May 16, 2008 - Guts

Guts.

It takes them to take a new $30k+ R32 and almost triple its output, and they're certainly needed for modification to help this particular DSG transmission not puke itself during the first couple miles. We can't provide pictures of the first kind, but what you see below is a good illustration of the second.

We'll be boxing-up the clutch-packs along with the DSG electronic control unit (pictured below) so we can send them up to HPA in Canada. We'd like to be able to offer pictures of the conversion process, but we'll need to check with HPA and ask if they'll accommodate us in that regard.

As the necessary parts begin to arrive, we'll be getting started on the rest of this monster project.















May 14, 2008 - Transmission Comes Out

VW's DSG twin-clutch automatic is an awesome piece of technology, but as far as we're concerned it has one major flaw - it cannot handle 600-hp to the wheels.

Of course we can't really fault VW for that as what we're building here is way beyond the ordinary and solidly into extreme territory. The DSG is an automatic, but rather than your standard torque converter, it uses dual clutches. These clutches (known as a "clutch-pack") are operated electronically by a separate control unit. The control unit is designed to recognize torque loads and VW sets it to get unhappy at around 400-hp or so. Luckily, there is a way around this.

The amazing folks over at HGP in Germany have developed a strengthened clutch-pack and control unit programming that doesn't interfere when power gets beyond 400-hp. HGP's North American distributor is HPA Motorsports and they've agreed to help us with this conversion.

We're sending them the clutch-packs for reassembly with the stronger pieces and we're also sending the transmission control unit so they can reflash it with HGP's programming.

While the transmission is out of the car, we'll begin constructing the PT67 turbo system.














May 6, 2008 - Big Plans

This is going to be a fun one.

We've got a customer with a 2008 R32 who's apparently awfully tired of getting picked on by some of his high-hp Nissan/Toyota/Honda-driving friends. Rather than simply switch camps, our guy is looking to keep his VW, but fight fire with fire, so to speak. How much power will he need? He tells us that 600-whp ought to just about do the trick. He adds that he'll need this monster to be reliable (subjective term if ever we've heard one) and require a minimal amount of sweat on his part. Yikes.

We say yikes not because of the power requirements or the fact he's looking for reliability (we've already covered that ground with our own 600+ hp Mk4 R32) - no, the reaction comes from the fact we're talking about a brand new model that incorporates a transmission that has grown to be something of an enigma in the VW/Audi aftermarket community. Of course we're talking about VWAG's brilliant DSG dual-clutch automatic. Electronically controlled, we have it from reliable sources that stock programming will allow for "only" around 350 to 400 lb-ft of torque before the engine is ordered to dial back power. Fortunately for our customer and us, German VWAG tuner-extraordinaire, HGP - along with their North American importer, HPA - has already come up with a solution in the form of upgraded "clutch packs" and a reprogrammed file for the DSG control unit. Inexpensive this stuff is not, but for now it's really the only option for power output of the magnitude we're talking about.

Much of the turbo system will mimic the spec found on our own in-house Mk4 R32, and will be a totally custom undertaking at the hands of our very talented lead-tech, Adrian.

As we said at the top, this is going to be a fun project. We're pretty much in uncharted territory but that only adds to the entertainment factor. We have the customer car in our possession and we're currently in the process of rounding up hardware. Further updates will come along often.