The genesis of MCPi.... DEFCONs
Greddy DV adapter? ... Nope
SFS silicone DV relocation hoses? ...Nope
It is the DEFCON product line that led to the founding MCPi.
Born of necessity and frustration: After a year of calling junk yards and salvage shops and scouring eBay and Craigslist postings trying to find a set of control arms from the 2000 model year TT (Audi changed the design implemented in 2001 onwards) with NO success, a way to emulate the same dimensions of the MY 2000 Audi TT arms was created. With the insertion of a metal bushing to the the "newer" arm design, the parts from the original arms could be used - but would it work?
In a word - ABSOLUTELY!
Now with more than 400 installations around the world, the DEFCON product line is the most successful product developed at MCPi. But don't just go by what we say, listen to our customers.
Why make a change in the first place? The original TT came with the now mythical “MK1” arms. In 2001 the original suspension parts were changed to what are referred to as the “MK2” arms, and have essentially remained the same through the end of the first generation TT’s production in 2006. The changes involved in the voluntary recall of model year 1999 and 2000 cars and incorporated since include:
1. Rear spoiler added
2. ESP made standard equipment
3. Front lower control arm design changed
4. Sway bar and shock rates modified
The control arm change introduced understeer to the cars handling, as it makes the handling of the car more "muted" and safer for non-skilled drivers. A solution to this change has been attacked on several fronts. A common approach is to increase the rear and front anti-roll bar diameters. Another solution is to install poly-urethane bushings in the front control arm bush position to dial out some understeer.
The “Holy Grail” solution for TT enthusiasts, though, has been to obtain a set of original MK1 control arms. This has proven very difficult - and quite costly - if they can even be found at all. Any original MK1 arms involved in the recall for the above modifications were destroyed. Many arms have been changed without specific knowledge of their performance attributes during routine work conducted as part of this optional recall.
Now there is a new option in this “Arms Race”. No longer do you have to scour eBay, hoping to get lucky by finding one of the few remaining MK1 arms or scour scrap yards, in search of 1999 or 2000 model year cars that had not undergone the recall work.
DEFCON bushings convert your current MK2 arms, allowing them to accept bushes designed for the model year (MY) 1999-2000 TT in the front position of the front control arms of MY 2001-2006 TTs. The end user has the option to use OEM rubber bushes, or aftermarket urethane bushes (MCPi can supply urethane bushes produced by PowerFlex) in the front of the control arm. In the rear position of the front control arm, the end user can choose to not replace their existing bush, use a solid OEM bush as was provided on MY 2001-2006 cars, or use an OEM bush that was provided with the MY 1999-2000 TT with "cutouts" in the rubber. Bolt kits are also available, as the bolts used to mount the arm are intended for one-time use only (stretch bolts). Finally, for cars with 3.2L motors, the subframe must be dropped to replace the control arms - this means the subframe bolts should also be replaced, as they too are one-time use "stretch" bolts..
The change induced in the car’s handling with DEFCONs installed is significant: Faster turn in, a huge reduction of understeer, and much more communicative steering feedback - all with no or only minimal negative impacts to vehicle NVH (noise, vibration, and harshness). By choosing different front and rear bushes, the end user can either duplicate the original MK1 arm characteristics EXACTLY, or tune to their specific needs.
The DEFCON bushing is a precision component, machined from solid 6061-T6 aluminum billet stock. The part is hard anodized, to guard against corrosion in the aggressive environment in which it must operate, and then lasermarked to indicate authenticity. Installation is straightforward, but use of a high capacity press is suggested to ease the process.
DEFCON Vehicle Compatibility
The DEFCON product line is compatible with all model years of the MK1 Audi TT - 1999 through 2006.
In addition, the MKIV Golf chassis can use DEFCONs, if they also use TT control arms. The MKIV Volkswagen R32 (MY2004) comes with "TT control arms", and the DEFCON kit can be fitted to the R32 with no other changes required. All other MKIV Golf's need to replace their OEM control arms with TT control arms. Depending on the actual arms sourced, the front swaybar mount may need modification (e-mail us for more details if needed).
Installation
Please see this link for a full photo-documented process of installation of the DEFCON product. This is applicable to the installation in to a 1.8L 4-cylinder Audi TT. The installation in to a car with a V6 engine (either the 3.2L Audi TT or the VW R32) is slightly different, as it requires the subframe to be dropped in order to get access to remove the control arms. Installation of the DEFCON components in to the arms is identical, but the process to remove the control arms themselves is different for 1.8 and 3.2L cars.
The most difficult part of the process is removal of the front OEM bush, but the end user will need a large press (a vice is normally not strong enough) to mount the new parts.
NOTE: After installation of DEFCON components, the end user must have their car aligned. Removal and replacement of the control arms WILL change the alignment on the car, and can lead to rapid wear on tires and unexpected handling issues if it is not performed shortly after installation.
Installation Services
Too intimidated by the installation process? Can't find a local shop to do it for you or do they seem overly expensive? MCPi will gladly help you out. We offer two different services to our customers:
DIS - DEFCON Installation Services
DAT - DEFCON Assembly Transaction
DIS - With this service, the end user removes their OEM control arms, and ships them to MCPi. We then rework the customers control arms, removing the old parts, and installing DEFCONs with new bushes. The reworked arms are returned to the customer. This usually takes less than a week. The customer's car will be "out of commission" during this time. The cost for this service is $133, which includes return shipping from MCPi to the end customer (within the lower 48 states - for other regions, please contact us to discuss shipping costs).
Example DIS transaction with DEFCON 2 Purchase:
DAT - With this service, the end user can have the benefit of DEFCONs with the least amount of downtime - usually under 2 hours. MCPi supplies the customer with a set of control arms with DEFCONs already installed. All the end user needs to do is swap their existing control arms with the ones provided, and return their original arms to us - literally remove 4 bolts and 6 nuts, swap the arms, and replace the nuts and bolts. The cost for this service is $200, plus a $200 refundable deposit. The deposit is returned when the customers' control arms are received and inspected by MCPi, verifying they are undamaged. The $200 fee includes shipping the control arms with DEFCONs installed to the customer, but does NOT include the shipping of the customer's arms back to MCPi (pricing, again, is within the lower 48 states - for other regions, please contact us to discuss shipping costs).
Example DAT transaction with DEFCON 2 Purchase:
Pricing listed here is for the service only, component costs are separate (see below).
Note: Both service options are avaliable to owners of original MK1 style arms as well. Please e-mail us at sales@mcpii.com us for more details if needed.
