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neuon2003

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  2. neuon2003

    And then there was three!

    By neuon2003,

    Have not posted for a long time, mainly due to an extended period overseas. The red VR6 is still in hibernation and the silver VR6 is in bits awaiting a re-spray.
     
    Anyway, back in UK for a while, so I decided to buy a run-around pending completion of the Silver VR6 (getting painted soon) and ended up with a third Corrado, a 1996 8v in Midnight Blue with full leather interior. A dealer demonstrator for 3 months, then the car was owned by a woman (airline cabin crew). She seems to have absolutely loved the car for the last 17 years and maintained it well, including: a £4800 bill (!) four years ago to replace the entire ABS system (pump, ECU, sensors, loom) to cure a fault; another £500 for a Jetex stainless exhaust in March 13; plus a full suspension change 10k miles ago costing £1200. The car has 152k on the clock and is in pretty good condition overall.
     
    The car was presented with a full service and MOT, and a full detail with corrected paintwork. A few dings and paint chips to sort out; a bit of preventative work to do; the odd fastener needed here and there where garage staff have been lazy; driver's bolster to sort out. Overall it is in pretty good condition with a few parking dings on the swage line and a small bump in a rear arch.
     
    Should be a decent run around, hopefully. I enjoyed the drive home, especially getting over 40 mpg.
     
    Here are the photos taken for the agreed insurance valuation:
     
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  3. neuon2003
    Last Thursday was spent changing over the front sub-assembly. As with the rear axle, the aim was to recover the one fitted to the car so it could be refurbished and then refitted, along with all new components, bolts and fastenings. So this work is just an interim position. It was a long day, starting at 10.00 and finishing at just after midnight. Not finishing was not an option as the garage space was needed on Friday morning.
     
    I have been fortunate to have access to a professional garage with pit and all the tools. I have little prior mechanical knowledge so these jobs are proving a whole new experience requiring lots of research. Having a mechanic friend on hand to advise and help with the tricky bits is a massive bonus. My mechanical apprenticeship is progressing well as I am having to learn a lot of new skills.
     
    The task for the day was to remove the existing sub-assembly, wishbones, ARB and hub carriers. Then to fit replacement items complete with new wheel bearings; new control arm bushes; new steering rack bushes; new rear engine and gearbox mounts; new ball joints, drop links and track rod ends. All the useable recovered items, like the bolts and fastenings, will be de-rusted, refurbished and recycled onto the Silver VR6 in time. The replacement assembly and control arms had been previously nylon coated.
     
    The work progressed well considering it looked like nothing had been disturbed since new, apart from a track rod end which was seriously stuck fast (had to remove the rod and use a TIG welder to heat the track rod end to red hot); a front wheel bearing which needed grinding off the driver's side hub; the compressor for the hydraulic press failing. The latter was a complete pain as the whole task needed one set of hubs and front bearings removing and a new set fitting along with one set of wishbone bushes removing and a new set fitting. Doing this by hand was not funny. Because of the temporary nature of the replacement parts, pattern bushes and bearings were used. The genuine VW items will used when the original item is refitted.
     
    The car and engine all supported.
    [ATTACH=CONFIG]47852[/ATTACH][ATTACH=CONFIG]47853[/ATTACH][ATTACH=CONFIG]47854[/ATTACH][ATTACH=CONFIG]47855[/ATTACH]
     
    The existing items to remove. Not in bad condition for 17 years.
    [ATTACH=CONFIG]47856[/ATTACH][ATTACH=CONFIG]47857[/ATTACH][ATTACH=CONFIG]47858[/ATTACH]
     
    Work in progress.
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    The old sub-frame off and preparing the replacement. A bit of impact driver action for the hub ABS screws.
    [ATTACH=CONFIG]47861[/ATTACH][ATTACH=CONFIG]47867[/ATTACH]
     
    Back on with various replaced items. The splash shields, hubs, carriers, discs, brakes etc will be renewed when the original sub-frame is refurbished and put back on.
    [ATTACH=CONFIG]47862[/ATTACH][ATTACH=CONFIG]47863[/ATTACH][ATTACH=CONFIG]47864[/ATTACH][ATTACH=CONFIG]47865[/ATTACH]
     
    All finished at 00.15 - see the clock!
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    And, the following morning, the final activity was a professional digital 4 wheel alignment.
    [ATTACH=CONFIG]47868[/ATTACH] [ATTACH=CONFIG]47869[/ATTACH]
     
    With all the work that has been done the car drives unbelievably well. Once the suspension and top mounts are replaced, it should be back to being as close to the factory settings as is possible.
  4. neuon2003

    Rear axle refurb

    By neuon2003,

    Right, on with the refurbished rear axle with new discs, bearings and bushes. This is a temporary measure while I refurbish the axle that was on the car which is not as corroded and will look as new when coated. Then it can all be refitted and the initial one used for the Silver VR. Double the work, but the car needed to be mobile for the MOT and due to storage demands.
     
    Given it looked as though nothing had been undone in 17 years, all went well except for: stripping the head off a sub axle bolt; trying to get the brake bias valve off; needing to replace some of the brake lines (all will be done in any case). Given the car's age, the original items are in pretty good shape, as expected.
     
    Ready to go
    [ATTACH=CONFIG]47791[/ATTACH]
     
    Looking good under here, just needing a bit of clean
    [ATTACH=CONFIG]47792[/ATTACH]
     
    Stripping off the old
    [ATTACH=CONFIG]47793[/ATTACH]
     
    Apart from dirt, little wear after 17 years
    [ATTACH=CONFIG]47794[/ATTACH]
     
    And it's off
    [ATTACH=CONFIG]47795[/ATTACH]
     
    As expected, needed to replace some brake pipe hard lines and needed new ABS sensors. For the brake lines, used Cunifer (copper nickel alloy) rather than copper or steel. It is stronger than copper, doesn't work harden, easier to work with than steel. Not as tough as steel but will not corrode like steel, especially from the inside. And you don't need to weaken it by scraping off external rust. These should last a lifetime. Also fitted some newly refurbished tank straps while I was at it.
     
    [ATTACH=CONFIG]47799[/ATTACH][ATTACH=CONFIG]47796[/ATTACH][ATTACH=CONFIG]47797[/ATTACH][ATTACH=CONFIG]47798[/ATTACH]
     
    Fitting the new beam was OK. Had to tap a few holes to clear the nylon coating and do a quick weld on a broken exhaust bracket, to get through the MOT.
     
    [ATTACH=CONFIG]47800[/ATTACH][ATTACH=CONFIG]47801[/ATTACH]
     
    And then it was fitted, re-plumbed to the brake lines and the stub-axles, new discs and brakes refitted. As this is not the finished deal, some of he old bolts and parts were re-used. All new ones will be put on when the original axle is re-fitted.
     
    [ATTACH=CONFIG]47802[/ATTACH][ATTACH=CONFIG]47803[/ATTACH][ATTACH=CONFIG]47804[/ATTACH]
     
    As mentioned, had a couple of gorillas on the way. Needed to weld a nut onto a sheared stub-axle bolt so it could be extracted:
     
    [ATTACH=CONFIG]47805[/ATTACH][ATTACH=CONFIG]47806[/ATTACH]
     
    But the main swine was the original brake bias valve. It was completely stuck fast and a welded-on bolt just snapped off. So, welded on a piece of bar which did the trick and cracked the screw. A bit of grinder action to cut off the bar, then some serious adjustables to extract it. You can see that the bolt was galvanically corroded along its length. Not wanting this to happen again, did a bit of research and came across 'Duralec', a lubricant designed to stop galvanic corrosion http://www.intek-uk.com/duralac.htm. So shall be using this on the brake bias valve in the future.
     
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    The 'new' valve in place. This one has been recycled from -Neil-'s white VR when he broke it earlier this. Was relatively new and in good condition. A brand new one awaits the refurbished axle and this one will be for the Silver VR.
     
    [ATTACH=CONFIG]47829[/ATTACH][ATTACH=CONFIG]47830[/ATTACH]
     
    The next day, the car passed its MOT. As the Inspector said: "You don't find many of these as clean as this any more".
     
    Finally, the best tool of them all. A truly serious cordless impact driver which made short work of 17 year old stuck-fast nuts and bolts. If I ever had the money (about £500) I would buy one in a heartbeat.
     
    [ATTACH=CONFIG]47831[/ATTACH]
  7. neuon2003

    Some pictures

    By neuon2003,

    Original post and pictures is here: http://the-corrado.net/showthread.php?55215-And-then-there-were-two.../page2
     
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  9. neuon2003
    The original post with displayed photos is http://the-corrado.net/showthread.php?55215-And-then-there-were-two...

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