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Thread: My Corrado 1.8 20v turbo build

  1. #31
    Newbie
    Join Date
    14th January 2013
    Location
    Rotherham
    Posts
    40
    A bit of an update from the weekend, Tried to start the car today after finaly finishing up the wiring. The fuel pump wirred into life, the throttle body buzzed away and the engine cranked over but would'nt fire. We spent an hour or so problem solving and checking over a few things and then realised that the crankshaft sensor wasn't plugged in. Doh! Tried the car again and it sprung straight into life. to say that I'm happy is an understatement.

    So I then went and refitted the fusebox and put the dash back together.
    corrado86.jpg

    Posty came and left me this Temp sender.
    corrado84.jpg

    Fitted
    corrado85.jpg

  2. #32
    Newbie
    Join Date
    14th January 2013
    Location
    Rotherham
    Posts
    40
    Got this intercooler donated to me from my son's old Polo GTI, it's a bit big but I reckon it will work ok. I do like freebies

    corrado78.jpg

    corrado79.jpg

  3. #33
    Newbie
    Join Date
    14th January 2013
    Location
    Rotherham
    Posts
    40
    I found an 80mm Maf that I had from my old Focus ST, so I took the Ford sensor out of it and tried the VW one in it. I now have a choice of 70mm or 80mm maf.

    corrado87.jpg

  4. #34
    Newbie
    Join Date
    14th January 2013
    Location
    Rotherham
    Posts
    40
    I made a boss for my MAP sensor and got mt mate to weld it into my intercooler.
    corrado92.jpg

    I then gave the intercooler a coat of high temp black paint, it's the only black spray I had to hand at the time

    corrado88.jpg

    corrado89.jpg

    As things were going so well I thought I'd get the front panel back on, which then led me to fitting the headlights and grille.

    corrado93.jpg

    corrado94.jpg

    I think I might need a new grille badge now?

    corrado95.jpg

    It's all coming together now, won't be long before it's back on the road.

  5. #35
    Newbie
    Join Date
    14th January 2013
    Location
    Rotherham
    Posts
    40
    I was going to fit my rear brake hoses today, but as I got under the rear of the car I noticed that the rear beam bushes looked a little tired

    corrado97.jpg

    Now that I had seen this I just had to get the beam off and get those bushes out, not a job I had planned on.
    I used Ed China's trick of suing a bolt through a socket to pull the middle out of the bush, then using a 35mm hole saw I drilled the remaining rubber out.
    corrado98.jpg

    corrado102.jpg

    Then it was just a simple case of using the hacksaw to cut through the outer steel shell and knocking it out with a hammer and chisel.

    Whilst I was removing the beam I disconected the ABS sensor cable from inside the car and pushed it and the gromet though the boot floor, unforunately I also removed a little bit of rot at the same time

    corrado111.jpg

    So I cut a plate and repaired the hole, I'll dill it out for the gromet later and paint it all back up.

    corrado112.jpg

  6. #36
    Newbie
    Join Date
    14th January 2013
    Location
    Rotherham
    Posts
    40
    I removed all of the brake lines from the beam whilst I had it out on the floor, they were pretty much shot.

    corrado101.jpg

    I also noticed that the little plastic wheel that goes inside the spring for the proportioning valve was broken.

    corrado106.jpg

    corrado107.jpg

    So I couldn't really leave that, time to fire up the lathe.

    corrado108.jpg

    So new Floflex bushes on order, less than half the price of the Powerflex ones. and that's about all I can do for now with the beam. I'll give it a clean up and paint before refitting.

  7. #37
    Newbie
    Join Date
    14th January 2013
    Location
    Rotherham
    Posts
    40
    The exhaust flange turned up in the post today so I could get on with making the decat pipe.

    corrado109.jpg

    All done, I made an extended 02 boss, sorry I didn't get pics of making that.

    corrado110.jpg

  8. #38
    Enthusiast
    Join Date
    24th December 2008
    Location
    Colchester, Essex
    Posts
    586
    You're making good progress. I wish I had more space for large tools and to get into some welding

  9. #39
    Newbie
    Join Date
    14th January 2013
    Location
    Rotherham
    Posts
    40
    I have stripped every thing off the rear beam ready to clean it up and repaint
    The brakes look like they've had it and the back plates are pretty much non existant.

    corrado115.jpg

    corrado117.jpg

    corrado118.jpg

    corrado116.jpg

    I went on a little shopping trip to Toolstation and bought these

    corrado113.jpg

    They should rip through the rust in no time, probably the most lethal tool ever inveted by man

    All of the loose flakey rust removed from the beam and ready to paint

    corrado119.jpg

  10. #40
    Newbie
    Join Date
    14th January 2013
    Location
    Rotherham
    Posts
    40
    Rear beam has had 2 coats of red oxide primer and now ready for some gloss black enamel.

    corrado120.jpg

    I decided to strip the calipers and see how bad they actually were, to my suprise they weren't seized so I tackled them with my wire wheel on the grinder to remove the worst of the rust and gave them a lick of silver paint before reassembling them.

    corrado121.jpg

    corrado122.jpg

    corrado123.jpg


    That's all for this week due to being on 12hr days all week. I have bought a roll of copper brake pipe, so I will be remaking all of the brake lines next weekend then I'll move on to making up the intercooler pipe work. This is all going to be done in 2.5" stainless with as little silicone hose conections as possible.

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