The 2L pt.2(also uber long!)

[jlagnese at massed.net (John S. Lagnese)]

The Roc's outer cv is more tapered than other VWs.
----- Original Message ----- 
From: "Scourge" <scourge@cogeco.ca>
To: "Rocco list" <scirocco-l@scirocco.org>
Sent: Wednesday, October 20, 2004 6:54 PM
Subject: The 2L pt.2(also uber long!)


Ok, so we left off on Sunday night, car ran, when it would start. One CV
bolted up, one hanging. No downpipe.

Monday morning, tow truck is late, don't get the car to the shop till 8:45,
it gets in at 9:30(and I'm officially late for work). So we get started, fix
a coolant leak(clamp was loose, lol), fix the timing belt cover(wouldn't sit
right), and start on the exhaust. Well, I guess my exhaust was meant for a
TT race DP, because it fit PERFECTLY(with a cat I might add, mine sits back
behind the shifter though). On to the axle, I ask for a used one...NOPE, no
rocco axles, or anything that will fit for that matter. So we pull the inner
CV to put on a 100mm inner. Search around, find a good used inner, and slap
it on........ Only to find out it won't fit. Apparently the rocco inner cv's
are more narrow than the ones they had in stock. So we search through the
stock room for about a half an hour before deciding to throw the 90mm back
on and swap the flange down to a 90mm. So I'm back where I was before, plus
a few hours labour. Then go to start the car, click, click. ^$*&^&(!! Ok,
hook it up to the booster, nothing. Jump the battery ground to the motor,
nothing. Battery terminal to the starter, nothing. Hook up the booster to
the motor and starter, vvrrroooom. Ok? I still said bad power cable. The guy
at the shop said starter. So we slap in a used starter, turn the key
and......nothing. Hook a jumper from the battery to the block, vrrooom. Ok?
Ground, pull the ground, clean it up(LOTS) Fresh bolt, and all is well. By
now it's 2:00 and I've missed enough of work that there is no point to going
in, so I call in and tell them I won't be showing up.
    I drive home to pick up the bolt for the speedo cable(always forget
something eh?) and smile the whole way. By the time I get home(3 minute
drive) the idle is at about 2k rpm. I pop the hood and check the idle screw.
Haha, it's almost all the way out, I love poly mounts!!(Yes all four 4!).
Grab some locktight and screw that bitch in. Speedo cable bolt in hand I
drive back to the shop, again smiling the whole way. Proceed to struggle for
a good half hour to get the F(*&(*&! bolt in, finally it grabs and tightens
down.
     Later that evening, I go to drive the girlfriend home. All goes well,
until(lol how'd ya know that was coming?) I drive away from her house and
shift the second....it felt kinda weird. Stop at a stop sign and go for
first, only to have the car give me the finger. I can't get it into any
gear, GREAT!! So I shut the car off and it slides into first, start the car
up and drive away, go for second and it'll only go in when the rpm are
matched(like shifting without the clutch). So I limp it home and go to bed.
Tuesday morning, go to work, car's doing the same thing, So I do what I have
to get to work. On the way I stop beside a mid 90's Buick Gran sport. Now I
looked this up after I got to work, 3.8L 6Cyl, somewhere between 170 and 210
HP. I kicked it's ass...twice, with a screwed up clutch!! lol So to say the
least, I was happy about that. After work I head back to the bug shop,
where, after 5 I get on the hoist. We drop the tranny and check out the
clutch.....it all looks good. DAMMIT!!! So we put it back together with
another PP I had around. And now the clutch lever has wayyyyyyy to much
play, and it still wont release fully. Well, we pulled it all apart again,
and figured out the problem. The FLYWHEEL, you see this Brunberg? Eh? Eh?
Eh? Well good, I'm coming to get you!!!!!!  Lol, just kidding. It turned out
the clutch surface of the flywheel was too narrow and screwing with
everything in the clutch, so we welded some material on the pushrod, and
ground it down to the stock diameter. Throw it all back together and all is
well, YAY!!!
    At this point, Peter, the guy that helped with all the clutch
shenanigans takes the car for a drive(with me in it, don't worry).
Unfortunately it was a little wet out, so he couldn't experience the full
"power" of the car. But never the less, he claims it to be faster then a
16V, I'm assuming he means stock 16V. He's a rocco guy to(he's had 6 I
think, and his was the first rocco I ever rode in) and I trust what he says,
but we'll see soon just how fast it is.
    Now that brings us to one odd experience today, lol. I was driving
behind my bro in his rustang(yeah yeah, it's a POS) and he decides to pull a
brake torque, so like any good dubber, I pin it and out do him, lol. Then
drive away and discover during a shift that my car is now idling at 3k
rpm.....wtf?  lol I pull over and pop the hood expecting to find a vacuum
line off. Sure enough, there's a big fatty one sitting there smiling back at
me, so I slap it's ass back on and hope in the car, start it up
and..........3k rpm.....ahhhhhhhh! I look again, and nothing is wrong(that I
could see), so I grab my trusty 7mm wrench and check the idle screw,
thinking that perhaps it backed out again. Nope, so I tighten it and get the
idle down to 2.5k rpm. And head out to pick up the girlfriend. On an uphill
section I pin it to see what the car can do, I take it through 2nd 3rd and a
little of 4th. Pretty good. Stop at a light to make a right hand turn and
wtf....my idle id normal again...ok?   So I'm not sure what the hell it is,
I'm thinking perhaps something with the ISV, but we'll see, I need it to
happen again so I can figure it out.

Now, overall I'm impressed. It's got some massive torque. For those who
haven't followed, the buildup includes: ABA bottom end, 30mm oil pump, ABA
oil baffle, JH solid lifter head(fresh rebuild, new guides, seals, ground
seats, 3 angle valve grind), G-Grind cam, dual outlet manifold, TT race
downpipe, 2" stainless(kinda bent) exhaust, 4k tranny w/.75 5th, all four
poly mounts, 16v PP, 8V clutch disc.
It's quick, and in the dry it'll spin the tires at any rpm in first all the
way to 6k. It's like learning to drive all over again.
I hope to go to the track on Friday for a bit of a comparison. I know it's
too cold for a good run, but I don't have enough patience to wait until
spring. I think it might beat it's old 18 second QM time, lol.

And this brings us to the end, thanks for reading and I hope you learn a bit
from it.
-George
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