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SRS Automotive 2.0 TDI Common Rail and 4Motion Caddy Race Van Build

SRS Automotive 2.0 TDI Common Rail and 4Motion Caddy Race Van Build

Below is a brief rundown of the major build we were involved in for the SRS AutomotiveCaddy Van. The vehicle has been in the family for quite a few years now, coming to us with a blown BLS Engine (rod through the block - standard!). We swapped in a 2.0 16v PD BKD Engine, initially tuning it to 220bhp & 350Ft/lbs, but finishing off with 340bhp & 435Ft/lbs before Stef decided he wanted to get some Common Rail DSG action!

The build started in September 2017. The Engine was ripped out of the Caddy whilst Stef at SRS sourced a Tiguan 2.0 CR140 4-Motion DSG - not an easy feat! The reason we chose the Tiguan setup as a base was the DQ500 DSG Gearbox. In the Golf platform, the DSG Box is a DQ250, which is widely tuned and used on big power projects, but does require expensive DSG Clutch Packs when you start to push the torque pretty high, which is what we planned to do. The DQ500 is the same box as found in the TTRS / RS3 S-Tronic models, as well as the Transporter T5.1 / T6 DSG Models, obviously with different ratios depending on the fuel type. We did some stripping out of the loom while the lump was still in the Tiguan to ensure we did not remove anything that would cause the various control units to misbehave. Once we were happy with that, the Tiguan shell was sent to the scrapyard in the sky and the drivetrain bolted into the Caddy, minus the Prop Shaft and Rear Diff setup of course!

So the front wheels are sorted, but what about getting the power to the back? Obviously there is a rear axle setup available from the Caddy 4-Motion, but this is a beam and uses the leaf springs. OK for doing some occasional green laning (for those of you who are unaware - https://www.glass-uk.org/), but not so good for hitting the track hard! A 4-Motion Caddy with multi link rear suspension is nothing new, with VW Motorsport / Racing Line running one in the VW Cup for quite a few years (See Here) as well as a number of conversions done by private individuals both in the UK and Europe. All had different ways of doing it, but we settled on a method that requires minimal cutting of the Caddy Chassis, minimal custom parts and looks neater overall. We have the capabilities with our Fabrication team to get the job done, but not the time to do it, so we enlisted the help of our local drifters Slide Motorsport who were keen to work with us to get the idea from Stef’s head to reality. It is basically the rear chassis of an A3 Quattro, grafted to the underside on the van, so there was no need to cut the original floor meaning from the inside it wouldn't look unlike any other Caddy, except for the rear suspension strut tubs. After this was done the original Caddy cross bracing was fitted back in to give the floor some strength. Once we got this all seam sealed and under sealed it looked like it came from the factory like this. While all this was getting done, it would have been rude not to weld in a custom roll cage, with the door bars fitting as low as possible so it would still be easy to get in and out. We also requested the rear strut brace be removable so we can easily take it out when we're off to collect parts in it Some progress photos are below, and I will let Stef at SRS take over for the rest of the build, since our involvement extends to the drivetrain only :-)

While the Caddy was away having some work done at Slide Motorsport we thought we may as well get some parts ready for it's return, everything that could be has been blasted & powdercoated by KTS Refinishing. We've tried to stick to the SRS Logo colours to keep a theme and I think it's worked out well. They've turned out so nice it's almost a shame to fit them as they won't be seen. Some parts needed to finish the re-build were still on the van so were sent after we got it back from Slide.

So after ripping it all to bits, it’s time to start putting it back together!

Before all the shiny bits could be bolted up, we decided to strip all the underseal from the chassis and spray it with some Upol Raptor in the White. I wouldn’t recommend doing this unless your underseal is in bad shape, as it was a horrible job! The Rear Subframe was then built on the deck and fitted. Thanks to PowerFlex for supplying everything we needed to get the job done!

We then moved back to the front and got all this sorted Porsche 6 Pot 18Z Calipers - Fitted using the Darkside Fitting Kit TT Alloy wishbones & hubs Tiguan Steering Rack with TT Arms & Ends Powerflex Camber Correction Bushes KW Clubsport Coilovers with camber adjustable top mounts

Once that was done, we moved on to the interior, and got all the cage painted.

Cage painted and all dry, on to the fiddly and time consuming interior refit! I wanted to fit as much as possible with it being my daily driver so we cut some Touran door cards around the cage and flocked the top to match the dash. I also fitted a rear view camera on an ignition live to use as a rear view. Andy Forrest does this on his Time Attack Subaru so thought I'd give it a try. We used an A3 Quattro tank and had to move the filler neck (A3 fills on the drivers side, Caddy fills on the passenger) so the best option we had was to come up behind the passenger seat & fill through the side door as there was no room to take it to the original Caddy filler location.

Even though the Caddy wasn’t 100% finished (will it ever be), GTI International 2018 was upon us. This was the Caddy's 1st proper outing other than me driving to and from work in traffic, so the idea was to get some chassis testing done before going crazy with the engine. I went out on a sighting lap in my MK2 track car and asked my mate to swap the Caddy from road to track wheels, but for some reason my brother told him to go out in it instead? Bad idea! What we didn't know was that there was an issue with the ABS, which caused the rear wheels to lock up under hard braking, sending him straight into the gravel. Luckily no real damage was done and the 200 hours spent on the underside wasn't massively ruined either, just some scratches to the black coated parts. We fixed what we thought had caused the issue (a broken wire to the drivers rear sensor) then I took it out on the Sunday. After 3 laps it did the same thing again, but I managed to keep it on the tarmac so it was then parked up for the rest of the day. When we got back and looked further into it, the pipes on the ABS pump had been put in the wrong positions, so now this was sorted it's been fine ever since. Thank god something so silly didn't cause lots more damage, on another track or a different corner with less runoff, things could have been a lot worse.

What do all race cars need? Aero!

We started with a Front Splitter. This still needs work but seems to do what's intended as the bumper started to pull away from the wing after a few laps at VAG Tuner, so I think I might need to add something between the wing & bumper to stop this happening again. We also made some canards and a roof gurney flap, this may or may not work as well as we hope but if not it can be removed in a few minutes.

For anyone who is interested, below is a video of how a gurney flap works, it's long and very detailed but well worth a watch if you have the spare time.

A month after Inters we were at Donington for VAG Tuner Live 2018.

The only real changes, aside from a working braking system, we the aero mods. We didn’t think we had tested the chassis enough to start pushing the Engine any further. Despite only having ~230bhp, the van performed brilliantly. The chassis feels great and will easily take another 100+bhp. The Craner Curves were an easy flat all the way from Redgate, through Hollywood down the Old Hairpin.

The only thing we found to be an issue was cooling. The van currently has the stock Tiguan Radiator, so we need to swap it back to the Alloy Radiator that was fitted when the van had the BKD Engine, and possibly look to fit an electronic water pump and controller like the CitiGo.

Other than the engine, there is not much else left to do, we had some interior parts trimmed to match the Corbeau seats. The ‘Jacquard’ material was bought direct from Corbeau Seats UK at a very reasonable price and was delivered quickly.

Thanks to Luxe Automotive for the brilliant job and quick turn around. It really has transformed the overall look of the interior.

17 09 2018

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