D Racing

First off Happy New Year!

Where does the time go! Time to get Caught up!

So After the Track day last year, Some descussions were had behind the scenes.

So to fill in the Gaps for the non-VW people, VW are masters at building there cars on a platform bases - Not the only ones but 100% up there with regards to using it on such a range of cars.
Early DSG equiped cars were refered to as PQ35 base, and the 2012+ cars are in the current MQB platform.

So what does this mean for me, the Focus DSG was from a PQ35 build, This was the only option at the time i started the conversion. But like everything Tech moves so fast and the advantages of it.
And just on Q, Syvecs's Newly released "beta" softwear for the MQB Generation of gearbox's was released.
After a talk with the lads at PERON Automotive and Romain RaceCal Ltd, I decided that it was the right move to make the jump to the MQB generation. The logic is the TCU being more advanced and just up to speed with regards to DSG control.

A Quick switch of TCU's would of been nice but the coding for the syvecs was diffrent from before so alot of other changes had to be made in the back ground.
Peron supplied the MQB TCU, flashed with the TVS softwear, and Romain provided the Syvecs MQB Firmware for the S7.
Rest is now up to me to get it in and working, before a trip to the dyno to get it all dialed back in.!

So what has changed.
Biggest thing is the requirment to run a VW "shifter". I liked the look of the Cupra one the best to picked that.
There also a requirment for a few more wires. And by a few i mean a good bit more!
So i had to make up a new CANBUS loop, This had to included the shifter being in the same loop as the TCU. So a bit of thought had to go into running a new loom for that. Also while i was in about it all, i added a Syvecs TinyDash V2 supplied by Team Legacy. This allows me to not only see ECU information, but has the added benift of allowing me to Switch Maps, TC and other settings i can program into it. So 7 more switches added but i actually removed 2 toggle buttons and a rotary switch and free'd up 3 inputs at the same time as this is all on CANBUS.

Next up was installing the VW shifter, i could of bolted this to the floor and called it done. But i like a project!
Having been in about VW's TCR cars i liked the little centre consel they had, only issue was its £900 and designed for LHD. So i thought id make my own!

Designed it in CAD, then needed it printed so i could mould it. After getting some silly quotes back, i ended up buying a 3D printer of my own so i could print it!
Once printed, a mould was made and i then made it out of Carbon.
That last paragraph took about 2-3 weeks of on off work to get it to resemble something i was ok with inside the focus! I was going to have to look at it so it had to be nice!

With the done, the switchs were added, Tinydash hooked up and with a bit of help from Steve and Martin off the syvecs groups it was all in and working!

Well well well where are we 🫣

So thats 2024 done with! How did that happen!

Anyway, with a bit of time off work ken fit like, start looking at the focus and armed with the grinder thinking what can i cut out now!

Luckly, i put the grinder down but while looking about the engine bay there was one thing still annoying me. Im a big beliver in sealed air box's, pulling in nothing but cool air from outside the engine bay, but for now with out redesigning everything, i just cant run a airbox :( So the next best thing was to run a heat sheild.

So not one for taking the easy route of getting some sheet alloy out and making a box to the best of my metal work skills, i decided i hadnt played with carbon in a while so thought that was the route to go down!

First things first it was take a photo and get microsoft paint on the go. Few lines here and there i had solved the issue of what i wanted.

Next was look out the bin bags, air filter removed and then mix up some expanding foam to give me a 3D shape that i could work with.

Once my mash potato looking foam fitted the area it was a bit of shaping, making the most of the area i had with out looking stupid. Then moved onto body filler, and i dont know why i put myself through this. Filler, sand, filler, sand it honestly feels like it go's on for ever! I took extra care to make the part slightly tapered as to help it not lock into the mould.

With that shaped, it was a case of spray it with 2k and make the mould.
Flanges added then gel coat down and wet layed up.... easy!

Then came time to pop the mould... yup locked in! No idea if the heat from the layup causes the 2k clear to attach or if the expanding foam starts to expand again, or if i just have no luck with the chemical release stuff.... But a few hours later 1 plug destroyed but 1 mould saved! Little touch up needed but it will be good after a wet sand and polish and several layers of good ald WAX!!!!

Might have a heat sheild next week, might delete this post and pretend nothing happened! Wish me luck! 😂

Lights... Cam.... ok just lights!

So engine is back in, few things to button up there like making new boost pipes, intake pipes, but we are getting there!

So since i was at a bit of a stop i thought id continue with the lights, these took a bit more trimming to get to fit and once i was happy i set about wiring in the plugs from some doner headlights. The standard sockets on the ford headlights can be stipped, re pinned very easily and it ends up as a neat job that doesnt require you do chop both ends and fit aftermarket plugs. So simpel case of matching the pins to the correct light and there we have it!

Final fit (or as near as was done) i looked at the big holes i now had for air intakes. The drivers side pointed directly at the water tank and the pasanger side was 50/50 split between the bay and the inside of the front arch... Less than ideal! So as i still have Andys 3D printer i set about thinking how i could make use of the holes to direct air to where i wanted it! Now after a few prototypes to get the hole PCD on the morrette headlights right ( im using the online CAD program tinkercad which isnt exactly professional!) i had a base made that bolts directly to the headlight.

So with that as the start point it was then a case of shaping a duct or 2 to make the most of the air avalible! DS was a sharp 90% that should push air directly behind the water rad into the turbo/wastegate area, and the PS was angled at about 40 Degrees with a tilt down pointing to hopefully where the new air filter will sit.

Not a overly complicated job, but with print times for the ducts being 12-15 hours its been a weekend affair!

Just hope they dont melt 🤣

Cheers