11-09-2009   It is getting time for a big winter build and we have our first shop project for the winter. We have a Tornado Red 2004 VW R32 that only has 18k miles on the clock. This car is in mint condition but is about to be transformed into a turbocharged street monster. Jason Koenig out of Denver Colorado owns the R32, and was kind enough to meet up with me back in September to discuss what he envisioned for his R32. Basically Jason had one thing on his mind and that was more power! Although along with the power we will be upgrading some other things as well. His ultimate goal was to have around 500hp to 600hp. So my task was to create a setup that would not only perform well but also would grab anyone’s attention when the hood is open and remain discreet while the hood is closed which would involve hiding or masking the intercooler and piping.
     After getting the list from Jason down onto paper I decided to give Chris at C2 Motorsports a call to discuss what the customer was looking for. Chris, as always knew just what to come up with and he put together somewhat of a hybrid turbo package. Below is a list of what we have decided to go with. 

1.  Precision Turbo
   -model 6265B
   -billet wheel
   -dual BB
   Cast Turbo Manifold
2. Stainless Steel Tubular Turbo Header
3. Tial 38mm WG
4. Stainless Steel 3” Down Pipe: V-band
   Equipped
5. C2.R32 Front mount intercooler with
   a 24 x 8 x 3.5 Garret IC Core and custom laser cut end tanks. The hidden end
   tanks allow for the lower grilles to be used
6. Stainless Steel Intercooler Piping
7. Custom 3” Custom Stainless Steel
   Exhaust With 4” Tips
8. 3” Stainless Steel Hi-Flow Cat
9. Stainless Steel Intake Turbo to TB
10. R32 High Volume Fueling Kit
11. 6 550cc Bosch #52 Injectors
12. 4.00" Open-Element Filter
13. C2Motorsports Turbo Software
14. T304 Laser Cut Stainless Steel
    Lowered CR Spacer 9:1
15. OEM Crush Gaskets
16. Raceware Head Studs
17. “The Bat” 4”Stainless Steel Intake
    w/MAF
18. Forge DV
19. Silicone Couplers
20. Stainless Steel Braided Oil
    Feed/Return Lines
21. Oil Fittings
22. Forge Manual Boost Controller
23. Southbend Stage 5 Clutch Kit With
    Aluminum Flywheel
24. 264/260 High Performance Schrick Cams
    
25. Agent Orange Haldex Controller
26. New South Oil Pressure And Boost
    Gauges
27. VF Engineering Mounts Engine,
    Transmission, and Pendulum
28. Upper And Lower
    Bluewater Performance Rear Adjustable Control
29. Arms
30. Brembo 6 piston 355mm Big Brake Kit
31. 2 piece Drilled Rear Rotors
32. Hawk Pads
33. Stainless Steel Braided Lines
    

 

This is
what we are starting with.

 

Well the
car came in to the shop last week and the first item on the list was the clutch
setup. Originally we were going to go with a Streetwerke stage 4 setup, which
utilizes the stock dual mass flywheel, but since I had a good experience
recently with the new Southbend setup I purchased one of their Stage 5 clutch
kits with a lightweight single mass flywheel instead. This setup should not
only handle even more power than the Streetwerke setup but it also should last
longer. It is a full faced clutch instead of a puck design like the Streetwerke
one.  This clutch setup is capable of
holding 750 ft.lbs of torque!!!

Update:11-15-2009 So this weekend we worked on pulling the head and installing the 9:1cr head spacer. Also the Schrick cams will be in this Monday just in time for the install. Enjoy the pics.

Update:11-17-2009 Schrick cams installed!!

Update:11-24-2009 We have hit a wall in our turbo build and we are just waiting on parts... So to change the pace up we decided to install the upgraded brakes to stop all of that power. We decided to purchase the 6 piston 355mm Brembo Big Brake Kit. This kit is HUGE!!!! and should slow this beast down in no time.

Update 12-06-2009 This weekend was a big one. We installed 2 sets of BW Performance rear control arms, the same ones that I manufactured for G&G Motorsports, all 3 VF Engineering Mounts, a Walbro inline fuel pump, and a lot of the turbo parts that came in from C2 motorsports. Enjoy the pics.

 

Update 12-15-2009 We got the Short Runner Intake finally installed with the new fuel injectors/wiring harnesses and the fuel pump wired up. Also we have rerouted a lot of the lines and hooked back up most of the sensors in the engine bay. It still looks like there is a lot to do but honestly most of the hard work is done. We are now just waiting on more parts to come in. Oh.. Also we got the oil pan pulled and the oil return bung welded in but I forgot to take pics.

Update 12-27-2009 The Final pieces... Things are winding down and we tried to have the car finished for  Christmas eve so the customer could drive it and this is what has been done over the last 10 days.

Old Vacuum lines removed.

New Silicone vacuum lines.

New South Perfect Match Boost Gauges

Update 1-07-2010 Finally the car is back in for the last installment which happens to be a Snow Performance Stage 3 water meth kit, upgraded pads and rotors on the rear and we also took off lots of parts to have them ceramic coated or powdercoated. This will be our last installs on the R and we will be sad to see it go.

 

More to come!!!!