[Phantom]

Great project I just have a few comments.

1. The CV joints rebuild them with OEM parts. I know on the TDI Passats (I have an 05) most of the time replacing the cv with aftermarket results in excessive vibration at idle.

2. Grill block on my Golf TDI Blocking the upper and side grill (non inter-cooler side) helped reduce drag and did not increase engine temp actually it reduced it a little. When I block the lower portion of the grill that is when the temp increases. It might be a little different for you since diesel produces less heat and i have not tried it on the passat.

3. For the wheel gap try spring compressors they usually have them at auto part stores it is a bolt with two plates that you tighten down on the springs to lower the car a bit.