Sharkie's TSI Amarok Build

[The_Hawk]

I love watching your builds

[EZZA]

This thing is going to be a beast once you're done!!

[Sharkie]

So as part of the path to getting a full Stg 3 motor build, we identified that traction will be a problem due to the fact the TSIs only ever came in RWD. With Big Red developing a 3rd gear synchro issue of late, and with us getting more adventurous with our builds, this arrived this week ....

Manual TDI400


Can a conversion be done? All research points that way, so we will found out over the next few months.

[TSOTSI]

Cant wait to see this progress build going to epic Sharkie...

[lloydus67]

I thought I read somewhere that the zf gearbox was only good for 450nm torque and/or 200kw? Not totally sure on the numbers but that’s why the v6 was auto not manual.(apart from a limited number of detuned cores)


Sent from me [emoji2957]

[Sharkie]

I thought I read somewhere that the zf gearbox was only good for 450nm torque and/or 200kw? Not totally sure on the numbers but that’s why the v6 was auto not manual.(apart from a limited number of detuned cores)


Sent from me [emoji2957]

Stock rating on the 6spd manual for the BiTDI and TSI is 450NM. That does not mean it cannot handle more ..... Tuned BiTDIs typically put 550+NM through the boxes with little complaint.

My Golf R's 6spd manual is rated at 350NM and has handled more than 500NM for over 3 years quite happily so far.

For what it's worth this conversion will include a visit to a gearbox specialist as I want the internals redone to lengthen the ratios on 1st, 2nd and 3rd and to fit more robust synchros and possibly stronger gears. And finally will be followed up by an aftermarket clutch that can handle up to 750NM.

[Sharkie]

Bit of an update ....

The AWD conversion actually looks pretty straightforward. All the mounts etc, bolt holes etc are all there on the TSI chassis. Once I finish work on the GTI Polo (which is nearing the end now) the conversion will start.

Once the AWD conversion is in and running the next power stage build will commence. Thanks to a donation of a MK6 GTI exhaust camshaft from HP, i ordered the KO4 kit from HPA (thanks Spring sale) 2.0T K04 Turbo Upgrade Longitudianal
– HPA Motorsports, so a MK6 GTI K04 Stg 3 tune will be able to be loaded netting 250+kw and well over 500NM of torque.

[EZZA]

Wow this thing is going to eat V6 Ranger Raptors for breakfast

[EZZA]

Hi mate. Currently getting my exhaust altered and was wondering what the specs are on the Miltek system you have? Is it 3" cat back with a single muffler?

[Sharkie]

Hi mate. Currently getting my exhaust altered and was wondering what the specs are on the Miltek system you have? Is it 3" cat back with a single muffler?

That is the 1 currently on the car yes. Beware that it is (IMO) too loud with some drone in the midrange. At idle it is awesome, at full throttle it is LOUD. Too loud for me but OK for my son. We even had a custom resonator fitted which improved it a bit, but not enough I think. The X-Force we had before sounded tinnier but was less loud and build quality was below average whereas the Miltek's build quality is great.

When we go KO4 later this year, we will have a full custom turbo back (probably 2.75") made and fitted.

[TSOTSI]

This is going to be a Awesome machine, maybe do the V6 diff id like to do that

[EZZA]

That is the 1 currently on the car yes. Beware that it is (IMO) too loud with some drone in the midrange. At idle it is awesome, at full throttle it is LOUD. Too loud for me but OK for my son. We even had a custom resonator fitted which improved it a bit, but not enough I think. The X-Force we had before sounded tinnier but was less loud and build quality was below average whereas the Miltek's build quality is great.

When we go KO4 later this year, we will have a full custom turbo back (probably 2.75") made and fitted.

Right ok good to know. I fitted a rear muffler delete pipe that drops at the diff and it's far too loud. I had already replaced the front muffler/resonator with a straight through Lukey muffler. Looking at fitting up a 2.5" Borla muffler And then dropping at diff. Should keep the noise down but still flow well.

Yeah I agree, when I was in my 20's I had a Mazda RX3 with a 13b Bridgeport that was about 100db but now days I can't handle a loud exhaust. Must be getting old haha!!

[EZZA]

So as part of the path to getting a full Stg 3 motor build, we identified that traction will be a problem due to the fact the TSIs only ever came in RWD. With Big Red developing a 3rd gear synchro issue of late, and with us getting more adventurous with our builds, this arrived this week ....

Manual TDI400
[ATTACH=CONFIG]55121[/ATTACH] [ATTACH=CONFIG]55122[/ATTACH]

Can a conversion be done? All research points that way, so we will found out over the next few months.

Sharkie, have you started on the conversion yet?

If you end up pulling your diff I may be interested in buying it. My TSI doesn't have a diff lock and it's one thing i'd like to add.

[Sharkie]

Sharkie, have you started on the conversion yet?

If you end up pulling your diff I may be interested in buying it. My TSI doesn't have a diff lock and it's one thing i'd like to add.

Hi Mate

Yes, we have started, working on it about 1 day (normally a Sunday for a few hours) a week. Progress so far has been on the donor, stripping the interior to get to the transfer case controller (and all the wiring necessary to connect it) as well as the front driveshafts and propshaft. This weekend probably be pulling off the front diff on the donor. Next weekend fitting all of that except the proposhaft. Will be done by end July (maybe August) I think

Have a RF grab handle for sale with all the parts needed to fit to a TSI. Years ago I did mine already (Post 138 in this thread Sharkie's TSI Amarok Build), so this 1 is extra. Will also probably have a leather MF (left side only) steering wheel and the necessary controller/bits to add to a non MF Wheel TSI in due course available too.

Edit: also have a X-Force cat back for the Amarok that's been lying under the carport at the back of my house for a few years. Free to anyone who can pick-up. It has surface rust, but still completely intact.

[EZZA]

Good to hear mate, can't wait to see the final result!

So sounds like you'll keep the current diff in place. I've read there's a few different gear ratios out there when it come to Amarok diffs. Have you used you're diff lock much and with the 2wd when does it disengage? Guessing it has a speed it unlocks for 'safety' haha!