Although it's a very tight fit, a full 3" turbo-back exhaust was constructed from stainless steel to ensure plenty of flow from the boosted 12v motor. A high-flow cat helps scrub the spent fuel of toxins, while a Borla muffler keeps the exhaust note sporty, without it being too aggressive. A Spearco intercooler core was selected for the task of chilling the pressurized charge, and Ron finished the job by fabricating the rest of the system with mandrel-bent piping. All the plumbing and the intake manifold were then powdercoated matte black, and look pure business under the hood.
A Forge Motorsport 007P diverter valve was used rather than a blowoff valve to minimize lag between shifts, and a C2 Motorsports 36# injector, software and fueling package was used for tuning. Normally this package is fool-proof, but the European ECU caused some unexpected quirks in the fuel delivery, so a house-call was made to smooth out the wrinkles.
"Chris and Jeff from C2 took care of it. They did a custom map on the dyno and now the car's running mint," Steve mentioned.
Once everything was smoothed out, the black Rallye spun NGP's Dynojet to the tune of 330whp and 356wtq at 15psi of boost. This was done while the rear driveshaft was disconnected, effectively making it a front-wheel drive run.
Knowing the standard Syncro transmission would never stand up to over twice the power of the stock engine, a Peloquin 02C torque-biasing front differential was installed, along with eCodeparts billet aluminum Gebo adapters. A Spec stage 3 clutch and NGP flywheel rounded out the drivetrain upgrades.
To bring the car down to the tarmac, FK Konigsport coilovers, featuring Koni adjustable shocks, were installed to keep it solid at high speed and in the turns. The stock brakes were retained, but with Zimmerman cross-drilled rotors and Mintex Red Box pads helping to slow the car without drama.
"It actually stops pretty well. I had a set of Wilwoods on one of my previous cars, but I had to downgrade to G60 brakes with the Girling calipers and it worked out fine with that, too. I'm not drag racing or autocrossing it, so I don't think I need to worry about the heat or anything like that," Steve admitted.
With the Rallye's wide fenders, just any set of wheels wouldn't do. So Steve kept a sharp eye out and managed to score a rare set of three-piece BBS RFs, measuring 16x8.5" front and rear. The wheels are wrapped in 205/40 Kumho Ecsta Supra 712 tires, which provide just enough stretch to look great and do their best to maintain traction when the pedal is pushed to the floor.
The exterior is one area little improvement was needed. In fact, it's completely stock, right down the to VW emblems. The interior mods were kept basic as well, and since the car came with electric Recaros, there's no way Steve was getting rid of those! You'd be hard pressed to find a more comfortable, supportive and classic-looking seat for the Mk2. However, the hands-on experience is enhanced by a Momo steering wheel and shift-knob.
The stock VW stereo was removed to make way for a set of VDO gauges, allowing the driver to monitor the oil pressure, and oil and water temp at a glance. A custom panel was also used to mount a VDO boost gauge in the left vent, rather than a bulky A-pillar mount.
The lack of in-car entertainment doesn't bother Steve one bit. "I was happy to take the stereo out because I love hearing the engine. I love knowing what's going on with the car. And there's nothing like the sound of a VR6 turbo on the highway!"
Steve certainly isn't afraid to use his new- found power. "When I first picked the car up from NGP, going home I ran into a new Shelby GT500. I've raced two of those and smoked 'em both. They were kinda surprised," he laughed. "The first guy was really pissed, but the other gave me the thumbs up and wanted to go again. It was pretty cool."
Steve keeps the Rallye safely garaged most days, bringing it out for get-togethers or when he wants a little fun. "I go out driving on the back roads with the local guys in the 757 area. It's a beautiful car for that; it handles awesome, so there's nothing better than being out on a nice sunny day," he said. "The Rallye's a great ride. It's just so smooth."