GolfGTIforum.co.uk
General => General discussion => Non-Golf gallery => Topic started by: Ferdinor on 06 April 2013, 22:47
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Ok so i have been meaning to make a thread about this for a while now so here goes....
I bought the car at the beginning of December it looked a bit like this
(http://i97.photobucket.com/albums/l224/ferdinor/corrado%201%208t/aqybu7e7.jpg)
(http://i97.photobucket.com/albums/l224/ferdinor/corrado%201%208t/y7ypyjam.jpg)
(http://i97.photobucket.com/albums/l224/ferdinor/corrado%201%208t/y2ymazud.jpg)
(http://i97.photobucket.com/albums/l224/ferdinor/corrado%201%208t/y6uqe5um.jpg)
It wasn't perfect had a few dents, some rust and had been resprayed (badly)
It had a running 1.8 16v which i soon removed after buying the car dont have any photos of this.
so i decided smoothing the bay was a good starting point ill let the photos do the talking
Mocking up the plate
(http://i97.photobucket.com/albums/l224/ferdinor/corrado%201%208t/IMG_0331.jpg)
Plate all welded in
(http://i97.photobucket.com/albums/l224/ferdinor/corrado%201%208t/IMG_0333.jpg)
Starting smoothing the bay of both sides
(http://i97.photobucket.com/albums/l224/ferdinor/corrado%201%208t/IMG_0359.jpg)
(http://i97.photobucket.com/albums/l224/ferdinor/corrado%201%208t/IMG_0362.jpg)
(http://i97.photobucket.com/albums/l224/ferdinor/corrado%201%208t/IMG_0354.jpg)
soon started to remove the un needed brackets
(http://i97.photobucket.com/albums/l224/ferdinor/corrado%201%208t/IMG_0361.jpg)
it is not much further on than that as i wanted to get the lump in to make sure i had covered all areas and sort a few things out so in the new engine goes
(http://i97.photobucket.com/albums/l224/ferdinor/corrado%201%208t/IMG_0438.jpg)
(http://i97.photobucket.com/albums/l224/ferdinor/corrado%201%208t/IMG_0439.jpg)
Also as you can see from this photos the wheels and suspension have been removed
(http://i97.photobucket.com/albums/l224/ferdinor/corrado%201%208t/IMG_0435.jpg)
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Apart from engine side of things i have been doing some body work started on the door looks like people liked opening there door on to this side of the car
(http://i97.photobucket.com/albums/l224/ferdinor/corrado%201%208t/IMG_0432.jpg)
first layer of filler went on
(http://i97.photobucket.com/albums/l224/ferdinor/corrado%201%208t/IMG_0440.jpg)
(http://i97.photobucket.com/albums/l224/ferdinor/corrado%201%208t/IMG_0441.jpg)
It seems really hard to get it all smooth so i have left it like this for now
today i started to fit and mount the intercooler and also run the boost pipes there wasnt a lot of room to fit the intercooler but worked out the best place and started grinding, tried to do it without removing anything structural main two points are show here
(http://i97.photobucket.com/albums/l224/ferdinor/corrado%201%208t/IMG_0455.jpg)
(http://i97.photobucket.com/albums/l224/ferdinor/corrado%201%208t/IMG_0454.jpg)
Not finished as i want to tidy up and weld a bit of support onto the second cut but it now fits
(http://i97.photobucket.com/albums/l224/ferdinor/corrado%201%208t/IMG_0450.jpg)
As for running boost pipes i have mocked this up but i want to make a few changes but as for now it looks a bit like this
First i used the original pipe and cut to make it work
(http://i97.photobucket.com/albums/l224/ferdinor/corrado%201%208t/IMG_0446.jpg)
Used a reducer of the turbo
(http://i97.photobucket.com/albums/l224/ferdinor/corrado%201%208t/IMG_0444.jpg)
(http://i97.photobucket.com/albums/l224/ferdinor/corrado%201%208t/IMG_0448.jpg)
Sits a lot higher than id like but as i said i may change this next time
(http://i97.photobucket.com/albums/l224/ferdinor/corrado%201%208t/IMG_0449.jpg)
mocked up like this for now
(http://i97.photobucket.com/albums/l224/ferdinor/corrado%201%208t/IMG_0456.jpg)
(http://i97.photobucket.com/albums/l224/ferdinor/corrado%201%208t/IMG_0459.jpg)
Just need to order some bends to mock up the other side
(http://i97.photobucket.com/albums/l224/ferdinor/corrado%201%208t/IMG_0461.jpg)
I did want it to show a little through the bumper but this is the best i could get it for now with this intercooler you can just see the bottom of it (not a very good photo)
(http://i97.photobucket.com/albums/l224/ferdinor/corrado%201%208t/IMG_0462.jpg)
Thats about as far as i have got so far, im going to take more photos of the stuff i do along the way and will update after
cheers
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For a moment I was excited by the thread title.
Then I clicked on it and you're welding sheet steel over the top of the chassis legs :huh:
Isn't that just creating moisture traps so it's going to rot out underneath?
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Will you be able to get a bonnet on with the boost pipe sitting that high?
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Not trying to keep all comments negative, but as I said in your thread on the Corrado Forum, why didn't you paint up the rest of the bay to cover the original colour when you took the KR out? You went to the effort of welding in metal and painting that................... :undecided:
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For a moment I was excited by the thread title.
Then I clicked on it and you're welding sheet steel over the top of the chassis legs :huh:
Isn't that just creating moisture traps so it's going to rot out underneath?
I see what your are saying but in between the two photos i sprayed etch primer on the underside of the sheet welded in and also the whole of the chassis leg (didn't get a photo) i also plan to use wax oil to spray in the gap i have left to help give it a bit more protection i think it should be ok i researched a lot of build threads and have seen a lot of people do this with little or no problems :smiley:
Will you be able to get a bonnet on with the boost pipe sitting that high?
Yes the bonnet closes completely without hitting the boost pipes but i am about to show some things i did this morning that have given a bit more clearance :wink:
Not trying to keep all comments negative, but as I said in your thread on the Corrado Forum, why didn't you paint up the rest of the bay to cover the original colour when you took the KR out? You went to the effort of welding in metal and painting that................... :undecided:
I have seen your post on the corrado forum and will reply to let everyone know in there aswell, like i said in the first post the bay is not finished yet the engine went in to sort a few things and check i have smoothed as much as i wanted and the black paint was just sprayed on the parts that were bare metal to protect them as thats all i had down my unit at the time :wink:
Update coming soon :cool:
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ok so i have done a little more to this today was not happy with the way i had layed my boost pipes so decided i would change them, i need to buy 3 bends and some clips to finish it but it should look something like this now :D
(http://i97.photobucket.com/albums/l224/ferdinor/corrado%201%208t/IMG_0465.jpg)
(http://i97.photobucket.com/albums/l224/ferdinor/corrado%201%208t/IMG_0466.jpg)
Its a little tight to the starter motor but nothing is clamped up yet
(http://i97.photobucket.com/albums/l224/ferdinor/corrado%201%208t/IMG_0467.jpg)
(http://i97.photobucket.com/albums/l224/ferdinor/corrado%201%208t/IMG_0468.jpg)
(http://i97.photobucket.com/albums/l224/ferdinor/corrado%201%208t/IMG_0470.jpg)
As shown in the photos the boost pipes are a lot closer to the engine and now run in a straight line so i am a lot happier i know there is two bends at the bottom but i dont think it will restrict air flow to much?
Still got plenty more to do and will update again soon :)
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with engine movement, I think your gonna end up with a big crack in that pipe sooner rather than later.......
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with engine movement, I think your gonna end up with a big crack in that pipe sooner rather than later.......
Once again as said if you read the posts its not in its finale position as the 90 degree bend is in the post not with me so its all going to move as im using the starter motor to hold it in its rough position........ :rolleyes:
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Good luck chasing down boost leaks as well I count 9 or 10 joins from the ic to turbo :lipsrsealed:
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Good luck chasing down boost leaks as well I count 9 or 10 joins from the ic to turbo :lipsrsealed:
Well how would you or anyone else get from there to my intercooler using less joins? :huh:
yes i could weld a solid pipe before anyone says anything..... but any other options?
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change that pipe off the turbo, its too high for this application , what mounts u using ? iv used same oem pipe in a mk2, used a mk3 subframe. also used it in a mk1 and that was not high like yours :undecided:
also, smoothed bays always crack.. :sick:
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Good luck chasing down boost leaks as well I count 9 or 10 joins from the ic to turbo :lipsrsealed:
Well how would you or anyone else get from there to my intercooler using less joins? :huh:
yes i could weld a solid pipe before anyone says anything..... but any other options?
Like this:
(http://i1218.photobucket.com/albums/dd408/prawn16/df2ad49a.jpg)
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change that pipe off the turbo, its too high for this application , what mounts u using ? iv used same oem pipe in a mk2, used a mk3 subframe. also used it in a mk1 and that was not high like yours :undecided:
also, smoothed bays always crack.. :sick:
I used the pipe of the original because thats all i have and being a budget project all i can afford atm, i will mount it using the original mount to help support it, if it doesnt work i can always change it
Good luck chasing down boost leaks as well I count 9 or 10 joins from the ic to turbo :lipsrsealed:
Well how would you or anyone else get from there to my intercooler using less joins? :huh:
yes i could weld a solid pipe before anyone says anything..... but any other options?
Like this:
(http://i1218.photobucket.com/albums/dd408/prawn16/df2ad49a.jpg)
I would love to have the money to go out and buy the perfect forge pipes but atm i dont so i guess i will stick to my boost leaks :wink:
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The only forge pipe there is the one that goes into the TB, the rest are from here: http://myworld.ebay.co.uk/mrsilicone (http://myworld.ebay.co.uk/mrsilicone)
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The only forge pipe there is the one that goes into the TB, the rest are from here: http://myworld.ebay.co.uk/mrsilicone (http://myworld.ebay.co.uk/mrsilicone)
Thanks for the link i had already seen there pipes when i was having a browse earlier, i will have to see if i can make the run a bit smoother :smiley:
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Looking good mate i personally like the smoothed bay look
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Looking good mate i personally like the smoothed bay look
Cheers, i have always liked smoothed bays and always wanted to do it, if it cracks then i will have to work out a way around it but for now im happy with it :smiley:
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The problem is with our roads its unlikely to last forever but if there are flexible joins then you should be fine.. Keep us posted
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This is how we do them using the very same metal OEM pipe from the Turbo
much cleaner look than the faffy looking bay Dom posted up
done this on a mk2 and a mk1 too where they have had KO3 and KO3S turbos
(http://imageshack.us/a/img526/4583/img4356ev.jpg)
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The problem is with our roads its unlikely to last forever but if there are flexible joins then you should be fine.. Keep us posted
Yeah i guess but time will tell aha should be doing some more this week so will post after that :smiley:
This is how we do them using the very same metal OEM pipe from the Turbo
much cleaner look than the faffy looking bay Dom posted up
done this on a mk2 and a mk1 too where they have had KO3 and KO3S turbos
(http://imageshack.us/a/img526/4583/img4356ev.jpg)
I like that set up, have you got any photos of how you did the pipe straight after the turbo where mine goes up but yours must go a different direction? if you see what i mean? :huh:
Also you might be able to help me with this, when the bonnet is closed it is pretty much touching the throttle body was wondering what front mount i should use to solve this issue or would it be a back mount? its all very similar to a mk3 golf but just doesn't seem to sit the same? im using standard corrado 1.8 16v mounts all round currently?
cheers
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I have pictures but i dont realy want to show all my tricks public, i may send you a picture when i get a moment (not at home aright now) :smiley:
when we installed a AGU into a MK2, we used a MK3 subframe (MK2 is the most similar to corrado this is why i mention the MK2)
With the Mk3 subframe, we had no clearance issues but on the mk1 we did, and to overcome this we had to remove a tiny bit of the strengthener thats on the bonnet
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Well if you could that would be good :smiley:
Ok so trying a mk3 subframe might be a solution? Does it have to be a 16v or can it be any mk3? i did notice when i was down my unit last that i have two front mounts that are different one fits straight on the other could fit with a small slot and it looks like it would lower the front end? ill try and get some photos to show this better :smiley:
Cheers
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Just been looking at your pipework again, the first red 90 degree bend that comes out of the IC...why not turn that so it points upwards? That way you'll be able to get a better angle on the black pipe that it joins to it.
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Just been looking at your pipework again, the first red 90 degree bend that comes out of the IC...why not turn that so it points upwards? That way you'll be able to get a better angle on the black pipe that it joins to it.
I do see what your saying but i had it similar to what your saying when it was like this
(http://i97.photobucket.com/albums/l224/ferdinor/corrado%201%208t/IMG_0459.jpg)
but i didnt like it when you looked in the bay as it was on its own in the middle on the piss (shown here)
(http://i97.photobucket.com/albums/l224/ferdinor/corrado%201%208t/IMG_0457.jpg)
So having it how it is now it mae it look a lot better in my opinion?
(http://i97.photobucket.com/albums/l224/ferdinor/corrado%201%208t/IMG_0468.jpg)
Cheers
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I know your on the Corrado forum, but not sure if you've seen this so might be worth having a read mate.
http://the-corrado.net/showthread.php?36117-The-Forced-Induction-20V-Thread
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I know your on the Corrado forum, but not sure if you've seen this so might be worth having a read mate.
http://the-corrado.net/showthread.php?36117-The-Forced-Induction-20V-Thread
Cheers for the link i had a quick read through the first few pages but iv book marked it :wink:
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So friday i got a good few hours on it, looks and feels like going backwards but hopefuly when i have done all i want to do the engine can go in for good so i first popped to local dealer and picked up some brand new flywheel and clutch release plate bolts
(http://i97.photobucket.com/albums/l224/ferdinor/corrado%201%208t/IMG_0478.jpg) (http://s97.photobucket.com/user/ferdinor/media/corrado%201%208t/IMG_0478.jpg.html)
Also got a rear ashtray and a maf sensor from the forum
Im running a standard g60 flywheel with a luk vr6 clutch, i will be lightning the flwheel and upgrading the clutch at a later date.
ok so engine back out with the gearbox removed
(http://i97.photobucket.com/albums/l224/ferdinor/corrado%201%208t/IMG_0480.jpg) (http://s97.photobucket.com/user/ferdinor/media/corrado%201%208t/IMG_0480.jpg.html)
Going to clean and paint the gearbox had a little go at it but still looking pretty dirty
(http://i97.photobucket.com/albums/l224/ferdinor/corrado%201%208t/IMG_0481.jpg) (http://s97.photobucket.com/user/ferdinor/media/corrado%201%208t/IMG_0481.jpg.html)
Ok so where i modified the lower crossmember to fit the intercooler i wanted to put a bit of strength back into it
(http://i97.photobucket.com/albums/l224/ferdinor/corrado%201%208t/IMG_0483.jpg) (http://s97.photobucket.com/user/ferdinor/media/corrado%201%208t/IMG_0483.jpg.html)
i have painted this but it didnt turn out to well so i didnt take a photo
ok so with the engine out i wanted to spray some bits and bobs just going for a matt black finish
(http://i97.photobucket.com/albums/l224/ferdinor/corrado%201%208t/IMG_0486.jpg) (http://s97.photobucket.com/user/ferdinor/media/corrado%201%208t/IMG_0486.jpg.html)
(http://i97.photobucket.com/albums/l224/ferdinor/corrado%201%208t/IMG_0487.jpg) (http://s97.photobucket.com/user/ferdinor/media/corrado%201%208t/IMG_0487.jpg.html)
(http://i97.photobucket.com/albums/l224/ferdinor/corrado%201%208t/IMG_0488-1.jpg) (http://s97.photobucket.com/user/ferdinor/media/corrado%201%208t/IMG_0488-1.jpg.html)
Also did the front pannel pretty happy with how it tuned out
before:
(http://i97.photobucket.com/albums/l224/ferdinor/corrado%201%208t/IMG_0479.jpg) (http://s97.photobucket.com/user/ferdinor/media/corrado%201%208t/IMG_0479.jpg.html)
After:
(http://i97.photobucket.com/albums/l224/ferdinor/corrado%201%208t/IMG_0489.jpg) (http://s97.photobucket.com/user/ferdinor/media/corrado%201%208t/IMG_0489.jpg.html)
(http://i97.photobucket.com/albums/l224/ferdinor/corrado%201%208t/IMG_0490.jpg) (http://s97.photobucket.com/user/ferdinor/media/corrado%201%208t/IMG_0490.jpg.html)
It was still a bit wet thats why it looks a bit shiny, ok so thats it for now i want to do loads more but im away this weekend so will update when i have more
Cheers
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Ok so a big update had the engine out for the last time to do some final little bits, changed the flywheel bolts and clutch pressure release plate bolts to brand new vw parts, sprayed some parts and cleaned the gearbox, also managed to spray the bay and joff came down this morning to get it running so here are some pictures and a short video.
Also modified and painted the lower front cross member for my intercooler to fit
(http://i97.photobucket.com/albums/l224/ferdinor/corrado%201%208t/IMG_0483.jpg) (http://s97.photobucket.com/user/ferdinor/media/corrado%201%208t/IMG_0483.jpg.html)
(http://i97.photobucket.com/albums/l224/ferdinor/corrado%201%208t/IMG_0495.jpg) (http://s97.photobucket.com/user/ferdinor/media/corrado%201%208t/IMG_0495.jpg.html)
(http://i97.photobucket.com/albums/l224/ferdinor/corrado%201%208t/IMG_0494.jpg) (http://s97.photobucket.com/user/ferdinor/media/corrado%201%208t/IMG_0494.jpg.html)
Final work before engine bay was sprayed
(http://i97.photobucket.com/albums/l224/ferdinor/corrado%201%208t/IMG_0497.jpg) (http://s97.photobucket.com/user/ferdinor/media/corrado%201%208t/IMG_0497.jpg.html)
(http://i97.photobucket.com/albums/l224/ferdinor/corrado%201%208t/IMG_0499.jpg) (http://s97.photobucket.com/user/ferdinor/media/corrado%201%208t/IMG_0499.jpg.html)
(http://i97.photobucket.com/albums/l224/ferdinor/corrado%201%208t/IMG_0496.jpg) (http://s97.photobucket.com/user/ferdinor/media/corrado%201%208t/IMG_0496.jpg.html)
The result was something like this
(http://i97.photobucket.com/albums/l224/ferdinor/corrado%201%208t/IMG_0532.jpg) (http://s97.photobucket.com/user/ferdinor/media/corrado%201%208t/IMG_0532.jpg.html)
(http://i97.photobucket.com/albums/l224/ferdinor/corrado%201%208t/IMG_0534.jpg) (http://s97.photobucket.com/user/ferdinor/media/corrado%201%208t/IMG_0534.jpg.html)
(http://i97.photobucket.com/albums/l224/ferdinor/corrado%201%208t/IMG_0535.jpg) (http://s97.photobucket.com/user/ferdinor/media/corrado%201%208t/IMG_0535.jpg.html)
Hand balling the engine into the car as we didnt have a crane at the time
(http://i97.photobucket.com/albums/l224/ferdinor/corrado%201%208t/IMG_0537.jpg) (http://s97.photobucket.com/user/ferdinor/media/corrado%201%208t/IMG_0537.jpg.html)
(http://i97.photobucket.com/albums/l224/ferdinor/corrado%201%208t/IMG_0540.jpg) (http://s97.photobucket.com/user/ferdinor/media/corrado%201%208t/IMG_0540.jpg.html)
All in well sort of
(http://i97.photobucket.com/albums/l224/ferdinor/corrado%201%208t/IMG_0542.jpg) (http://s97.photobucket.com/user/ferdinor/media/corrado%201%208t/IMG_0542.jpg.html)
Last bu not least a video of the car running, isnt very long as there is no water in the engine no boost pipes connected and as you can see/hear no downpipe but you get the idea :lol:
(http://i97.photobucket.com/albums/l224/ferdinor/corrado%201%208t/th_IMG_1227.jpg) (http://i97.photobucket.com/albums/l224/ferdinor/corrado%201%208t/IMG_1227.mp4)
More to come soon :D
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Ok not a massive update but i have managed to plum in the whole water system and fit the radiator in its new home, just need to mount the expansion tank or fit an in line filler.
How the rad sits now nearly the same but just had to drill a few holes
The original mounting points i kept the same
(http://i97.photobucket.com/albums/l224/ferdinor/corrado%201%208t/IMG_0508.jpg) (http://s97.photobucket.com/user/ferdinor/media/corrado%201%208t/IMG_0508.jpg.html)
(http://i97.photobucket.com/albums/l224/ferdinor/corrado%201%208t/IMG_0512.jpg) (http://s97.photobucket.com/user/ferdinor/media/corrado%201%208t/IMG_0512.jpg.html)
Then drilled a new hole at the bottom where i have moved the rad over to allow for my intercooler pipe work notch
(http://i97.photobucket.com/albums/l224/ferdinor/corrado%201%208t/IMG_0511.jpg) (http://s97.photobucket.com/user/ferdinor/media/corrado%201%208t/IMG_0511.jpg.html)
Just need to make some sort of fixing for here
(http://i97.photobucket.com/albums/l224/ferdinor/corrado%201%208t/IMG_0509.jpg) (http://s97.photobucket.com/user/ferdinor/media/corrado%201%208t/IMG_0509.jpg.html)
Then the top pipe was made up
(http://i97.photobucket.com/albums/l224/ferdinor/corrado%201%208t/IMG_0505.jpg) (http://s97.photobucket.com/user/ferdinor/media/corrado%201%208t/IMG_0505.jpg.html)
As said before i have done all the pipe work now but dont need pictures for it all
I will be doing loads over the weekend i will update when i have more :)