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General => General discussion => Non-Golf gallery => Topic started by: Smiithy on 03 February 2014, 16:10

Title: Carbed Rado + Now a 5dr gti mk2 aswell, updates on rado build and pics of mk2.
Post by: Smiithy on 03 February 2014, 16:10
Seems this is the place to put an ongoing dub project so here is mine!

Seem to be finding myself using this forum more and more recently due to the vast amount of useful information!
Thought it only seemed fitting to put my build up on here to keep track of it and maybe pass on information to other people.

So where to begin…
Brought myself a lovely clean example of a 2.0 16v Vw corrado last year.

(http://i389.photobucket.com/albums/oo331/5miithy/20130217_141626_zps5113cc6c.jpg) (http://s389.photobucket.com/user/5miithy/media/20130217_141626_zps5113cc6c.jpg.html)
(http://i389.photobucket.com/albums/oo331/5miithy/20130217_141636_zpsd4807a40.jpg) (http://s389.photobucket.com/user/5miithy/media/20130217_141636_zpsd4807a40.jpg.html)

Other than the wheels it was untouched. First I fitted some AP coils and a set of bbs reps then onto a set of borbets, while doing little touches and general maintenance.

(http://i389.photobucket.com/albums/oo331/5miithy/DSC_8358_59_60_fused_zps99c94e3a.jpg) (http://s389.photobucket.com/user/5miithy/media/DSC_8358_59_60_fused_zps99c94e3a.jpg.html)
(http://i389.photobucket.com/albums/oo331/5miithy/904524_513063578730281_1881703251_o_zps1d5278d1.jpg) (http://s389.photobucket.com/user/5miithy/media/904524_513063578730281_1881703251_o_zps1d5278d1.jpg.html)
(http://i389.photobucket.com/albums/oo331/5miithy/964267_548343735204498_2005776834_o_zps48dbb08f.jpg) (http://s389.photobucket.com/user/5miithy/media/964267_548343735204498_2005776834_o_zps48dbb08f.jpg.html)

This is how the car spent the majority of last year until September when it decided to give up the ghost and die on me. The problem being caused by the KE-jet system fitted to the later 2.0l engines. After having replaced the metering head twise already I decided to pull the lot and rebuild the engine and car.

So plans for the build are :
- Stock bottom end
- Stock gearbox with G60 clutch
-KR head ported and skimmed
-ABF inlet and KR exhaust cams
-Vernier pulley (home-made)
-EDIS-4 megajolt ignition
-R1 carbs
-Strut braces (front upper and lower, rear upper)
-Mk3 gti 5stud widetrack conversion.
-General cleaning up and making a tidy install.

The build so far :
Engine came out -
(http://i389.photobucket.com/albums/oo331/5miithy/20131127_212527_zpsd53ec34f.jpg) (http://s389.photobucket.com/user/5miithy/media/20131127_212527_zpsd53ec34f.jpg.html)

Rear brace went in -
(http://i389.photobucket.com/albums/oo331/5miithy/20131110_103924_zps33f2801e.jpg) (http://s389.photobucket.com/user/5miithy/media/20131110_103924_zps33f2801e.jpg.html)

5 stud lightweight 2 piece forged wheels (need refurbing) -
(http://i389.photobucket.com/albums/oo331/5miithy/volkrims_zps86d2f316.jpg) (http://s389.photobucket.com/user/5miithy/media/volkrims_zps86d2f316.jpg.html)

Head skimmed and rebuilt with new seals etc -
(http://i389.photobucket.com/albums/oo331/5miithy/Mobile%20Uploads/20140123_075442_zpsvjvylwdx.jpg) (http://s389.photobucket.com/user/5miithy/media/Mobile%20Uploads/20140123_075442_zpsvjvylwdx.jpg.html)
(http://i389.photobucket.com/albums/oo331/5miithy/Mobile%20Uploads/20140123_075456_zps3sqvgczu.jpg) (http://s389.photobucket.com/user/5miithy/media/Mobile%20Uploads/20140123_075456_zps3sqvgczu.jpg.html)
(http://i389.photobucket.com/albums/oo331/5miithy/Mobile%20Uploads/20140123_075519_zps9wphh50y.jpg) (http://s389.photobucket.com/user/5miithy/media/Mobile%20Uploads/20140123_075519_zps9wphh50y.jpg.html)

Homebrew vernier pulley -
(http://i389.photobucket.com/albums/oo331/5miithy/Mobile%20Uploads/20140124_124714_zpsw75ui1p4.jpg) (http://s389.photobucket.com/user/5miithy/media/Mobile%20Uploads/20140124_124714_zpsw75ui1p4.jpg.html)
(http://i389.photobucket.com/albums/oo331/5miithy/Mobile%20Uploads/20140124_124719_zpsof0uxpz8.jpg) (http://s389.photobucket.com/user/5miithy/media/Mobile%20Uploads/20140124_124719_zpsof0uxpz8.jpg.html)

Began stripping the loom and cleaning the bay / painting crossmembers etc -
(http://i389.photobucket.com/albums/oo331/5miithy/Mobile%20Uploads/20140202_132407_zpswstad5dw.jpg) (http://s389.photobucket.com/user/5miithy/media/Mobile%20Uploads/20140202_132407_zpswstad5dw.jpg.html)

Comes up well for a 22year old car! -
(http://i389.photobucket.com/albums/oo331/5miithy/Mobile%20Uploads/20140202_132411_zpskrqwqarj.jpg) (http://s389.photobucket.com/user/5miithy/media/Mobile%20Uploads/20140202_132411_zpskrqwqarj.jpg.html)

And finally the gearbox finished in black and bronze/gold (same colour wheels will be) -
(http://i389.photobucket.com/albums/oo331/5miithy/Mobile%20Uploads/20140202_133856_zpserwdri6q.jpg) (http://s389.photobucket.com/user/5miithy/media/Mobile%20Uploads/20140202_133856_zpserwdri6q.jpg.html)
(http://i389.photobucket.com/albums/oo331/5miithy/Mobile%20Uploads/20140202_133913_zpsamsxjpyz.jpg) (http://s389.photobucket.com/user/5miithy/media/Mobile%20Uploads/20140202_133913_zpsamsxjpyz.jpg.html)

Thanks for looking, sorry for all the pics, just trying to get the thread upto speed! Advice and all input is appreciated!

Title: Re: R1 Corrado Project - The beginning
Post by: Rhyso on 03 February 2014, 16:18
Yay!! No 1.8T conversion!!!!

Nice to see something a bit different  :cool:
Title: Re: R1 Corrado Project - The beginning
Post by: Smiithy on 03 February 2014, 16:40
Think its more fitting with the era of the car :) Plus the noise of carbs is awesome!
Title: Re: R1 Corrado Project - The beginning
Post by: Diamond Hell on 03 February 2014, 22:58
Unlike the fuel consumption will be.  :whistle:

Shoulda got ITBs.
Title: Re: R1 Corrado Project - The beginning
Post by: Smiithy on 04 February 2014, 07:15
Not fussed about economy, only a weekend toy. Itbs would of cost me alot more in management than carbs have and you can get mid20s set up right.
Title: Re: R1 Corrado Project - The beginning
Post by: Smiithy on 04 February 2014, 16:15
Made up a quick distributor "plug" / bracket for my coil pack today, trying to keep it all OEM positions. Quite happy with the outcome..... 

(http://i389.photobucket.com/albums/oo331/5miithy/Mobile%20Uploads/20140204_161135_zpsoz1dyobc.jpg) (http://s389.photobucket.com/user/5miithy/media/Mobile%20Uploads/20140204_161135_zpsoz1dyobc.jpg.html)
(http://i389.photobucket.com/albums/oo331/5miithy/Mobile%20Uploads/20140204_161129_zpsmufkvndm.jpg) (http://s389.photobucket.com/user/5miithy/media/Mobile%20Uploads/20140204_161129_zpsmufkvndm.jpg.html)
Title: Re: R1 Corrado Project - The beginning
Post by: Smiithy on 05 February 2014, 12:27
Decided to put abit more time in on the coil bracket as it looked messy, New results --

(http://i389.photobucket.com/albums/oo331/5miithy/Mobile%20Uploads/20140205_121457_zpsmqeolmoc.jpg) (http://s389.photobucket.com/user/5miithy/media/Mobile%20Uploads/20140205_121457_zpsmqeolmoc.jpg.html)
(http://i389.photobucket.com/albums/oo331/5miithy/Mobile%20Uploads/20140205_121506_zpskyvbgiyu.jpg) (http://s389.photobucket.com/user/5miithy/media/Mobile%20Uploads/20140205_121506_zpskyvbgiyu.jpg.html)
(http://i389.photobucket.com/albums/oo331/5miithy/Mobile%20Uploads/20140205_121934_zpsypwraod7.jpg) (http://s389.photobucket.com/user/5miithy/media/Mobile%20Uploads/20140205_121934_zpsypwraod7.jpg.html)
Title: Re: R1 Corrado Project - The beginning
Post by: mark-mk3gti on 05 February 2014, 17:37
like it! look forward to seeing more :)
Title: Re: R1 Corrado Project - The beginning
Post by: golfyste on 05 February 2014, 19:39
I do love a corrado and this is a very tidy example!! Looking  forward to seeing the build progress!  :cool:
Title: Re: R1 Corrado Project - The beginning
Post by: Smiithy on 06 February 2014, 09:02
Thanks guys, will probably be abit slow for the next few weeks, getting to crunch time with buying my first house, but soon as I'm in ill have a garage to build her up in then progress will really begin.
Title: Re: R1 Corrado Project - The beginning
Post by: Diamond Hell on 07 February 2014, 13:36
You haven't mentioned the flywheel anywhere.  As you're going for the throttle response you'd do well to drop it to about 6kg to lose the inertia.  Barely notice mine in traffic etc, but it comes on song much nicer.
Title: Re: R1 Corrado Project - The beginning
Post by: Smiithy on 07 February 2014, 13:48
I have thought about it a few times, and then read up and thought ahh no point bothering. As a machinist i could probably do something myself, but its knowing where to remove the meat etc. Ill probably leave it tbh, but I'm not 100%
Title: Re: R1 Corrado Project - The beginning
Post by: Diamond Hell on 07 February 2014, 14:49
One of the best simple mods out there.

Look at the flywheel - it's pretty obvious where the meat is available to go! Wazzzer on here did his at work, or had a mate do his on a lathe IIRC.  Due to the circular nature of a flywheel and how a lathe works it's pretty easy to take off material evenly.  :grin:
Title: Re: R1 Corrado Project - The beginning
Post by: Len on 07 February 2014, 15:48
Had my flywheel done by a member on here (spikenipple) down to 6.1 kgs
You just take it all off the back (engine side)

The guy that has been most publisised (hotgolf) has taken one down to 4.5kgs!
Title: Re: R1 Corrado Project - The beginning
Post by: Smiithy on 08 February 2014, 09:10
What do they start as? For the use its gna get it would be worthwhile I imagine
Title: Re: R1 Corrado Project - The beginning
Post by: Diamond Hell on 08 February 2014, 15:19
They're about 10kg to start - the weight loss is definitely worthwhile!
Title: Re: R1 Corrado Project - The beginning
Post by: lewis1641 on 10 February 2014, 14:08
loving the one off parts
Title: Re: R1 Corrado Project - The beginning
Post by: Wayne on 10 February 2014, 22:08
Looks a great project, looking forward to more updates :afro:
Title: Re: R1 Corrado Project - The beginning
Post by: Dave_IOW on 11 February 2014, 00:16
Had mine turned down on a lathe, was an ABF one.

Fairly noticeable :wink:
Title: Re: R1 Corrado Project - The beginning
Post by: thai-wronghorse on 12 February 2014, 00:11
Nice little bit of fabrication there. :wink:
Title: Re: R1 Corrado Project - The beginning
Post by: Smiithy on 13 February 2014, 08:40
Thanks guys.  Will look into it more and maybe even go around the 7kg mark then. Cant wait to get my new garage and get cracking! No updates unfortunately :(
Title: Re: R1 Corrado Project - The beginning
Post by: Smiithy on 06 March 2014, 09:31
So, an update finally...

Corrado is officially in its new home.
(http://i389.photobucket.com/albums/oo331/5miithy/Mobile%20Uploads/20140303_130450_zpsrxtzrtzv.jpg) (http://s389.photobucket.com/user/5miithy/media/Mobile%20Uploads/20140303_130450_zpsrxtzrtzv.jpg.html)

Started stripping the loom down further....
(http://i389.photobucket.com/albums/oo331/5miithy/Mobile%20Uploads/20140305_195427_zps3zy0agah.jpg) (http://s389.photobucket.com/user/5miithy/media/Mobile%20Uploads/20140305_195427_zps3zy0agah.jpg.html)

To find this....
(http://i389.photobucket.com/albums/oo331/5miithy/Mobile%20Uploads/20140305_192212_zpscay4oieg.jpg) (http://s389.photobucket.com/user/5miithy/media/Mobile%20Uploads/20140305_192212_zpscay4oieg.jpg.html)
(http://i389.photobucket.com/albums/oo331/5miithy/Mobile%20Uploads/20140305_192220_zpsrgqhtw2w.jpg) (http://s389.photobucket.com/user/5miithy/media/Mobile%20Uploads/20140305_192220_zpsrgqhtw2w.jpg.html)
(http://i389.photobucket.com/albums/oo331/5miithy/Mobile%20Uploads/20140305_192247_zpsmlgciqlo.jpg) (http://s389.photobucket.com/user/5miithy/media/Mobile%20Uploads/20140305_192247_zpsmlgciqlo.jpg.html)

Any ideas what my un-used, half botched together wires are for? could they just be un-used generic loom or has it been faffed about with. The wires into the "plugs" are from the battery and go through the bulkhead below the ecu loom. the triple fuse holder is also between the battery and the un-used plugs.

Thanks for looking.
Title: Re: R1 Corrado Project - Wiring Woes!
Post by: Diamond Hell on 06 March 2014, 11:06
Looks like a disused uprated headlight loom to me.
Title: Re: R1 Corrado Project - Wiring Woes!
Post by: Smiithy on 06 March 2014, 11:25
Dont think it would quite reach the headlights tbh, but you raise a good point!

Can totally see why the stock headlight loom is crap!, theres around a meter of loom thats not needed in there for 1!
Title: Re: R1 Corrado Project - Wiring Woes!
Post by: Diamond Hell on 06 March 2014, 16:16
What won't reach the headlights?  The relay block?

When I said it was disused, I think it's also incomplete - there aren't enough wires there.  Those to the headlights and the relays for the power might have been yanked out/cut at some point.

The alternative is it's something to do with the alarm, which no doubt will have been installed by some feral electrician. 

The three fuses is a clue - one for the main beam and two - one each for the dips for better resilience.
Title: Re: R1 Corrado Project - Wiring Woes!
Post by: Smiithy on 06 March 2014, 16:26
Fair enough. I can see where you are coming from but why would it be going into the car on the passenger side behind the glovebox to then need to go all the way across to the driver side?

Also there are around 2/3 looms all going into that final set of "plugs" .

Car has an aftermarket alarm fitted, could be to do with that but from what i have seen there is a single loom from the alarm speaker into the bulkhead, might have to follow this into the car see if there are any links as it could make sense as i suppose an alarm can be used for many different cars so will have un-used plugs and loom??

Also this was found in a large grey cover (maybe factory) that i cut off to assess what was underneath and was found under the washer bottle rammed in.
Title: Re: Carbed Rado + Now a 5dr gti mk2 aswell, updates on rado build and pics of mk2.
Post by: Smiithy on 16 July 2014, 09:03
So really need to start getting some updates in, been a hecktick few months with the new house and been having issues so anger has stopped me wanting to post.

So as the story goes, I built up the head I had spent time working on, all skimmed etc, to then find when built up the cams wouldn’t turn due to it being warped. So that was that scrapped.

Luckily I found an ABF head with 276inlet and 288exhaust cams going cheap, so snapped it up, was in mind condition so dropped straight on and painted bits up and now my engine turns over lovely with 3.5mm valve clearance.

(http://i389.photobucket.com/albums/oo331/5miithy/temporary_zpsd16eba99.jpg) (http://s389.photobucket.com/user/5miithy/media/temporary_zpsd16eba99.jpg.html)
(http://i389.photobucket.com/albums/oo331/5miithy/10336756_10203896472153369_6884297820087917894_n_zpse2235c63.jpg) (http://s389.photobucket.com/user/5miithy/media/10336756_10203896472153369_6884297820087917894_n_zpse2235c63.jpg.html)
Built the engine up and dropped her in, and as it pretty much stands now..

(http://i389.photobucket.com/albums/oo331/5miithy/temporary_zps1b1ca2e6.jpg) (http://s389.photobucket.com/user/5miithy/media/temporary_zps1b1ca2e6.jpg.html)
Megajolt trigger wheel in…

(http://i389.photobucket.com/albums/oo331/5miithy/temporary_zps1b1ca2e6.jpg) (http://s389.photobucket.com/user/5miithy/media/temporary_zps1b1ca2e6.jpg.html)
Valvetrain cover painted up.

And the last little edition is the momo wheel, and also have a rear ARB.
(http://i389.photobucket.com/albums/oo331/5miithy/WP_20140505_001_zps01149633.jpg) (http://s389.photobucket.com/user/5miithy/media/WP_20140505_001_zps01149633.jpg.html)

So this is where the corrado stands at the moment, am fabricating the carb manifold, have sorted the new exhaust manifold. Bit that’s holding up the show is the wiring as its not my strong point… but its getting there, all be it slowly…

In other news, I’ve brought a new car for me and the misses to share. After lots of looking about I have managed to pick up a solid, fairly tidy (has a dented bum unfortunately, but not bad) mk2 golf 5dr gti 8v.
Picking it up on Saturday and cant wait to get stuck in and do some work to it. Needs lifting abit as its stupidly low, other than that it’s a good car, ready to go.

(http://i389.photobucket.com/albums/oo331/5miithy/10488927_10154327713140014_895527253_n_zps149ad2af.jpg) (http://s389.photobucket.com/user/5miithy/media/10488927_10154327713140014_895527253_n_zps149ad2af.jpg.html)

(http://i389.photobucket.com/albums/oo331/5miithy/10478522_10154327713135014_699721443_n_zpsdea560d0.jpg) (http://s389.photobucket.com/user/5miithy/media/10478522_10154327713135014_699721443_n_zpsdea560d0.jpg.html)

(http://i389.photobucket.com/albums/oo331/5miithy/10477943_10154327713145014_1979161480_n_zps39d312b7.jpg) (http://s389.photobucket.com/user/5miithy/media/10477943_10154327713145014_1979161480_n_zps39d312b7.jpg.html)

Im terrible keeping these things updated, but now I have 2 classic dubs I have no excuse, so will keep updated from now on in. Drop me some replys guys 