>
> So far what I am finding is that Initial Current to extend the Solenoid
> can be in the 25-35Amp range

That would bring the voltage drop along that 6mm^2 wire up to maybe 0.6V,
still leaving 0.9V available for the rest of the positive path plus
allowance for degradation.

Don't misunderstand -- I love relays.  I would put them everywhere.  But
that's not the same as saying that VAG *should* have used one.  Fat wire
alone, vs skinny wire and relay is an engineering choice.

Yrs,
d