boost monkey

Could well be at the factory matey, I think most of us have sections of our C's reminiscent of Firday Afternoon Cars :( Also, do you think you could resize your pictures when you upload, maybe 800x600? I'm worried I might havr to book holiday to trek across those landscapes of pics you're linking to! ;)

Hi Raymond, I'm afraid the new calipers have gone now. I have some rebuilt ones I would be happy to sell at a discount? Handbrake cables still available. Thanks, Jon.

you should try a breaking thread fella. Oh look! someone is breaking a car same year as yours :D *cough cough*

Yeah, this is true. tbh I can't do a fatigue study as I don't know how to set up the prerequisite motion study in SW. Temp should be fine and corrosion can always be dealt with by powdercoating etc. But development is always good! Yeah I didn't load the stem. I guess it would actually be much weaker than the other parts. Just some other pics from messing about with this BJE model (attached) looks like the LBJ and the BJE will have to be secured together before attaching to the hub as there's no clearance for the 6mm allen key with the BJE in place. Doubt it's a big issue for assembly/disassembly really. Also as can be seen there's good clearance for a standard sized 18mm ring spanner (modelled this to answer your question Kip!) with a turning range of approx 110degrees currently (although this may decrease with strengthening webs etc). However, there are some issues with getting the spanner in and over the LBJ pin whilst in position as it may clash with some of the other parts there. Just a thought really - surprised I actually remembered to give that consideration! Of course, this is all based on the fact that the LBJ and hub geometry is accurate to start with so I'm looking forward to confirming this :D

Really?! I thought this was meant to be the top of the line sports coupe! Bah. I bow to your Corrado nerdship :norty: I'm going over to the Plum tomorrow to start stripping the big parts so will check then matey :salute: Hi Raymond, as far as I know the rear calipers are standard across the whole range (perhaps someone could confirm?) - all part numbers seem to be the same on VAGCAT. I'll sort a picture asap. They look as you would expect - still in gold galvanised coating with tags and plastic plugs in the hose holes. Would you like to collect or pay postage?

Will do Dox. Will let you know asap. Cheers.

you're a brave man doing a 16v to VR6 conversion! :salute:

I did dude! I said just up there ^^^ "£10 posted? IIRC it has a rust scab about 2" long on the upper lip where it goes under the spoiler (hope i'm thinking about the right part?) I'll try to get some pics for you." ---------- Post added at 02:39 PM ---------- Previous post was at 02:38 PM ---------- I think all Corrados have electric windows fella! :D And the regs are included with the price of the doors so they're a bit of a bargain really. If g60knight doesn't collect I'll let you know.

Here are the stress plots as promised. Shows a colour scale for the stress concentrations, and yield strength of material underneath. Green arrows are fixed constraints (stop part moving) and purple arrows are location and direction of force applied. Spec as follows: Static test - 5000N (~500kg) applied square to upper face in the downward direction to replicate an increased load due to weight from hub and upright pressing down on BJE. - Max Stress of 170MPa; ~50% of yield stress therefore a FOS (Factor of Safety) of 2. Cornering test - 5250N (~525kg; 1.5g for vehicle corner weight of 350kg) acting outwards/inwards (depending on NS/OS orientation) due to hard cornering. - Max stress of 1010MPa. This is a catastrophic failure of the part due to Max stress ~ 3 times that of material yield stress. FOS = 0.3 Braking test 5250N (~525kg; 1.5g for vehicle corner weight of 350kg) acting forwards/backwards (depending on NS/OS orientation) due to hard acceleration/braking. - Max stress of 115MPa; ~33% of yield stress therefore FOS of 3. Pics attached.

Andy, this is why you should give me the VRT. I'm local so you can pop round anytime :wave: :D

Great stuff fella! Where in Oxon are you? Not seen you about. I'm mainly in Cowley/Littlemore area (not the rough end!) in Oxford itself. the sound of the 4-branch is nice. Adds a real growl I found. You probably won't notice much of an improvement from the exhaust, perhaps 5hp if your old one was shot.

^^^ Agreed. Always liked the Z4 :D much better than the jelly mould '3.

Looks great Jay. Even the trim looks a deep black :D What are your next plans?

Seeing as you're local Andy I'll let you give it to me :lol:

Steve, if you need some cables I'm selling the ones off my early 16V and IIRC they're all the same. Only want £10 for them, but hope you manage to fix the issue whatever it is :salute:

Well the travel would be compromised yeah as you'd have to use a shorter base shock unless you wanted to run a normal length one at -40mm into bump or something. ---------- Post added at 09:06 AM ---------- Previous post was at 09:05 AM ---------- from memory the ball goes in and then the socket is pressed inwards under high pressure to seal the ball joint in, hence why you should bin LBJs that have torn rubbers. I think a circlip would be too risky. ---------- Post added at 09:41 AM ---------- Previous post was at 09:06 AM ---------- No probs :salute: It’s literally just joining the two LBJ points in the model by building a new part inbetween. It’s still quite ugly tbh but I’m working on it. No I hadn’t actually. I was just measuring up from 300-750kg through the top angled face (i.e. the face DIRECTLY under the LBJ mount on the hub) as the hub would be pressing down on this. Obviously the 5deg angle means the forces go off to the side slightly and leave a nice stress concentration on the first corner it finds! Edit @11am: Max strain seems to be 0.4 microstrain min and 1.4 microstrain max. There seems to be one problem corner that always has stress risers on through static, cornering or braking analyses. Cornering/Lateral load of 5250N gives a stress 3x material yield strength (1005MPa stress achieved in a 350MPa material) :( I'll try to get pics up later. That sounds like a good starting point. But what mass value? I actually have a spreadsheet program I made for coursework at Uni somewhere that can calculate lateral loads at each corner of a vehicle (you have to put in track/wheelbase/mass etc etc etc along with corner radius in metres) and it tells you which wheels loses grip or lifts off first. Perhaps this could be adjusted to create accurate lateral loads at the front wheels for a Corrado. It would be another sub-project though. Perhaps just using say 350kg (or 3500N) would be a good starting point for lateral forces. Both outwards for corner accel'n, and front/back for braking. I'll get it mocked up :salute: Additionally, I’m assuming the lateral forces would be “end on” to the wishbone as it will go across the tyre contact at right angles to the wheel, regardless of steering angle? Been about 6months since I did Chassis Engineering module :lol: Yeah an 18mm ring spanner is ~26mm diameter at its widest so I’ve allowed for that in the concept BJE. There is clearance around it for tools :D But as mentioned, there are concerns about how you’d get a 6mm allen into the top. Perhaps a much shortened allen with a 90deg bend that’s only 10mm long or something? I could mock one up in like 5 mins tops. Just a basic sweep with 6mm hex cross-section. Cheers for all the input guys, keep all the thoughts coming. Internet is lame at home so I don’t check the forum that much after hours. Also, my Solidworks at home has expired and it’s £80 for the basic version now I’ve graduated. Better than £2000 for the bells and whistles version I guess…!

bumpage. Everything must go! Happy to take offers :D

IIRC mine was green? small little box. Haven't looked at it for probs 3 years. even the scissors are rusty!

Ditto ^^^ A sleeper is a car that is much faster than it looks. A corrado is a car that is slower than it looks.

Yeah that sounds good. Did we ever discover whether the 3-bolt fixing pattern for the LBJs is the same on the wishbones?

My early one is in the armrest in the rear bench :shrug:

Good point, I'll model that and see what happens. That steel is like 3mm thick minimum on the concept so can handle some abuse ---------- Post added at 01:47 PM ---------- Previous post was at 01:40 PM ---------- No probs. I thought it would be easier to refer back to the last few pages than try to explain it all again! The wings sound interesting. I'll try to mock something up and put up some pics on here. Yeah, I like your idea of a 16v lower BJE and VR upper to fit in the hub. Sounds like a great compromise really and as you say you don't need as much clearance. That would mean that a BJE for a -30mm drop would still be possible (not wishing to sound like "if I can't do it then it can't be done!" :bonk:) It's good to have all these inputs, after all this is your idea! I'm just a tool (:lol:) to help you 6pot lovers along :D :salute: ---------- Post added at 02:10 PM ---------- Previous post was at 01:47 PM ---------- Just a little more info for tool clearance: 18mm spanner (for M12 locknut) is 40mm at widest point of open jaw. Closed end is approx 26mm. So we need to build these in if we want to be able to tighten the BJE into place :D Not really sure how we're gonna sort out 6mm allen key clearance though... answers on a postcard...

Sounds great Jay, look forward to seeing your ideas. AFAIK The adjustment of the shock to hub bolts is purely inboard/outboard (across the vehicle) so it will affect the camber too if you were thinking of playing around there. I’m sure you know that already though. That 60mm concept BJE I threw up last night has been stressed to (equivalent of) 750kg acting downwards and square to the balljoint mount face and it’s only hitting 40% of yield strength (based on a standard automotive steel with 350MPa yield strength) which gives us a factor of safety of 2.5 which is pretty good. I’ll throw up some screenshots if that would help clarify things.

you mean modify/weld the hub so that the bottom LBJ mount point is 30mm lower? Nothing I guess. This is why I've been putting up screenshots of ideas as I'm sure I miss something from time to time!

If the suspension is damp adjustable I think it will have a separate little reservoir for nitrogen(?) gas which will look like a little cylinder on the side of the upright.