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Model specific boards => Golf mk2 => Golf mk2 gallery => Topic started by: Gti_Jamo on 20 February 2014, 20:23

Title: 1991 Tornado Red Corrado G60 Daily / Project
Post by: Gti_Jamo on 20 February 2014, 20:23
Thought it was time I put up a thread on my recent ebay purchase.

(http://i41.tinypic.com/25hpdo8.jpg)

Lovely looking car on the surface, no welding so far but will need some work done to the front passenger sill where its been crushed. Its rotten behind the seal at the top of the drivers side windscrean. Its needing replaced anyway, I just hope the auto-glass man can leave it with me a couple of days inbetween removal and refitting so I can repair it. Its also leaking water somewhere but yet to verify its the screen causing this.

Other issues is the interior as its not great and not put together well. Bits missing here and there. Front seatbelts are not mounted to pillar correctly and rear belts not even there. Have Mk2 Golf ones there but not sure they're the same. No parcel shelf or spare wheel and boot carpet. Central locking not working most of the time. Front strut top are hanging off it, ruining the osf tyre on inside edge. Small dent in osr wheel arch. Has a momo steering wheel I want to swap for a standard one and aftermarket rear lights i'm not too keen on. Bit of laquer peel on ns door and a few wee other stonechips etc but nothing major there. Loads of history adding up to 10k+ and recently had a new distributor and fuse box.

The job that takes priority though is changing the engine as sadly after only the second day of ownership one of the pistons melted. I have one lined up off another svag member just need to pick it up.

(http://i44.tinypic.com/2ij3hg6.jpg)

(http://i44.tinypic.com/2qc33oh.jpg)

Obviously i'll need to figure what caused this as usually related to a fueling issue. Poor injector maybe. I'll probably clean up the bay and paint the new engine while its out but all dependant on cost and motivation but morale is low with this just now. At the stage where I wish I never bought it and just kept my tidy vr6 but I know it'll pass once some progress is made and it'll be worth a good few qud once its done. Just want it running and on the road as it's still mot'd till august. Still waiting on docs from previous owner due to private plate going on retention so cant even tax it until then but its been about 3 weeks so hopefully not long to go. Also need to recieve docs confirming last charger rebuild as left them behind when I collected it. Apparently on a stage 3.

So upto where i'm at now I picked up a 1H rallye engine at the weekend. Just a head and block with low miles but has sat for a good whille.

Anyway got it on the engine stand and began ripping it apart. The head's fine, real good condition. Will just require stripped, cleaned and rebuilt. However, although the bores are really good in regards to wear as it's practically nothing, some moisture has got into one of them and suffered some corrosion or a build up of rust. This is what i'm left with after cleaning away all the brown mankyness and hitting it with wone wd40 and some 2000 grade wet and dry.

(http://i57.tinypic.com/33vf8s1.jpg)

So more #1 piston/bore fun. Cars killing me lol. I'm not sure on the what the next best course of action with this or if it's needing the machine shop. I have a bore honing tool for the dril and various air tools that I could try. It is quite prominent when you run your finger over it.

I also had some movment of the same piston so removed it and found the ring to be sticking which after cleaning up seems to be fine. Some moisture got down there too.

Other than this everything else appears to be spot on but yet to do any measuring but it is obviously low miles so in general i'm happy aslong as I can resolve this bore issue quickly.

Some other pics.

(http://i58.tinypic.com/2zyygps.jpg)

(http://i57.tinypic.com/vpkgsl.jpg)

(http://i61.tinypic.com/103yibp.jpg)


Title: Re: Corrado G60 Project / 1H Rallye Engine Strip Down
Post by: gazareth on 21 February 2014, 00:01
hey why not swap the pistons in to your original block? along with new set of rings :nerd:
Title: Re: Corrado G60 Project / 1H Rallye Engine Strip Down
Post by: Gti_Jamo on 21 February 2014, 10:53
The pistons/bore are slightly smaller in the 1H rallye engine so not an option sadly. Displacement is 1763cc whereas my old normal pg is 1781cc. Plus the 1H Is a better engine. My old engine has considerable bore wear too. I'm going to run the honing tool down it and see how it does.
Title: Re: Corrado G60 Project / Daily
Post by: Gti_Jamo on 05 March 2014, 20:19
Right then, i've had the block inspected at a machine shop and had the bore honed and its much better but still there although much less obvious to the touch. Obviously a rebore would 100% cure the problem but it's not an option just now so i've decided just to build it up and see how it goes. I'm hopefull the rings will sort it out. Basically run it in and keep an eye on the compression and oil consumption.

(http://i60.tinypic.com/2ir1yeg.jpg)

It's not ideal but no other option really.  I'm confident though.

So going to start building it back up tomorrow then commence with the swap.

(http://i62.tinypic.com/23uojcz.jpg)

(http://i62.tinypic.com/2vv1kl5.jpg)
Title: Re: 1991 Corrado G60
Post by: Gti_Jamo on 12 March 2014, 19:54
Couple of the infamous piston nunberm1 now removed from it chamber of carnage.

(http://i60.tinypic.com/2n03tr5.jpg)
(http://i61.tinypic.com/23lm5af.jpg)

The 1H block now has its pistons back in along with some new big end bearing shells. Also stripped and cleaned the head. Its had some previous porting done on the inlets. Just now need to get the various seals and gaskets to build it all back up.
Title: Re: 1991 Corrado G60
Post by: Gti_Jamo on 26 March 2014, 20:05
A little update with how things are progressing.

Engine block and cam cover got hit with some wrinkle black.

(http://i59.tinypic.com/sp9qgz.jpg)

Then just started building. Just need to bolt on the gearbox.

(http://i62.tinypic.com/2vaxp1i.jpg)

It doesn't look great but not going mad with it making it like new if its all coming out again, which it will at some point after the summer. Just need to see how this runs first. Its had the bores honed, new big end shells, both crank seals replaced, crank bolt, stem seals and valves re-lapped, metal head gasket and new bolts, sump painted / new gasket, new timing belt Also have oil / filter, red coolant, thermostat and new expansion tank bottle, fuel filter also along with a bottle of STP.

Also during the build I came across the injector loom.

(http://i58.tinypic.com/2e0trip.jpg)

(http://i57.tinypic.com/j9y24m.jpg)

Quite possibly the cause of my piston detonation. Will need to get another from somewhere as the wiring is split at the base off all the connectors and various other places. I'm surprised it ran at all.

Bay given a minor spruce up along with sorting out the rough loom.

(http://i62.tinypic.com/25gaywh.jpg)

Engine goes back in it tomorrow.
Title: Re: 1991 Corrado G60 (Update 26/3)
Post by: Simeon on 29 March 2014, 00:28
Looks good mate :) Good attitude re not wasting time painting everything, built properly and back on the road asap is best.

You may need to get a local electrician to sort that injector loom, only place I've seen them new is bar-tek... for lots of cash!
Title: Re: 1991 Corrado G60 (Update 26/3)
Post by: gazareth on 29 March 2014, 00:35
it looks the same loom as the mk2 golf pb engine. but you could also use an agg loom with all the earths joined together.
Title: Re: 1991 Corrado G60 (Update 26/3)
Post by: Gti_Jamo on 29 March 2014, 11:42
Cheers guys, luck would have it I have a mk2 project with a mint injector loom so checked and fitted that. Engine is in now, going over to garage soon to finish off hooking it up. Need to source a new charger oil feed pipe as mines corroded and broke real easy. Not a cheap part apparently.
Title: Re: 1991 Corrado G60 (Update 26/3)
Post by: Simeon on 29 March 2014, 12:56
Onlychargeddubs have them, not overly expensive
Title: Re: 1991 Corrado G60 (Update 26/3)
Post by: Gti_Jamo on 29 March 2014, 13:00
Yeah they seem to be the only distributor in the uk. Expensive for a length of braided hose but they are specic to the lubrication needs of the charger. Going to order one soon as wont be able to run it without it.
Title: Re: 1991 Corrado G60 (Update 26/3)
Post by: matt@onlychargeddubs on 29 March 2014, 19:33
Ouch! Just read through and a real shame it gave it on day 2! Those injector looms a serious issue though after 20 years!

Every car I get in is the same though if the engines never been out!

As for the feed line, you're right, they aren't cheap! It's due to the internal diameter VW used meaning the banjo ends are very odd and unusual to most hose specialists.

Hence me being the only Uk supplier of them as I've them made especially for me :)
Title: Re: 1991 Corrado G60 (Update 26/3)
Post by: clipperjay on 29 March 2014, 20:02
When first installing that stupid banjo check for oil leaks before you drive off trust me one washer missing, can give you a world of pain.
 I remember picking mine up it cost me about £40 odd quid when it was last in stock, stupid design to share oil path ways from main block to charger feed!!!!
I was tempted to fabricate complete separate feed, clean free of crap oil on tap from a mini pump & reservoir!   
Title: Re: 1991 Corrado G60 (Update 26/3)
Post by: Gti_Jamo on 29 March 2014, 20:28
Ouch! Just read through and a real shame it gave it on day 2! Those injector looms a serious issue though after 20 years!

Every car I get in is the same though if the engines never been out!

As for the feed line, you're right, they aren't cheap! It's due to the internal diameter VW used meaning the banjo ends are very odd and unusual to most hose specialists.

Hence me being the only Uk supplier of them as I've them made especially for me :)

Yeah mate i'll be ordering one of those from you on monday when I get paid so you'll need to get that out to me sharpish lol. Need to see if there is anything else on the site I fancy.

When first installing that stupid banjo check for oil leaks before you drive off trust me one washer missing, can give you a world of pain.
 I remember picking mine up it cost me about £40 odd quid when it was last in stock, stupid design to share oil path ways from main block to charger feed!!!!
I was tempted to fabricate complete separate feed, clean free of crap oil on tap from a mini pump & reservoir!   

Yeah don't worry it'll be checked meticulously before it goes anywhere mate. Least of my worries lol. Yeah it is a strange setup for the oil feed but probably the cost effective way of doing it.

How she sits this evening...

(http://i61.tinypic.com/15egrhu.jpg)

Title: Re: 1991 Corrado G60 (Update 26/3)
Post by: clipperjay on 30 March 2014, 10:06
Looking good mate do you own a workshop manual for the Corrado G60?
Title: Re: 1991 Corrado G60 (Update 26/3)
Post by: Gti_Jamo on 30 March 2014, 12:40
Looking good mate do you own a workshop manual for the Corrado G60?

Cheers mate, no workshop manual unfortunately. You needing info on something particular?
Title: Re: 1991 Corrado G60 (Update 26/3)
Post by: clipperjay on 30 March 2014, 12:44
No I have the rare G60 Corrado Bentley manual some where so thought you might need it its PDF format and helped me out with the Rallye G60 no end!
Title: Re: 1991 Corrado G60 (Update 26/3)
Post by: Gti_Jamo on 30 March 2014, 12:54
I'm ok so far but cheers. Have autodata and a shelf full of old diagnostic books, many of which cover the G60. Served me well so far.

One think i'm not too clear on is the torque setting on the crank bolt. Obviously originally a stretch bolt but my new one isn't and quite rightly so.
Title: Re: 1991 Corrado G60 (Update 26/3)
Post by: clipperjay on 30 March 2014, 13:10
Non stretch crank bolt - N 040 106 4 DX bolt from memory! Use lock tight if its DX off a MK1
Torque values would be 59 lb/ft (80 Nm) for the non stretchy.
But if its a PG stretchy one then 200NM Quite a difference in Torque values
I would be tempted 100NM with lock tight
Title: Re: 1991 Corrado G60 (Update 26/3)
Post by: Gti_Jamo on 30 March 2014, 14:25
Well the original PG bolt has been revised but still carry original part number apparently. Don't do stretch bolts for them anymore so i've been told. Looks identical though.
Title: Re: 1991 Corrado G60 (Update 26/3)
Post by: clipperjay on 30 March 2014, 15:07
Yeah I'm a bit skeptical MK1 bolt all the way TBF.  :lipsrsealed:
I've still got a brand new stretchy bolt somewhere, bought it before I knew DX bolt would fit like glove when I did my Rallye.
Title: Re: 1991 Corrado G60 (Update 26/3)
Post by: Gti_Jamo on 30 March 2014, 15:59
I'll double check, i'm sure its 10.9 grade on the bolt.

Edit - It is still a stretch bolt although vw only do an revised version that won't shear apparently.
Title: Re: 1991 Corrado G60 (Update 26/3)
Post by: matt@onlychargeddubs on 31 March 2014, 10:13
Yeah the new bolt has had the shearing problem sorted out.

So torque up as factory :smiley:
Title: Re: 1991 Corrado G60 (Update 26/3)
Post by: Gti_Jamo on 31 March 2014, 19:06
Yeah the new bolt has had the shearing problem sorted out.

So torque up as factory :smiley:

Yeh it's torqued up now. Hopefully it won't give me grief in the future. Might end up pinning the sprocket to the crank to spread the load a bit. I'll be ordering that oil feed just after midnight mate when monies are in bank.
Title: Re: 1991 Corrado G60 (Update 03/04)
Post by: Gti_Jamo on 03 April 2014, 17:17
Got my new oil feed pipe this afternoon from OnlyChargedDubs so fired it on and started her up. Initial impressions are all good, no excessive breather blow back or blue smoke. Engine sounds nice and smooth. No oil leaks but small water leak from the temp sensor flange on the front of the head but have a spare one if needed. Not put coolant in it yet. It is running very rich though, like off the scale so will need to spend some time getting it set up correctly but overall i'm very happy. Will post some pics and maybe a wee vid tomorrow hopefully.
Title: Re: 1991 Corrado G60 (Update 12/04)
Post by: Gti_Jamo on 12 April 2014, 19:35
Got my overfueling issue rectified, was the oxygen sensor in the end so all appears to be good now. Runs pretty sweet. Idles good.

(http://i59.tinypic.com/23linbb.jpg)

Front mount back on. It's a tad on the large side and sits very tight in there.

(http://i60.tinypic.com/nl33p3.jpg)

Got some new strut-top mounts as the old ones had about an inch of side-to-side play in them. Removed the coilovers and found the adjusters to be seized solid and the helper springs broken so will need to see if I can free them off and run them without helpers or chuck them in the bin. Look like cheapies judging by the state of them.

Other dissapointing news is that the charger, which was advertised as a stage 3 is actually a stage 2 which was done 15 year ago (around 45k) so that's going to need done soon although still sounds good and boosts well enoug although yet to check exactly how much. Contacted JabbaSport directly to confirm this using the numbers stamped on the charger casing. Jabba don't even do stage 3's apparently, just 2 & 4's.

Other jobs needing doing is to fit a new bonnet cable as the old one snapped when removing it. Also need to refit interior as i removed it due to a leak which moves me onto resealing the door membranes as the final job.

Also needing to get it taxed and get a tyre fitted and it's good to go.
Title: 1991 Tornado Red Corrado G60 (Update 18/04)
Post by: Gti_Jamo on 18 April 2014, 21:40
Well thats the G60 on the road now. So far so good!! No smoke out the back or any oil leaks and no piston detonation lol. Runs spot on.

(http://i60.tinypic.com/1690135.jpg)

(http://i58.tinypic.com/w2exx2.jpg)

(http://i58.tinypic.com/f40412.jpg)

Need to find some standard rear lights as those things aren't my cup of tea. Also some better coillies as one of mine has some lateral play in it. Some bigger wheels or g60 steels.

Still got the carpets out as need to make it leak proof but at least it's working and on the road. Good weather for it too.

Basically from here forward will be used quite a bit over summer and after then will no doubt rip the engine out again and paint the bay. Refurbish everything underneath. Just aim to make it as best as it can be but still retain originality as this will be a proper collectable car soon enough. Original reg number going back on and the private one going back to previous owner. I'm not really a fan of them to be fair.

Title: Re: 1991 Tornado Red Corrado G60 (Update 18/04)
Post by: Gti_Jamo on 23 April 2014, 16:54
Developed a misfire at idle and medium throttle once warmed up. The blue temp sensor resistance is around 300 ohms at 80 degrees which is about right. Disconnecting it cures the misfire and revs increase. Also runs relatively fine with the lambda sensor disconnected. It's only a couple of weeks old but not a genuine bosch so i'm thinking it's dead already. It's not chucking out black smoke with it connected like it was doing with previous lambda, So it's either the blue temp or lambda i'm sure, or wiring related so will need to investigate it further.
Title: Re: 1991 Tornado Red Corrado G60
Post by: Gti_Jamo on 22 June 2014, 20:52
Not much of an update just a couple of pics. Have done very little to it bar drive it 4500 trouble free miles since I disconnected lambda sensor. Was cheap and failed real quick but goes fine without it for now.

(http://i57.tinypic.com/i5vedt.jpg)

(http://i57.tinypic.com/rtm6m9.jpg)

As you can see i've replaced the nasty red/clear rear lights (someone paid me 50 actual pounds on ebay for them) with standard ones and it looks much more original.

Engine has been using a bit of oil but was expected and will be sorted over winter. Windscreen cracked in both top corners and some rot behind there too. Plan to paint the whole car over winter too but the screen is top priority as mot is due soon.

Also note I still have the private plate on. Previous owner said the retention docs were sent ages ago (April) but dvla tell me otherwise so had to take matters into my own hands and sent of a v62 application for the log book so the plate will be also transferred to me. Not sure why the delays as it's in their best interest surely but i'm within my rights to take ownership of it.
Title: Re: 1991 Tornado Red Corrado G60
Post by: Gti_Jamo on 10 August 2014, 14:10
With MOT time approaching my plans were to just put the Corrado off the road until till next year but been enjoying running it so much I thought i might aswell just keep using it.

How she looks just now.

(http://i57.tinypic.com/260qqhl.jpg)

Anyway, first of the 'big' jobs. Ruined windscreen.

(http://i61.tinypic.com/4vfej7.jpg)

Got myself a bonded screen removal tool off ebay which turned out to be a pile of brown sugar and broke litterally after a couple of pulls so resorted to having to go round the inside with a stanley knife as much as I could around the top and both sides then kicking the hooor out. Worth pointing out i've not covered anything. Well I have no carpets in just now and the paintwork is past its best and will be getting redone. But remember, goggles and heavy duty gloves.

(http://i59.tinypic.com/30ur67p.jpg)

(http://i57.tinypic.com/5txqtt.jpg)

Then went round the frame with a soft chisel and a rubber mallet.

(http://i58.tinypic.com/vowrqu.jpg)

Knew i had some rust issues and this is what I have to deal with.

(http://i57.tinypic.com/1z6xwf9.jpg)

One sides totally rotten while the others not too bad.

The other job taking second priority is my crushed sill. What was originally a hole about an inch or two in diameter turned into this. Hence why the wings off.

(http://i62.tinypic.com/5n4z78.jpg)

Obviously needs to be a good job as it's on display so my metal fabrication skills will be tested on both here and the screen frame.

Not much else needing done for MOT, drivers window is held up with a block of 2 x 4, no bonnet cable fitted either.

Will update as it progresses.
Title: Re: 1991 Tornado Red Corrado G60 MOT Prep
Post by: VW BUSH on 10 August 2014, 19:04
Be interesting to see how this comes out the bonded screens used by VW seem to be a real rust trap, they leave a leading corner / edge which chips easily and lets the water in :angry:
Welding in around the roof will be a real test of ye skills, far beyond what my ham fists are capable of good luck...
From what you did on the Mk3 I don't think you will have any issues with the sills :smiley:
Title: Re: 1991 Tornado Red Corrado G60 MOT Prep
Post by: Gti_Jamo on 10 August 2014, 22:28
Cheers mate!

I think also a previpusly poorly fitted screen has contributed to the rot here. Hopefully shouldn't be too bad to do and at least it'll be hidden by the seal. Aslong as it completely rust free and has a fresh flat base for the screen to bond to. The sill worries me a bit as it's a complicated section. Ideally i'd be looking to cut a bit out of a scrapper and weld it in flush.
Title: Re: 1991 Tornado Red Corrado G60 MOT Prep
Post by: Gti_Jamo on 12 August 2014, 17:49
Cut out everything that was rotten and started to fabricate some strips of metal. Luckily the rot hasn't penetrated the lower skin of the frame so just a matter of replacing that then weld in a vertical strip and all should be good. Punched holes so i can puddle weld then grind smooth, also left small gaps between the strips so i can stitch weld then again smooth them off.

(http://i62.tinypic.com/1zmjslk.jpg)

Part of the upper skin on the passenger side wasn't to clever either so replacing with another strip.

(http://i62.tinypic.com/2nm397r.jpg)

Title: Re: 1991 Tornado Red Corrado G60 MOT Prep
Post by: Bandit127 on 12 August 2014, 19:09
That sort of cutting welding isn't engineering. It is art.

Good job so far.  :smiley:
Title: Re: 1991 Tornado Red Corrado G60 MOT Prep
Post by: Gti_Jamo on 12 August 2014, 19:25
That sort of cutting welding isn't engineering. It is art.

Good job so far.  :smiley:

Cheers mate, those strips of metal were part of a door skin of a mk3 golf this morning by the way lol. Art on a budget!!
Title: Re: 1991 Tornado Red Corrado G60 MOT Prep
Post by: Gti_Jamo on 16 August 2014, 16:02
(http://i59.tinypic.com/2ihtg6o.jpg)

(http://i58.tinypic.com/6fbf5f.jpg)

(http://i58.tinypic.com/e5i4b4.jpg)

Not too much left to do, just delicately weld up and smooth off the gaps. I'd urge anyone with a corrado to check these areas for rust.
Title: Re: 1991 Tornado Red Corrado G60 MOT Prep
Post by: Seanl on 16 August 2014, 22:31
Good work dude, it's a really common problem area due to bodged screen fitting. Mine is in for Windows out paint at the moment, and I've asked to be present when it goes back in to ensure it doesn't happen!
Title: Re: 1991 Tornado Red Corrado G60 MOT Prep
Post by: Gti_Jamo on 17 August 2014, 15:12
Cheers mate. Yeah i'll be keeping a close eye on mine being fitted too. Gonna paint the window frame myself prior to it going in and then prob do the whole car over winter. It's been polishd so much in places it's through to the primer.
Title: Re: 1991 Tornado Red Corrado G60 MOT Prep
Post by: Seanl on 18 August 2014, 20:52
Yeah mine was the same.  When I got it, it was in a real state.  I had to be very aggressive on the compound and pads to get a decent finish. Unfortunately it resulted in strike through on a couple of areas on the swage lines.  All worth it in the end though!  :cool:
Title: Re: 1991 Tornado Red Corrado G60 MOT Prep
Post by: Gti_Jamo on 22 August 2014, 19:46
Got the frame finally finished. All solid now.

(http://i61.tinypic.com/2d6siso.jpg)

(http://i58.tinypic.com/fy3e60.jpg)

(http://i62.tinypic.com/2hdtd8j.jpg)

Just rattle canned it along with a coat of laquer just to seal it. Also used an etching primer along with a base primer to ensure it stays rust free. Rest of car will be properly painted soon. Laquer peel is beyond a joke.

Windscreen getting fitted on wednesday through my insurance which saves me a good few quid so all working out well so far.
Title: Re: 1991 Tornado Red Corrado G60 Daily / Project
Post by: Gti_Jamo on 31 August 2014, 13:22
Windscreen now fitted. Looks great.

(http://i59.tinypic.com/fvfb0o.jpg)

(http://i62.tinypic.com/111m254.jpg)

Back to the sill....

(http://i59.tinypic.com/egydd4.jpg)

What a pain rhis has been to get right. Managed to chop a section out a breaker further along the sill. Made things a bit easier.

(http://i58.tinypic.com/2dgugw0.jpg)

Then i relised part of the floor section wasn't great as moisture had got in.

(http://i62.tinypic.com/2lcvd36.jpg)

Once i'd cut that out I ended up cutting the whole lip off the bottom and welded a new section to the inner sill and then mated both panels to that.

(http://i58.tinypic.com/244a6us.jpg)

Then the rest was all fabricated and welded up so to get the correct shape where it meets the ottom of the wing. Bit more smoothing off. Some etch primer, seam sealer, stonechip and paint and hopefully it'll look good. It's amazing to think that such a little hole ended up with this much work.

(http://i62.tinypic.com/96kyuv.jpg)

Picked up some cheap second hand coillies.

(http://i59.tinypic.com/2nh2e4x.jpg)

I could probably be quoted more than once saying i wouldn't go down the cheap coillie route again but my current front ones are properly past their best and making some nasty noises.

Also got one of these from Trimsport for the rear panel.

(http://i61.tinypic.com/2w2ig7l.jpg)

Still need to refit the interior and a few other wee jobs but hopefully get it mot'd and back on the road next week.
Title: Re: 1991 Tornado Red Corrado G60 Daily / Project
Post by: Andy-H on 31 August 2014, 16:06
That looks like you've had an epic task with the sill but at least you know it's all sorted  :smiley:

Windscreen looks great back in  :cool:
Title: Re: 1991 Tornado Red Corrado G60 Daily / Project
Post by: Seanl on 31 August 2014, 18:20
I hope the bodyshop don't have this bother with mine!  I've got 10p sized holes on the leading edge of both sides, and they're doing them along with a few other bits of rust.  I reckon there's far more than people realise that are like this though.  It's not visible with it being under the wing, until it's completely rotted through and too late.  Top job there though dude, wish I had this welding and fabrication skills!  :wink:
Title: Re: 1991 Tornado Red Corrado G60 Daily / Project
Post by: VW BUSH on 31 August 2014, 18:28
A 50p holes always seems to be 6 inches of rust on a VW :grin:
Good skills there.
Title: Re: 1991 Tornado Red Corrado G60 Daily / Project
Post by: Gti_Jamo on 02 September 2014, 20:06
Cheers guys.

Definately a corrado problem especially those with crushed sills. Having been in there and looking at the structural design of that area I struggle to see where the strength for jacking comes from. The inner sill bows outwards oppose to straight up vertical. Mine had been pushed up considerably.
Title: Re: 1991 Tornado Red Corrado G60 Daily / Project
Post by: Gti_Jamo on 04 September 2014, 21:16
Got it all built back up today and managed to get it in for a late mot. Passed with only a brake hose and the tyres as advisories.

(http://i60.tinypic.com/6se4gg.jpg)

(http://i57.tinypic.com/25t7wb9.jpg)

(http://i57.tinypic.com/345kgsm.jpg)

Need to sort out the ride height, maybe get some other wheels and also get tracking done.



Title: Re: 1991 Tornado Red Corrado G60 Daily / Project
Post by: Diamond Hell on 14 September 2014, 20:11
I honestly don't know how you drive anywhere with it that height - mine grounds out regularly on the splitter at standard height!
Title: Re: 1991 Tornado Red Corrado G60 Daily / Project
Post by: Gti_Jamo on 16 September 2014, 10:49
The pictures are quite deceiving with where it's parked, it's not that low at all. Still a good 2 inches of clearance from the front splitter. I can't put it too low or i'll never get it in and out the garage.
Title: Re: 1991 Tornado Red Corrado G60 Daily / Project
Post by: Gti_Jamo on 20 November 2014, 20:27
Not much of an update. Needing four tyres for the rz's but the're badly needing a refurb and I thnk one rim is beyond repair so decided instead to try and find a bargain and picked up these 16" Advanti SG40's with nearly new Dunlops quite cheap.

(http://i59.tinypic.com/2q8zwp4.jpg)

Not to sure about how they'll look until I get them on but need bolts and spigot rings first.

(http://i61.tinypic.com/24vvfrd.jpg)

As for the Corrado itself that's 8500 miles now since the rallye engine went in and it hasn't skipped a beat. Yeah it's using a wee bit of oil and the lambda's still disconnected but still works as it should and have great confidence in it. Rigged up a temporary boost gauge and only making 0.6 bar so not too great for a stage 2 but not bad either. As for recent work i've just replaced the o/s window regulator. Paintworks not standing up too great with spreading laquer peel but will get done at some point. Still heading in the right direction.

My oldman has took on this so garage space is limited for a while until we've finished replacing rot with metal.  :undecided:

(http://i59.tinypic.com/vyv0bk.jpg)
Title: Re: 1991 Tornado Red Corrado G60 Daily / Project
Post by: Gti_Jamo on 05 April 2015, 17:33
Hey guys,

Been a wee while since I updated. Not much going on with the G60. Limited funds so can't get the stuff done I want to do.

Recent work was to get rid of the front mounted intercooler, i've nothing against them but it's too wide and the pipework fitted together poorly so off  it came.

(http://i57.tinypic.com/2uf6eyu.jpg)

(http://i58.tinypic.com/29x6i6o.jpg)

Picked up a standard side mount and pipework along with a BBM RSR outlet so I could ditch the silencer box.

(http://i58.tinypic.com/5efx48.jpg)

(http://i60.tinypic.com/2a8hksw.jpg)

All solid now and no boost leaks.

When I was under the front end something caught my eye, it looked like my subframe was cracked just behind the front wishbone mounting. Gave it a wee poke with a screw driver and a big chunk of body filler fell out leaving a gaping rotten hole.

(http://i61.tinypic.com/14w7n69.jpg)

Same thing on the other side.

(http://i62.tinypic.com/r768og.jpg)

This sort of bull***t annoys the heck out of me. What kind of person does that at such a load bearing location? A botch by the previos owner no doubt. I've drove 10,000 miles in this since I bought it too, didn't even get picked up during the mot last year. Whoever done it certainly spent some time hiding it.

So on the hunt for a subframe now. Will probably fit new wishbones too as the're not looking to clever either.

Cowboys eh!!

P.S. - I've no idea why one of my previous car pics is now changed to a leather jacket. It's no mine.
Title: Re: 1991 Tornado Red Corrado G60 Daily / Project
Post by: VW BUSH on 05 April 2015, 18:25
That's a fine wee jacket you have there, don't lie its yours we have seen all you Scott's wearing them in Taggart :grin:

That filler is bodge central, a lot of stripping to weld in a new frame maybe do both sides......
good luck :smiley:
Title: Re: 1991 Tornado Red Corrado G60 Daily / Project
Post by: Gti_Jamo on 05 April 2015, 18:56
That's a fine wee jacket you have there, don't lie its yours we have seen all you Scott's wearing them in Taggart :grin:

That filler is bodge central, a lot of stripping to weld in a new frame maybe do both sides......
good luck :smiley:

''There's been a murder, call the fashion police''  :grin:. The Taggart episode 'Gingerbread' filmed in some woods near my village many years ago.

I use tinypic so hope it's just a temporary glitch. Either that or tomorrow it'll be choc-a-block with them and all the text will be in chinese.

Yeah i'll sort it out. Was considering a new one but they're not cheap and the chances of finding one decent second hand will likely be grim. I'll get it off and strip it down and see how bad it is.
Title: Re: 1991 Tornado Red Corrado G60 Daily / Project
Post by: VW BUSH on 05 April 2015, 20:56
That was one of the last of the proper Taggart's
Title: Re: 1991 Tornado Red Corrado G60 Daily / Project
Post by: Gti_Jamo on 06 April 2015, 10:20
That was one of the last of the proper Taggart's

Yeah, i didn't watch it much after then. Just reverted to Murder She Wrote.
Title: Re: 1991 Tornado Red Corrado G60 Daily / Project
Post by: VW BUSH on 06 April 2015, 12:03
That was one of the last of the proper Taggart's

Yeah, i didn't watch it much after then. Just reverted to Murder She Wrote.
lol that program makes me want kill :grin:
is the corrado sub frame mk2 or mk3 based or completely bespoke?
Never paid any attention under a corrado but it would be a suprise if VW did not lift some of it from there parts bin.....
Title: Re: 1991 Tornado Red Corrado G60 Daily / Project
Post by: Gti_Jamo on 06 April 2015, 20:45
The G60 / 16v corrados share the same subframe, mk2 golf would fit but they don't have the wee legs that extend back from the rear wishbone mounts like the corrados and mk3's do. Although unsure on mk3 subframes fitting though.
Title: Re: 1991 Tornado Red Corrado G60 Daily / Project
Post by: VW BUSH on 06 April 2015, 21:39
The G60 / 16v corrados share the same subframe, mk2 golf would fit but they don't have the wee legs that extend back from the rear wishbone mounts like the corrados and mk3's do. Although unsure on mk3 subframes fitting though.
Maybe you could cut and shut a Mk2/3 subframe together, reckon you could buy the Mk3 one new if you looked around.
Interested to to see how this resolves itself in your artisan workshop :wink:
Title: Re: 1991 Tornado Red Corrado G60 Daily / Project
Post by: della_mk3 on 06 April 2015, 23:04
captives on the wishbone bolts broke?
Title: Re: 1991 Tornado Red Corrado G60 Daily / Project
Post by: Gti_Jamo on 07 April 2015, 10:29
The G60 / 16v corrados share the same subframe, mk2 golf would fit but they don't have the wee legs that extend back from the rear wishbone mounts like the corrados and mk3's do. Although unsure on mk3 subframes fitting though.
Maybe you could cut and shut a Mk2/3 subframe together, reckon you could buy the Mk3 one new if you looked around.
Interested to to see how this resolves itself in your artisan workshop :wink:

There is a G60 one on ebay that I was hovering over last night but couldn't bring myself to buy it yet as I might just weld mine.

captives on the wishbone bolts broke?

Yeah they don't appear to be captive anymore so it's could well be it's been cut into and not stitched back up. That usually done from undeneath them where access is better.