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That Perfect Daily Wagon - illegal Passat b6 3.2 build thread

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#1
illegalr32

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FULL OF UNEXPECTED PLEASURES

 

VW-Logo.png

 

 

Build navigation menu (blue text has a link of upgrade attached - just click to visit)

 

Chassis

 

Exterior

 

Front custom made wide fenders (3 cm +): Part one / Part two

Rear custom body widening: Part one

  

Engine & performance

 

Interior

 

Maintenance

 

 

All you need to know about VR6 Fsi


Edited by illegalr32, Today, 04:36 PM.

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#2
illegalr32

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Hello everybody.

 

My name is Klemen and most of you guys already know me by the nickname illegalR32 or my Golf 5 R32 build thread which can be found here.

 

I know this Passat is not a R32 nor a Golf, but it is his step brother and a VR6 so let's say I am allowed to present my other build here good.gif

 

Starting off with a little story. My R32 was never daily driven in my ownership, I owned a second car for quite some time and it was a Renault Clio 1.2 - older than me, produced in 1995 shok.gif That car was immortal and a perfect drive for my daily needs. It just got complicated with safety since it is not safe at all to cover longer mileages with a car without any safety systems or airbags.

 

I've been in talks about my next daily for quite a long time. I am done with diesels, GTI was also not quite what I wanted. A good friend of mine, who is also my personal car painter owned his Passat 3.2 Wagon for almost a year and decided to build it to something special. Not going to tell you all the sweet things that were done to this car just yet, I am just going to tell you that he has changed his minds right before the build was nearly finished because he actually imported himself a R36 from Switzerland. So that's where I came into play and decided to buy his Passat b6 3.2L VR6 FSI and finish his job and of course add a little extra biggrin.gif

 

The good thing is that I knew everything about this car before I even bought it smile.gif

 

Full service history, one owner from 2007 to 2017, then the car went here and there by locals and I am actually the 5th owner now. The car was not even driven in winter conditions yet and it is completely rust free.

 

Picked up my Volkswagen Passat b6 3.2 FSI on June 6th 2020.

Price:  aprox. 8500 € 

Odometer:  191.698 km

Transmission:  DSG with F1 paddle shifters 

Specs:  Highline, Bi-Xenon,Cornering lights, Park sensors front/rear, electrical seats etc...

 

For now I am going to drop a picture or two and then contuine this thread slowly smile.gif

 

Eveybody says I am loco but I really am into VR6 adore.gif Oh and yes, that is not DPB wink.gif Stay tuned about the color, it's better biggrin.gif

 

Oh that little Clio in the background. Still the best investment in my life.

 

IMG-20200606-121725.jpg

 

Left or right that is the question wub.png

 

IMG-20200606-143718.jpg

 

IMG-20200606-143649.jpg


Edited by illegalr32, 17 October 2020 - 07:30 PM.


#3
VelovetAndy

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Awesome daily transport . It looks exceptionally good and I bet it is . Cracking buy 


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#4
Atomic41

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Yeah good choice ! I will follow this thread your the one for your R32. Epic content


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#5
illegalr32

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I think we have to start with a little talk about this 3.2 L VR6 FSI engine, because a lot of people think this engine is actually a V6 from an Audi whish is far away from being true.

 

h-YSANGZ3z-IAHWCy-MXi-XGVx3-E3-Fa8ib-TXP

 

The 3.2L and the 3.6L V6 FSI engines belong to the VR family of engines. Their reduced V-angle, compared with a traditional V-engine, gives them an extremely compact and space-saving design.

 

Screenshot-1.png

 

As you can see on the factory technical data, the V-angle is reduced from 15° (R32's) to 10.5°. I am going to paste the Self study program down below and it is helpful for everyone loving their VR6 engines and want do dig more into the engineering behind the engine. R32's are not the direct injection engines (they are MPFI - Multipoint fuel injection), while the the engine in the Passat is a FSI - direct injection.

 

Further innovations compared with the 3.2L manifold injection engine include:

  • Oil pump integral with the cylinder block
  • Better oil return from the cylinder block to the oil pan
  • Improved cylinder block rigidity, while reducing weight at the same time
  • Volume of coolant in the cylinder block reduced by
  • 0.7 liter, allowing the coolant to heat up faster.

Everything else apart from engine is pretty much the same as in the Golf 5 generation (Can Bus system, DSG, Haldex,...)

 

So while this is still the VR6 engine, it has some innovations that are better than previous generations (mk3, mk4, mk5). I've heard it from a lot of people that these engines are really better in terms of reliability and fuel consumption. I guess I'll have to drive my daily for a little bit longer to find this out, but the truth is, that I wouldn't own 2 VR6 cars if I wouldn't know how bullet proof this things are if maintained correctly smile.gif
 

 

Awesome daily transport . It looks exceptionally good and I bet it is . Cracking buy 

Thanks bud! Wait untill you see the process of making it and more awesome pictures smile.gif
 

 

Yeah good choice ! I will follow this thread your the one for your R32. Epic content

Thank you sir smile.gif

 

 

Attached Files


Edited by illegalr32, 26 October 2020 - 05:52 PM.

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#6
VelovetAndy

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Thanks for the link. Very interesting read.

 


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#7
illegalr32

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As I mentioned before, I've bought this car half finished from a friend of mine. A lot of progress here is going to be shown while he was still building the car, before I got it. I know the car as long as he bought it. So I am pasting some pictures of the car, before the whole process began.

 

The car was originally in shadow blue color. Pictures were taken in May of 2020 when the friend bought the car.

 

dav.jpg

 

rhdr.jpg

 

There is also my R32 on the picture, this shot was actually taken 1 day after I bought it. And here I didn't have a clue that the Passat is ever going to be my daily driver smile.gif

 

sdr.jpg


Edited by illegalr32, 17 October 2020 - 07:59 PM.

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#8
illegalr32

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Car wasn't in my ownership here yet

 

First the wheels came. These are 9.5J ET35 19inch BBS LM replicas. Damn wide for the Passat :D

 

A little testfit that showed these won't fit. UNLESS... We go wider :D

 

rhdr.jpg

 

cof.jpg

 

cof.jpg

 

This is tight as hell!

 

sdr.jpg

 

sdr.jpg

 

Nope won't work with OEM body. Have to widen the arches. Kinda go big or go home project and learning experience. I will save porn material for the next post ;)

 

sdr.jpg

 

sdr.jpg



#9
illegalr32

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Widening front fenders: part 1

 

I know there is some aftermarket companies that make wider fenders (SrsTec, MuckeCarbon,..) but anything above 2,5cm wide looks ugly as hell from both of them!!!

 

So front fenders had to be made by the guy himself. This was his first time doing this job, he was 19 years old at that time and was working in the whole car painting bussiness for 2 years. The end result is going to blow you. Insane work and skills.

 

First OEM fenders without rust, had to be cut by the lines and then widened by welding another exact but wider piece to the fender itself. Extra precise job since both sides have to be a match. Fenders are widened for over 3cm in an excellent and not too cury way. Both sides took him a little over a month to be prepared for painting. Enough talking, pictures are going to tell it all. Will continue. smile.gif

 

sdr.jpg

 

sdr.jpg

 

cof.jpg

 

sdr.jpg

 

sdr.jpg

 

sdr.jpg

 

sdr.jpg

 

cof.jpg

 

cof.jpg

 

sdr.jpg

 

sdr.jpg

 

cof.jpg

 

cof.jpg

 

sdr.jpg

 

sdr.jpg

 

cof.jpg


Edited by illegalr32, 26 October 2020 - 05:50 PM.

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#10
VelovetAndy

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Astonishingly good work. And a difficult and skilled job. And 19? Wow. He is good .



#11
illegalr32

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Widening front fenders: part 2

 

So the front fenders had to be prepared for the painting. All surface imperfections were repaired with bodykit filler. Done multiple times with the correct waiting time between different phases.

 

cof.jpg

 

cof.jpg

 

cof.jpg

 

cof.jpg

 

sdr.jpg

 

cof.jpg

 

cof.jpg

 

sdr.jpg

 

cof.jpg

 

cof.jpg

 

Put in primer and then let it sit for 2-3 weeks so any imprefections would become visible smile.gif

 

cof.jpg

 

Next post we are moving to the back biggrin.gif

 

 

Astonishingly good work. And a difficult and skilled job. And 19? Wow. He is good .

He is really really good at this! Glad I have that good of a friend who is also an automotive nerd as I am biggrin.gif (he is now 20 and is owning 1 out of 3 Passat R36 in our country, and also the Golf mk2 Edition One). Mindblowing what a collection we are making together at this age. Will drop some pictures when we gather them together good.gif


Edited by illegalr32, 26 October 2020 - 05:52 PM.

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#12
VelovetAndy

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Brilliant work. Looking forward to seeing how he did the rears !


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#13
Brother Moses

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Love it mate.
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#14
iooroiidvd

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Oh wow!
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#15
Janettut

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hqdefault.jpg

Select Dugout: Iyer’s secret to scoring big


#16
illegalr32

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Rear arch widening

 

Sadly I do not have any pictures saved from widening the back of the car (I know @velovetandy that sucks haha).

 

The principle was basically the same as at front. This time, the cut in the body was way smaller since rear is much more complicated than the front (you know, you f**k up one time and you are done because the rear side panel is made of 1 piece). Then the custom arch was pulled out with the fender roller tool, so the wheels fit under the arch. The final stage was to made the same edge as the OEM.

 

Rear end is now around 2 - 2.5 cm wider than OEM. smile.gif There is one thing to consider doing to the R32's tho. In my opinion widening the car like the R32 is not a way to go. Way too big of a classic to be messed with. The passat is the plan of our "learning", "custom work" and "daily car" so we went to the extreme. And the end result is just jawdrop reaction. Of course the lines have to be matching with the bumpers which are also going to be a little pulled out but you will see eveything is looking excellent.

 

I have a friend in our R32 community, who's R32 was widened but in an awful way so that car is ruined for me throught my eyes. So yeah it take balls and patience but this turned out perfect on Passat smile.gif

 

Before clean cut  biggrin.gif

 

sdr.jpg

 

And this is left side prepared for being painted smile.gif

 

cof.jpg

 

Brilliant work. Looking forward to seeing how he did the rears !

 

Thank you! Will post some pretty clean photos about details soon wink.gif


Edited by illegalr32, Today, 04:35 PM.

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#17
VelovetAndy

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Devastated. Just when I thought I was going to be treated to some wheel arch Widening porn !. Think you are right about the Mk5 shell. Widening the arches and keeping the overall balance of the shape of the car would be very difficult. The SRS wider front wings sort of work and solve a problem but do not , in my view, look quite right in conjunction with the standard rear. 
Anyway, keep the story coming .







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