iichels Polo 6R 1.6TDI DSG --> OEM++ R-Line conversion

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enas_aris
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Re: iichels Polo 6R 1.6TDI DSG --> OEM++ R-Line conversion

Post by enas_aris »

Hello iichels.
I have seen in your image gallery that you have connected an aux in to the rns 510 while
you also have a media in, where a usb is aslo connected to the rns 510.
How were you able to do that?
How did you connect the aux in socket (5KD035724A) to the rns?
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iichel
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Re: iichels Polo 6R 1.6TDI DSG --> OEM++ R-Line conversion

Post by iichel »

I connected the AUX in to the MDI module and the MDI module connects to the RNS. In this case it's like the left side R199.
If you don't have the MDI module, you connect it like on the right R199.

Image
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iichel
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Re: iichels Polo 6R 1.6TDI DSG --> OEM++ R-Line conversion

Post by iichel »

DSQ DQ250 wiring from VW Golf Mk6:

Image

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JoskeBlankenberg
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Re: iichels Polo 6R 1.6TDI DSG --> OEM++ R-Line conversion

Post by JoskeBlankenberg »

iichel your car is a dream, perfect example of how a Polo should be, I bet you enjoy that amount of torque very much. Well done sir
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iichel
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Re: iichels Polo 6R 1.6TDI DSG --> OEM++ R-Line conversion

Post by iichel »

JoskeBlankenberg wrote: Thu Sep 08, 2022 6:13 pm iichel your car is a dream, perfect example of how a Polo should be, I bet you enjoy that amount of torque very much. Well done sir
There is always room for improvement.
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iichel
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Re: iichels Polo 6R 1.6TDI DSG --> OEM++ R-Line conversion

Post by iichel »

iichel wrote: Fri Feb 04, 2022 11:26 am Polo 6C / PQ35 Dynamic Chassis Control (parts):

other things to remember:
Image
distance to copy from the OEM PQ35 lower control arm approx 135mm

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Installed front sensors on Polo 6R, by drilling a hole in the subframe and using bolt and nut:

Image

Measure 135mm on Polo 6R control arm and drill a new hole to accommodate the sensor
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iichel
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Re: iichels Polo 6R 1.6TDI DSG --> OEM++ R-Line conversion

Post by iichel »

--> viewtopic.php?p=589677#p589677
iichel wrote: Tue Mar 15, 2022 11:11 am Image
Test fit. I need a 12mm spacer to accommodate the rims.

I decided to go for different front calipers for the front axle, Brembo ZL17/ZR17 6-pot calipers (left) I'll retain the 4-pot calipers for the rear axle (right)
VW: left: 7L6615124T right: 7L6615123T (VW Touareg 2006, PR-1LC)
Porsche: Left: 955.351.421.33, Right: 955.351.422.33
Brake pads: 7L0698151J
Brake discs from Golf mk4 R32: 1J0615301AA + 1J0615302A (directional vanes)

Freshly painted in Guards Red:

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Image

Image

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Adapter: https://epytec.de/en/brake-system/adapt ... x32?c=2047

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The brake discs have a rotation (directional vanes) to aid in cooling.

Image
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Re: iichels Polo 6R 1.6TDI DSG --> OEM++ R-Line conversion

Post by ciclo »

I like it. 8)
Hopefully the level sensors send the information properly to your DCC unit.

Nice Ferrari colored brake calipers...

---
f1
This weekend in Monza.
Do you think Ferrari will win? I like the Ferrari 75th anniversary colors.😁
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iichel
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Re: iichels Polo 6R 1.6TDI DSG --> OEM++ R-Line conversion

Post by iichel »

ciclo wrote: Sun Sep 11, 2022 5:01 am I like it. 8)
Hopefully the level sensors send the information properly to your DCC unit.

Nice Ferrari colored brake calipers...
Yes I really hope the same, it's been a bit of a puzzle with orientation of the sensors and the turning direction. I guess I'll figure it out sooner or later. :mrgreen:

I really love the calipers, but they do require a 12mm spacer between the wheel and the brake disc to fit. I'm not so happy about that :twisted:
ciclo wrote: Sun Sep 11, 2022 5:01 am f1
This weekend in Monza.
Do you think Ferrari will win? I like the Ferrari 75th anniversary colors.😁
I think it's not a weekend that Red Bull will be as dominant as before. I really hope Charles can win the Italian GP for Ferrari.
The car is great, the team is chaos and the drivers have done little wrong this year.
On the other hand, it would be nice to see Max break some records on his way to his second title.
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iichel
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Re: iichels Polo 6R 1.6TDI DSG --> OEM++ R-Line conversion

Post by iichel »

Some geometries for DQ200 and DQ250 gearbox retrofit, and custom driveshafts are needed:

Image

The reference plane in the center is where the gearbox meets the engine.
The plane at the lateral sides is where the CV joint meets the wheel hub.

DQ200 in Polo 6R:
1 = 50 mm (measured)
2 = 220 mm (measured)
3 = 680 mm (measured)
4 = 400 mm (measured)
5 = 1 + 3 = 730 mm (calculated)
6 = 2 + 4 = 620 mm (calculated)

DQ200 in Golf mk6:
1 = 50 mm (measured in Polo 6R)
2 = 220 mm (measured in Polo 6R)
3 = 725 mm (measured)
4 = 455 mm (measured)
5 = 1 + 3 = 775 mm (calculated)
6 = 2 + 4 = 675 mm (calculated)

DQ250 in Golf mk6:
1 = 60 mm (measured on separate gearbox)
2 = 235 mm (measured on separate gearbox)
3 = 715 mm (measured)
4 = 440 mm (measured)
5 = 1 + 3 = 775 mm (calculated)
6 = 2 + 4 = 675 mm (calculated)

So, by deduction: DQ250 in Polo 6R
1 = 60 mm (from DQ250)
2 = 235 mm (from DQ250)
3 = 5 - 1 = 730 - 60 = 670 mm (calculated)
4 = 6 - 2 = 620 - 235 = 385 mm (calculated)
5 = 730 mm (from DQ200, front axle width does not change)
6 = 620 mm (from DQ200, front axle width does not change)

Now we only know the length of the left and right hand side half shafts, from reference plane to measurement plane.

So we know this:

Image

And the drive shaft company will make this:

Image

I must add manually the CV joints (6R0498099 A/F on the outside and 3C0498103 E/F/Q) on the outside. Do I know the geometry? Yes I do!

Inside CV joint on gearbox side
Image

1 = 85 mm = 2 + 3 + 4
2 = 45 mm
3 = 25 mm
4 = 14 mm
34 splines

Outside CV joint on wheel side
Image

1 = 64 mm = 2 + 3 + 4
2 = 7 mm
3 = 38 mm
4 = 19 mm

27 splines

so if the construction of the axle is defined as:
Image
<---- A ----> <----------------------------------------------------- B ---------------------------------------------------------------> <---- C ---->

A = 23mm for the inside CV joint - gearbox side
B = full length minus (17 + 19 + 22 + 38) --> ±570 mm for right hand side and ±285 mm for the left hand side
C = 38mm for the outside CV joint - wheel side
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Re: iichels Polo 6R 1.6TDI DSG --> OEM++ R-Line conversion

Post by alexperkins »

loving this!
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ag69
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Re: iichels Polo 6R 1.6TDI DSG --> OEM++ R-Line conversion

Post by ag69 »

Unbelievable!
I think you should be honoured with PhD for this.
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iichel
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Re: iichels Polo 6R 1.6TDI DSG --> OEM++ R-Line conversion

Post by iichel »

Haha thanks, already got one of those, and I think it's sufficient for the rest of my life. :mrgreen:
patil
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Re: iichels Polo 6R 1.6TDI DSG --> OEM++ R-Line conversion

Post by patil »

That's some serious rocketry going on :mrgreen:

Apart from handling more torque is there any other advantage of DQ250 over DQ200?
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iichel
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Re: iichels Polo 6R 1.6TDI DSG --> OEM++ R-Line conversion

Post by iichel »

It's more reliable and it has a wet clutch so less clutch wear as well.
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