Gareth

cool thanx henny :compress:

Thanx every1 and thanx dinkus for the thought.... anyway i sorced and purchased 2 calipers and the flexy hoses. i'll let u all know when i get them fitted. it would be nice if i had new guide pins as im not sure what condition mine are in but ive been informed that i would have 2 buy new carriers as they come with the pins. apart from making sure i use copper slip on the back of pads and also on the new studs i bought, any tips for durring fitting (like is there a torque for the banjo stud?) or just VT or maybe VFT? anyway any comments welcome :)

ive used the search and almost worked out what parts i need but i phoned GSF today and they can supply the calipers but the people i spoke 2 had no idea what flex hose is required. and the calipers are on an exchange and because i havent got a set of Mk4 calipers to send back i wont get the surcharge back thus pushing upto around £85 each, On UCP website is a genuine caliper 4 around that price. prices before VAT. (this is just the piston housings alone) i also looked on C&R's site but there site says Mk3 Caliper kits. so are the flexy's custom made? or from another car? ive read that they are custom made but i just wanted to check. i'd like 2 fit genuine calipers, if i can buy the flexy's on there own! where can i buy the the flexy hoses? and 1 more thing :? can i use the Mk4 carrier or must i use the corrado carrier's :) all help is gratefully recived :)

thats the 1 i have seen with the RS4, debadged grill. i'll keep an eye open 4 ya :)

hi chris , i did see that u were from boro but i'd already posted.... boro has a few C's kickin around i think ive seen yours but it was parked up on the 2 times i seen a red C maybe see u around some time

hi chris an ECU is a electronics device that the Chip is installed into... im not sure about the remap im sure some1 else will anser that Q 4 u.

its been over a month now since ive been on the forum due to my Pc not working and its very l8 but i would like to say a big thanx to G-Werks for all the work carried out on my car durring the weekend of the 2nd of dec 2004. i'm extreamly pleased :D with all work done and all the info Darren and Steve.....(I think steve is his name..Sorry) told me, i know its a bit l8 but ive just managed 2 borrow a laptop 4 a short while and im gonna use it to my full protential... at least till i have 2 give it back. anyway the real reason 4 my post is to say a big Thank You to G-Werks and i would recomend them to any1. "Thanx Darren and Steve" 8)

thanx for the info Beavis... ive done a little more searching and found some nice info about rod ratio and at the moment with the info i have, i will be changing the rods trying to keep as close as original rod ratio as possible :).... its not set in stone but at the moment think its best

Again thanx 4 all your help :) can any1 shed any light about "Rod Ratio" looking at a site offering engine internals it mentions using longer con rods for better "rod ratio" Any interesting web pages to look at explaning rod ratio? is there a calculation/formula i could use?? any help welcome

PM sent

the instructions i got are not very clear and dont even have the large disc or the plastic parts in the diagram :) thanx 4 all your help thou. but why do some of u think that the poly bump stops are not as good as the standard 1ns?. i'd like to get it rite first time so i dont have 2 remove the shocks again so all opinions welcome. no i dont have the dust covers (Gators) but i want some so will the standard 1ns fit over the shaft and shock body??

Yay i recived the Koni kit i orded but i have a question in one of the pics i have drawn a arrow pointing to some white plastic things (they have a slight concave to them on 1 side that runs full circumfrance) but i dont know what or where they a suppozed 2 do or go. Help plz Im guessing that they have somthing 2 do with the top mounts but i dont really know.

The book im reading on the subject has this formula for displacement: Pi/4 x bore^2 x stroke x 4. i'm going to give figures here so that there is no confusion this is my working out: first, Pi divided by 4 = 0.7853982 second, the book refers to bore but is talking bout cylinder diameter thus: mm converted to cm, 8.3cm^2 = 68.89 third, is stroke and im for now gonna use 92.8mm and convert that to cm = 9.28 forth, the amount of cylinders = 4 hense: 0.7853982 x 68.89 x 9.28 x 4 = 2008.41776376576 so 2008cc If i use the standard g60 bore and stroke then: 0.7853982 x 8.1^2 x 8.64 x 4 = 1780.87596717312 so 1781cc rite lets go back to 83mm but lets use the standard stroke 86.4mm: 0.7853982 x 8.3^2 x 8.64 x 4 = 1869.90619385088 so 1870cc so with the thinking that the 1H block is basically the same as the PG block lets use the maximum cylinder dimension that the bentley manual (described as 2nd oversize) recomends for the PG block, i'm asuming that this is actualy VW's own spec's i'll also use the 92.8mm stroke 0.7853982 x 8.151^2 x 9.28 x 4 = 1936.955554241520384 so 1937cc If everything ive said is wrong then i might just give up because i really felt sure i had it right but if i am wrong then i feel im not up 2 this engine conversion. anyway my thinking on the pistons is they are special ones because valve clearence and compression ratio need to be taken into account. i will speak to john but i really wanted to have as much info as i could then i can have sensible conversation with him and also not ask stupid Q's Formulas for displacment, stroke & bore: cylinder volume = Pi/4 x (bore^2) x stroke displacement = Pi/4 x (bore^2) x stroke x number of cylinders stroke = displacement / (Pi/4 x (bore^2) x number of cylinders) bore = square root of displacement / (Pi/4 x (bore^2) x number of cylinders)

ok so ive done some more re-search and would like to ask henny?? what was the reason for useing the 1H block?? was it purely because your PG block was no good (damaged) or that the 1H block can be bored more than the PG block??..... the reason i ask is if u have a 1940cc engine useing a 83mm bore then my figures just dont add up and im confused. because im trying 2 get basically the same bottom end as you then i need 2 find the right size crank and pistons. Formula for cc: Pi / 4 x (bore^2) x stroke x the amount of bores (4 in this case). Key: Pi = (pie), 3.1415927 so: 3.1415927 / 4 = 0.7853982 0.7853982 x (bore^2) x stroke x 4 = by the way i know that the bore and stroke are measured in mm but for the calculation it must be converted to cm. the closest i can get to 1940cc is 1937cc (rounded up) but thats not useing a 83mm bore. now as u can see i havent mentioned the size of bore and stroke that i used in my calculation to get 1937cc as im not wanting to get anyones back up..... but maybe if we could chat on the phone or summit then i'll give u the figures im using. i have tryed many diffrent bore and stroke combinations even useing the original stroke and as i said the closest i get is 1937cc i hope that i have not affended any1, as that is not my aim. i just want to build a reliable engine and need to know everything b4 i commit to buying anything :)

red corrado, not sure wot engine i just caught a look at the modded front end .... anyway in Teeside Retail Park........ Was It U?? :)

beavis thanx for that superb infomation, :) :) :nuts: My name in jonny five ....i need more input :nuts: seriously thanx to everyone for helping :)

thanx for that, german ebay is out of the question now i know that :)

ok thanx for all your help and advice its helped me sooo much.... i respect that John has put lots of time into researching the componants needed and at the end of the day if my only option is 2 buy the bottom end compleate then i probley will do that. i guess that my fear is i run out of money b4 its complete :cry: and im not even sure if sourceing the parts induvidually would save me money, i guess i just assumed that to be the case. anyway i know i must get prices and then work out what i can n cant do. Thanx to every1 again the research continues 8)

beavis im looking for a daily driver with 100% reliability. Henny ive taken everything that u said onboard and yes i will chat 2 as many ppl offering or owning engine conversions. also thank u for the stroke/bore info and i'll be careful not to over do stroke. ive heard that the transporter block can do the job but is not suited to forced induction so if its the same as u mentioned then i agree with u. ok so i know what block, i'd be guessing but might know what crank as ive read another 83mm bore conversion useing another VW crank but as the pistons are custom then i dont know about them. i dont really want 2 use forged pistons as i read that there is more cold tolerance as they expand more with heat thus using more oil and (plz put me straight if i'm wrong about this) IMO would reduce the life of the bores, but cast ones might not be suited to the type of torque that will be produced so i guess i need to look into this. thanx for telling me to keep aside money for the mapping of the chip as i did not think that it might cost that much:) yes my gearbox would go to stealth and prob get the longer 2nd too, with the power output of this type of conversion IMO the quaife is a must but my budgit will have its say. Brakes and suspension are also a must IMO so im with u all the way with that 1. but with regards to suspension and the possible weight increase the engine might have, would i require a different setup?? or is it ok to use koni TA with H&R springs for a 91 G60??, this might sound like a daft Q but IMHO its better to look stupid than to get it wrong. i didnt post the size of the crank im thinking of as i dont wanna upset any1 because as u said, and quote "at the end of the day, that's their little secret and research which they're making the money on". but is it possible for me to PM u the size of the crank im thinking of and car its from and you to tell me if im right or wrong. i don't expect this from u henny but i had to ask. thanx to everyone for your time.

thank u again g-man

thanx g-man ... what sort of damage to look for?? ive seen some pic's of cracked chargers but is there anything else to look out for??

i'm looking into doing a 2.0L 8v G60 engine conversion for my G60 and would like sum advice about what block, pistons, rods and crank to use?? i like the sound of a longer stroke as this is soppozed to give better torque what sort of compression ratio would i expect or look for?? keep original 8.0:1?? keep my ECU or get another?? im also thinking bout porting and polish the head and getting the inlet man and outlet man port matched. i read that my original exhuast man is a good one, but can i get better from another VW??. intrested in 4-2-1 type exhaust. also inlet man.. is there a better one from another vw?? a cam will be on the hope i can afford it list. b4 i had the funds for such a conversion i was going to get a mild cam from schrick, but now.. hehe :) so should i still use that sort of schrick cam?? the gearbox will get sorted too and maybe a 6th gear but i know where to get that done. one of my main concerns is will all the internal componants handle the torque that will be produced from this type of conversion. i want to take my time and re-search this properly b4 i start buying anything but im looking forward to it. but unfortunately my budgit will have its own say with regards to the finished product. ive seen engines for sale from proformance parts suppliers/specialists and could probley just buy one but thats not the route i want to take. ive looked at what Henny has done to his car and that really interests me but henny is far cleverer than me and knows what crank and pistons to use. i think henny's motor has been very well researched and exicuted, so how can i ignore henny's brilliance? i can't and must concider the same path, i take my hat off and bow down to you henny :lol: . but as i said before im without the Knowledge. anyway any advice and infomation welcome.... and thanx for reading

i'm looking 2 buy a G charger and was woundering whats the normal sorta asking/selling price of a charger.... ofcourse it depends on condition but lets say 1 thats had no porting done but has had regular services and is in working order. i just dont wanna get ripped of and pay thru the nose 4 summit thats a bag of S..t and also i dont wanna miis out on a bargin if i c 1. Plz help

sweet thanx guys :)

Excellent :) :) thanx for that info woody ..... your a star thank you too Henny :)