RS2 - a new lease of life

[Ross]

I went for the 35W kit shane... the 55W wasn't available in the slim ballast variant, although to be honest I could have fitted the 'fat' ballasts anyway. I didn't want to resitrict air flow on the driver side, so ended up mounting it on the inside of the wing near the A/C dryer. It was a right fit but went in snug with a sticky pad and cable tie to hold it when it inevitably falls off.

More phone pics - I really need to dig out the charger for my canon!

Some correction should probably be done on this... i didn't want the 'blue tint' HIDs hence the 5000K. They look white as white can be to the eye... I'm particularly proud of this, as the conversion looks smart and it worked first time!



And a quick view of the car when I put it away last night. A vast improvement over the 'old look', I now need to change the chipped and faded fogs at some point to match the rest

[Ross]

Southebend Clutch Stage #3 Endurance

My initial experience is positive.... obviously I can't give it a proper test until the clutch and engine have some miles on them.

But I took the car for a quick drive - could only use 1st and 2nd as the linkage needs adjustment - and it has a very smooth and progressive bite, just like stock really, and it's not much heavier either. It is certainly alot lighter than the ancient clutch that came off the car.

As long as it holds the torque as rated, I'll be very happy with this clutch set-up.

I'm really, really looking forward to testing this engine out - granted I've been driving a TDi since April but it feels very resposive and torquey from idle, in second it just wanted to take off, was smooth as silk too sat at 3000rpm. I love a well balanced engine

[4WheelDrifter]

Nice work, Ross. Looking good.

That's got to be tough, waiting for things to bed in, before you can give it the beans.

I'm still getting used to the idea of you owning that car. I still remember our test ride all those years ago.

[s2_wot]

Thanks Ross, I will go for the 5000k option and 55w if a slimline ballast is available at the time of ordering; otherwise 35w will do perfectly.

Car looks mean.

[europeanme]

good info regarding the clutch...it has made my mind up with regard the one i want..just got to work out the spec....

[Ross]

It's been a positive weekend - the car has transitioned from 'garage project' back to 'daily hack'

The gear linkage is adjusted, the poor running has been solved - it was down to unmetered air entering the system - and a rattling PAS pump just needed the wheel bolts tightening. I am still getting ( ! ) every time I mash the brakes hard but I'm hoping that is down to air still in the system. I also had the winter rubber swapped for a set of Eagle F1 Assymetric II's.

I put about 20 miles on the clock of suburban driving. The oil temps got pretty hot - about 100C - but I figure everything is still a little tight right now, so probably normal. Lots of part-load acceleration and overrun to bed in the rings.

The plan now is to keep putting the miles on and sort the remaining odd jobs, then I start thinking about mapping options:

• A/C - check the system for leaks and re-gas
• Boost gauge - rerun power (somewhere other than aux lights!)
• Resistor pack - sort the thermal resistor to get speeds 1-3 back and lube heater motor
• Fuel filter - fit new one
• Turbo - swap old hybrid for new :mischeif:
• Exhaust - sports cat and 3" downpipe to stock system and decat pipes

Annoyingly, the driver side CV boot needs regreasing - it's been recently replaced but is held on with a cable tie on the inside, which is not doing a good job

The car is still under a layer of dust, I need to clean it and get a few pics up. Might get a few of the new turbo too :mischeif:

A note on the clutch - it does have a bit more 'bite' than stock. It's very progressive for most of the travel, but then that last bit of pedal really grips. It just needs a little bit of care to take off smoothly round town, i.e. don't pull the clutch in quite so fast, and I'm looking forward to using that last bit of travel in anger

The engine feels so smooth, and it's definitely got that round town off-boost driveability I was looking for. Probably down to losing the 7A inlet cam and the JP Stage #2 headwork. Mapping can only improve it further...

[A80Avant]

good news Ross! looks like its going on well!

I have to say i never saw 100C of oil temp after my first rebuild, but having said that i had a much larder oil cooler as well fitted at the time.

the (!) would mean loss of pressure rather than air in the system, but if you do the lock to lock turn a few times, any air should go away and things should be ok thereafter.

I dont remember which Southbend cluth you got, but my current one(organic on one face and metal on the other) feels like stock on the pedal. It does bite more aggresively as you describe, but there isnt that feel on the pedal that you have. Make sure its bled nicely or if the master cylinder is working adequately as well.

[Billman]

I don't seen it recently but I think the (!) is low fluid level.

[pixsaudisex2]

I don't seen it recently but I think the (!) is low fluid level.

I had this and it was air in system.. One track day later it never came back...

Obviously there is a red and orange one..

[Ross]

Another 10 miles and alot less ( ! ) today! I had a slight coolant leak from the turbo line, cooked my knuckle but think I sorted it. And, gave it a quick shampoo + rinse to get rid of 4 months of dust!

Our two year old got so excited, he refers to it as the 'racing car'... he ran up and gave it a hug! Glad to see he has the passion

[saltinot]

I was just about to give you a hard time about some pictures and you beat me to it.

Looks great Ross. I bet you are glad to finally have it back on the road.

[irishs2]

Looks smashing. Well done. So whats on your niggle list? Those thing that were too small to bother with, but now can be devoted more attentionn

[s2_bo]

Looking great Ross! Good to see your son is as passionate as you are

[Ross]

OK so the 7A cams were actually 3B cams it seems... The Dialynx cam mystery is finally solved.

So, I just sold a 7A inlet cam that turned out to be a 3B cam and I presume the 7A exhaust cam in my RS2 engine is actually a 3B exhaust cam. Am I really going to suffer with this set-up at 400hp or do I need to find an RS2 exhaust cam and fit it before mapping? I'm kinda hoping my 'JP special' stage #2 head will make up for any shortfall, don't wanna take things apart again.

F***ing dialynx

On a positive note... 80 miles, engine feels looser and oil temps are down to normal after a good run. Only 'major' incident is losing the gears (linkage not tight enough I guess!) and a stubborn coolant leak on the turbo return. I've tightened up as much as it'll go but it's still leaking, it seems to be from the line fitting into the turbo which I didn't even remove! Is there a washer or gasket in there of some sort that could be the culprit?

[A80Avant]

shame about the cams.

I have been so happy with the ADU cams, that i wouldnt change them. If you are not going to have variable cam adjustments, then i think the ADU combo is one of the nicest.