes, and has 3 adjustable settings, soft, medium and hard. Me being me, set straight to hard :p

    Fitted:
    [​IMG]
    Next up, was just an oil change, seeign as it hadnt been changed since the new rods and shells went in. Here is imo a picture worth noting. This is why I ALWAYS run a magnetic plug or atleast a strong magnet on the sump after doing a build, you can be as clean as you like, but in a workshop environment/home there will always be **** that gets in places you didnt see.
    [​IMG]
    I also Fitted braided lines, and did a full fluid change for ATE Superblue. Here is a few pics as to why it is nice to use when bleeding through
    [​IMG]
    [​IMG]
    Old:
    [​IMG]
    New:
    [​IMG]
    Next up was an offer I saw on here, vermiglius@aol.com Joel Vermiglio is doing a cracking deal on alignment/corner weighting/camber/castor (basically, if you can change it, they'll set it up) etc for £50. he is part of Bridgwater college's motorsport course. Having been in contact, I got my car booked in for tracking check and corner weighting.
    I took the trip down for my booking slot at 5pm, arrived to meet Joel and his tutor (who's name has slipped my mind!) to discuss how the car was used and what I wanted out of it. I explained that I shall be using the car on track alot so would want a reasonably aggressive setup.
    [​IMG]
    [​IMG]
    First of all he went round checking my current setup, height, wheel alignment and damper settings. I had set the alignment and height up by eye, And I was impressed myself at the results:
    FL
    Toe 5mm TTout
    Height 588mm
    Bump 3 clicks
    Rebound 1.5turns
    Weight 428.5kg

    FR
    Toe 5mm TTout
    Height 590mm
    Bump 4 clicks
    Rebound 1.5turns
    Weight 495.0kg
    RL
    Height 619mm
    Bump 6 clicks
    Weight 347.5kg
    RR
    Height 622mm
    Bump 5 clicks
    Weight 296.0kg
    [​IMG]
    They then went on to disconnect the roll bars to enable corner weighting.
    [​IMG]
    I asked for my corner weighting to be setup with me and a passenger of similar weight, as Im usually on track with a passenger.
    The results looked like this:
    [​IMG]
    [​IMG]
    Shes a lardy mofo!!
    I let them work they're magic on it and here is the result(without passengers) after the 1st adjustment
    [​IMG]
    Not bad I thought!
    And after another tweek(with me and a passenger)
    [​IMG]
    Truely impressed!! Joel and his tutor then discussed any handling characteristics I liked or didnt with regards to the dampers, after a short chat they decided to stiffen the front and soften the rear a tad.
    Here are the final settings:
    FL
    Toe 5mm TTout
    Height 592mm
    Bump 6 clicks
    Rebound 2.5turns
    Weight 457.5kg
    FR
    Toe 5mm TTout
    Height 590mm
    Bump 6 clicks
    Rebound 2.5turns
    Weight 466.5kg

    RL
    Height 621mm
    Bump 2 clicks
    Weight 317.0kg

    RR
    Height 622mm
    Bump 2 clicks
    Weight 325.0kg

    All in all, I've not really had a chance to push it yet, but the feel of it is very different, feels alot more keen to corner rather than a bit, 'fidgity' like it was.
    I can highly recommend them for how it was set up and I'm happy to have taken it there, Its not actually a case study or part of they're course, the money goes towards they're castle combe race car running costs, and they get valuable learning experience of how to set different cars up.
    #3
  5. Dan1720v
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    Dan1720v Member

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    [Mar 12, 2012]
    27/2/12
    So!! Saturday came, And i departed at 8 to make the trip up to Bill, to have my map reviewed after a few changes.
    After chatting with Bill discussing how the car drove and what has been done he set about getting it on the rollers.
    [​IMG]
    He ran it up and Disappointment followed...
    Power was pretty much what P-torque said, however, torque was a good 60lb/ft down. Not only that, but it was very lean. VERY lean. to the point that EGT Protection was kicking in by 6000rpm.
    I shan't repeat Bills initial comments :( lol.
    At this point, it was decided a Full map would be done.
    So after a few Tweeks bill had the AFR's down to where they should be. He then started working on the boost pressure.
    A few running shots:
    [​IMG]
    [​IMG]
    [​IMG]
    We found that either i have a weak actuator or a rather worn turbo as peak boost even after a spike was 22psi. and tailing off massively towards high RPM. However, even with this little boost, both Bill and Tufty were impressed with the power it made. What impressed me and I feel is a testiment to Bills Mapping is the torque 'curve'
    As seen here:
    [​IMG]
    And here is the other sheet showing how bad the AFR's were,and how the boost tails off.
    [​IMG]
    On the Road, Its an absolute missile. scarey thing is how its acceleration between 3000-6000 is nigh on the same all the way through, makes a quick motorway overtake, with a dab of the throttle into silly speeds very quickly.
    Taken on bored Bills advice and have started on the parts he recommended, a new Actuator, and a water meth kit.
    Oh and I had to modify a sticker I had ;)
    [​IMG]
    Then yesterday I did a quick refurb of my wheels:
    Before:
    [​IMG]
    After:
    [​IMG]

    7/3/12
    Got my Methanol :)
    [​IMG]
    And the new actuator sorted the lack of a boost spike ;)

    [​IMG]

    10/3/12

    Oh My welly cooler turned up and so i took no time in fitting it.
    Old and new:
    [​IMG]
    New one:
    [​IMG]

    And thats to date
    #4
  6. Dan1720v
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    Dan1720v Member

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    [Mar 17, 2012]
    Sooo, Clutch change today.

    Not much else to say.

    1045am:
    [​IMG]

    12pm
    [​IMG]

    New clutch in
    [​IMG]

    1230
    [​IMG]

    230pm FINISHED!
    [​IMG]

    Then faffed about fitting new droplinks:
    [​IMG]

    Finished product
    [​IMG]
    #5
  7. warren_S5
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    warren_S5 Moderator Staff Member Moderator VCDS Map User

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    [Mar 18, 2012]
    Love a bit of Cupra R action.

    Dare I say it on an Audi forum????? LCR, the most fun you can have on the Mk4 Golf platform?!?!?!?

    Good work, and getting close to the magic 300!

    Like it all apart from the rear window sticker, great work!
    #6
  8. razza1
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    razza1 Well-Known Member

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    [Mar 18, 2012]
    Always liked these, looks good
    #7
  9. Dan1720v
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    Dan1720v Member

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    [Mar 18, 2012]
    The rear window sticker was originally a p-torque sticker that i arsed about with. Has gone now though came off when i washed it yesterday lol
    #8
  10. voorhees
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    voorhees Moderator Staff Member Moderator

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    [Mar 18, 2012]
    Impressive work
    #9
  11. Dan1720v
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    Dan1720v Member

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    [Mar 26, 2012]
    Yes, certainly hope so!!

    Anyway.
    The start of a 2 day detailing session. I started by tidying up a few bits a pieces i wasnt satisfied with. namely the routing of my WMI pipe work, no pics, but it now follows the brake pipes.
    Today, was refitting of the new Splitter after i destroyed it leaving the workshop when i did my clutch :censored: I also refitted my passenger fog:
    [​IMG]
    [​IMG]
    Then onto the arches and liners, Scrubbed using AG Engine and machine cleaner and a bucket of water and various brushes:
    [​IMG]
    [​IMG]
    [​IMG]
    [​IMG]
    And dressed with UB40
    [​IMG]
    [​IMG]
    Tomorrow, is Paint correction and glaze/wax etc etc. I shall be joined by My glamourous Assistant I have bribed with letting her use my car as a Test mule for her first rotary attempt. And probably food. lol

    Day 2:
    Heres a few pics after the finishing touches:
    Products used:
    Chemical guys Glossworx wash
    Dodo juice clay bar
    Poor boys SSR3
    PB Black Hole
    Nattys Blue Paste (didn't like the results, so topped it with some CG Butter wet wax)
    Clay(this was the most contaniment(sp)
    [​IMG]
    A few swirls before hand:
    [​IMG]
    [​IMG]
    No pics afterwards, however I shall grab some tomorrow.
    Finished Product, My glamours assistant was delayed before coming round so Turned up intime to put on the tyre shine lol
    [​IMG]
    [​IMG]
    [​IMG]
    [​IMG]
    My Favourite one:
    [​IMG]
    #10
  12. Dan1720v
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    Dan1720v Member

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    [Apr 5, 2012]
    My new plates arrived today, had the reg transferred over yesterday :)
    [​IMG]
    And I've bought a GT2871r kit :)
    #11
  13. Tommy g
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    Tommy g New Member

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    [Apr 9, 2012]
    Just gone through the build thread. Some very good progress. Look foward to future updates :)
    #12
  14. Dan1720v
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    Dan1720v Member

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    [Apr 9, 2012]
    Thanks fella
    #13
  15. Gops
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    Gops 6th gear @7000rpm

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    [Apr 10, 2012]
    Brilliant work here dan, very impressed and that car moves!!! Sounds great too! What map did you have that was running lean? I may have to get bill to check my map when i go for my tip as i have a feeling its not right. But lovely car!

    EDIT: read the post and it was p-torque doh!
    Last edited: Apr 10, 2012
    #14
  16. AlexGSi2000
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    AlexGSi2000 Well-Known Member VCDS Map User

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    [Apr 11, 2012]
    I love these cars - was going to buy one a few years ago, but due to my age and insurance costs, I had to settle for a MK3 Ibiza Cupra R.
    #15
  17. Dan1720v
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    Dan1720v Member

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    [Apr 12, 2012]
    Guess what's here :D[​IMG][​IMG]2871r time!Just need a clutch and injectors.
    #16
  18. S3 Rav
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    S3 Rav Well-Known Member

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    [Apr 15, 2012]
    Great read that.
    #17
  19. Westy
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    Westy Double Dark Side! Diesel & 8P

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    [Apr 17, 2012]
    Christ, someone doesn't hang about! Good work here mate.
    #18
  20. Dan1720v
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    Dan1720v Member

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    [Apr 18, 2012]
    Its like a bug isnt it ;)

    I've had a message from Bill saying my Hotside is ready to come back, he has ported it slightly and improved the wastegate as it was tiny apparently. And he has welded in an EGT Sensor boss.

    I also have some 630cc injectors en route :) Now all i need is a clutch :)
    #19
  21. Dan1720v
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    Dan1720v Member

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    [Apr 28, 2012]
    Castle combe action day today, car performed faultlessly apart from the atrocious weather and the continentals not coping very well(scrubbed 1.5mm off today) so they are now borderline. getting changed monday for the michelins.
    Had a minor excursion in the first session about lap 3, understeered at about 120 in folley which resulted in a minor tail slide correction, decided to take the safe route of the Grass for about 300 yards, and lost the splitter and passenger fog light grill. But it was very quick, across 4 sessions, i think 4 cars over took me, namly because of traction out the corners, wheelspin in 4th was a pain.
    Over took numerous cars, and pushed an hawk eye Impreza into a spin trying to out brake and corner me.
    Pics, note the grass :lol:
    [​IMG]
    [​IMG]
    [​IMG]
    [​IMG]
    [​IMG]
    [​IMG]
    [​IMG]
    [​IMG]
    #20
  22. Dan1720v
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    Dan1720v Member

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    [May 1, 2012]
    Busy saturday me thinks.
    [​IMG]
    #21
  23. Dan1720v
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    Dan1720v Member

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    [May 2, 2012]
    More of mine:
    [​IMG]
    [​IMG]
    [​IMG]
    [​IMG]

    Hassling the DC2
    DC2
    [​IMG]
    [​IMG]
    [​IMG]

    Then next lap, the m5:
    [​IMG]
    [​IMG]

    [​IMG]
    [​IMG]
    [​IMG]

    By the looks of my hand movement, i was getting a little frsutrated with the car infront...
    [​IMG]
    #22
  24. Dan1720v
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    Dan1720v Member

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    [May 2, 2012]
    I have ordered my new brake pads

    [h=3]RC8[/h]

    Outrageous stopping power, these pads must only be used with other CL products as power is so high. These are for use in the most severe conditions such as GT racing, WRC Tarmac, World Touring Car, and NASCAR.


    I think they'll do.
    #23
  25. Gops
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    Gops 6th gear @7000rpm

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    [May 3, 2012]
    Car looks lush matey! Nice to see it coming along great but ouch with the splitter lol!
    #24
  26. Paradox1
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    Paradox1 Active Member

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    [May 4, 2012]
    How the hell have I missed this thread! So much hard work has go onto this.

    Looking forward to the new turbo setup......as if you needed a bigger tutbo!!
    #25
  27. Dan1720v
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    Dan1720v Member

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    [May 6, 2012]
    So update. Unfortunalty, my camera died after about 4 pictures.
    Basically, all was ok, until, it came to fitting the downpipe. the 2871r is longer in a dimension somewhere meaning the relentless manifold and downpipe fouled each other. so a bit of 'tolerancing' was required. a small dink in the manifold and about 10mm of downpipe plange was cut away to allow fitment.
    This has meant its making contact with the body somewhere which is annoying as I cant see it, so it's coming off again tomorrow for more 'tollerancing'.
    Started up with the new clutch and it is genuinely silent. Ive not seen a SMF conversion like this until now.
    Clutch feel is lovely, very OEM.
    Turbo wise. Well. OH MY GOD. Spool is just the same as the K04, but, its holding 26psi at 75% throttle at 5000rpm Before I Bottled it. as my laptop didnt standby and had gone flat again.
    Laptop charged up today, +10% fuelling, and -5* of timing to make it run a bit safer when on boost.
    Did a quick log, it started to run lean at 6300 so aborted, however just as i aborted the highest MAF reading was 269.11g/s (336.25bhp) :) Its going to be a quick one :)
    N75 Now unplugged to limit it, and now its the LONG wait until the 2nd of june until Bill Can get it in to map it.
    #26
  28. Prawn
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    Prawn My other car is a MINI!!!!

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    [May 7, 2012]
    Sounds awesome Dan!

    I saw this on track at Combe, looked to be going well. Didn't realise the spec at the time, it's a proper sleeper!

    I didn't realise Joel was doing geometry for people now either! I went to school with Joel so I've known him for years. I think I'll have to get in touch to get mine setup!
    #27
  29. Dan1720v
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    Dan1720v Member

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    [May 7, 2012]
    Thanks fella, Yes it felt really good at combe, but there was too much traffic and too little traction to really press on. Joel seems to know what hes doing from my experience. Ive got a half decent idea of suspension setups from doing my apprenticeship in a motorsport based workshop, but it was good to speak and learn a little more ;)

    Yeh I like the idea of it being stock looking ;)
    #28
  30. Prawn
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    Prawn My other car is a MINI!!!!

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    [May 7, 2012]
    You need a diff my man! I think it was dryer when I went out later in the day, but I wasn't struggling with traction at all really
    #29
  31. olly quattro
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    olly quattro Member

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    [May 8, 2012]
    what clutch did you go for in the end?
    #30
  32. Dan1720v
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    Dan1720v Member

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    [May 8, 2012]
    A diff is certainly on the cards, I've got a spare box to rebuild, just time and money I don't.

    I went for the awesome GTI Clutch
    #31
  33. superkarl
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    superkarl MAN OF STEEL

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    [May 13, 2012]
    nice car and great work.

    is the gt28 an 'eliminator'?
    and where did you source that from?
    #32
  34. Dan1720v
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    Dan1720v Member

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    [May 15, 2012]
    Thanks.

    yes it s 2871 eliminator, was from a member on here.
    #33
  35. Dan1720v
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    Dan1720v Member

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    [May 16, 2012]
    Few deliveries to fit this weekend...
    [​IMG]
    Compbrake top mounts
    and my new RC8 pads :)
    [​IMG]
    We also have the arrival of my £400 beater :)
    [​IMG]
    #34
  36. Dan1720v
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    Dan1720v Member

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    [May 27, 2012]
    Well, new fuel pump fitted today, Cable tie was until i could replace it with a jubilee clip.
    [​IMG]
    Wired in with the other pump with an inline fuse.
    [​IMG]
    New RC8 Pads
    [​IMG]
    And its nice when people take pictures without you knowing...Yes I really need to shave...
    [​IMG]

    And on another note, I'm going to semi Start up as a specialist to 20vt's and Renaultsport among things. Ive got use of the workshop seen in the pics, and will be working under the name of the owners, but will be doing the specialist work for them. So feel free to bring the business to me if your in need of any work doing
    #35
  37. k1ano
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    k1ano Member

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    [May 27, 2012]
    Great read :)

    Martin
    #36
  38. Paradox1
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    Paradox1 Active Member

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    [May 28, 2012]
    Well done!

    Wheres the workshop??
    #37
  39. Dan1720v
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    Dan1720v Member

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    [Jun 3, 2012]
    Workshop is in Glastonbury :) and we're less than a mile from clarks village so perfect excuse to have your car done as the mrs can go shopping ;)

    Update:
    [​IMG]
    [​IMG]

    Comparison to the K04.
    [​IMG]
    [​IMG]

    Not quite the result I was hoping for tbh, but I believe this is down to the K04 flange being too restrictive for the 2871's flow.

    Final Figures were
    336bhp
    291bhp at the wheels
    321 torque
    #38
  40. Dane
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    Dane Faster than a V12 Q7

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    [Jun 4, 2012]
    The delivery is nice, even if the figures aren't quite what you were hoping for.
    #39
  41. Dan1720v
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    Dan1720v Member

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    [Jun 4, 2012]
    Oh certainly. Its an absolute missile once rolling. in gear 40-140 is quite frankly scarey.
    #40

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