Late Black G60

[Harry_G60 10]

Yeah sat and read the lot lol, I'm bagging mine 1st of March with airlift anything you recommend having done before install ? Having the rear beam bushes and lower arms replaced

[Riley 0]

Those are a good shout mate:thumbleft: Also worth looking at your brake lines (Hard and soft) while on with the job, front top mounts/wishbone bushes etc. I can recommend getting hold of as many air ride fittings as you can too, push fits etc...

 

Just back from my unit again, had to come home because of 'lighting' issues and my knee is spazzing out! Anyway, lots more measuring done and some brackets made. These will attach to the lower rear strut mounting point.

 

 

After having made them I found that they had some 'wobble' side to side which meant that the sensors were also moving up/down...No good for accuracy.

 

 

So I've put a fold in them as can be seen in the pic (Only one done in pic). Not ideal, but with limited tools/no welding skills it's the best I can manage in all honesty...

 

 

Will get more pics sorted so you can see exactly what I mean. But basically the ball stud you see will have a threaded bar which will attach to the sensor (Mounted on inner arch). When suspension is up, the sensor is at the bottom of its travel. And of course, when the suspension is down, the sensor is at the top of its travel.

 

 

Neil.

 

 

[Riley 0]

Well...

 

I fitted all the air ride around two years ago I think but never got around to fitting the height sensors as above. In that time the car has been off the road for most of it, probably covered less than 100 miles.

 

Anyway, been up to my unit many times getting on with the job of fitting the height sensors, and using the air ride to check heights etc. I also bought the I-Level in the meantime and hooked that up, all fine.

 

Went up there the other week, and my Touchpad controller is not lighting up at all, and is doing nothing when pressing any buttons. Checked to see if the I-Level was working on my phone and it wouldn't connect...Nothing.

 

After lots of head scratching, checking wires, fuses, power supply with a tester, unplugging things, plugging them back in etc...The I-Level just suddenly connected. But yet my touchpad is still completely dead.

 

Pretty damn disappointed and p|ssed off that I've virtually never even had the chance to properly use the air ride and yet it's died on me (Seems the Accuair ECU has taken a sh|t). Especially as I couldn't really afford to buy the recent i-level...

 

So the cars just been sat there on axle stands since, now rendered undrivable. Just pretending it doesn't exist at the minute, kinda wish it didn't. Could do with my unit disappearing along with all the parts and cars in it. Too much hassle, stress, time and effort.

[rolex 0]

Think positive!! any up dates?

[Riley 0]

After I got a bit of enthusiasm back I emailed Accuair. Initially it was pointed out that the ECU's rarely fail, so best to try a new touchpad and USB lead...

 

I got a quote of near on £90 inc delivery from U.S. And then I left it a while once again...I was struggling to justify spending yet more money on the damn thing, especially as I'd literally just bought the I-Level and already spent around £4K on the whole air ride setup.

 

 

After some thinking time, I decided to order it, and it turned up at the door the other day with the delivery guy demanding.......£32!!!!!! in import tax! Unreal!!!

 

 

Anyway, long story short...The air ride is working again. Pretty p|ssed off that the touchpad died though, it's had literally no use! So I'm now back to square one...Car still off the road with the air ride needing finishing off.

 

 

Pic, new touchpad lit up next to the I-Level.

[Riley 0]

Here is the dead Touchpad controller split open, nothing to really see. It does have a very, very slight smell of burning...

 

 

 

 

[Riley 0]

Onto the sensor mounting. Absolute nightmare trying to work out where to mount them, after lots of messing I eventually came up with this. I've literally only just got these (Rears only) mounted. Excuse the surface rust, the car has sat here on axle stands for like 3 years!

 

 

I drilled two holes in the inner wing and inserted Rivnuts then bolted the sensors up. I then decided that my sensor cable needed to run through the inner wing too. It previously ran through the ABS sensor wire holes under the rear bench seat and along the rear beam. So another small hole drilled and a perfectly sized grommet inserted. I did have to split/resolder the looms but it was worth it.

 

 

 

 

 

 

 

 

So that's the two rear height sensors mounted. I got everything tightened up, ran some up/down tests without wheels then I finally got my wheels back on the rear and the car sat down on the floor after 3 years!

 

 

I instantly went to try the I-Level, no go!

The wifi just would not connect! after trying for some time I decided to have a tidy up. Tried it again later and all of a sudden it worked. I tested the manual calibration with less than 4 sensors and all went well. I can finally! use a little more of the Accuair features! The ride height on start works, as do the 3 preset heights. During playing about with it, the firmware updated too.

 

 

Now to mount the front sensors!

[Riley 0]

Today it actually moved for the first time in 3 years! I wouldn't normally take pics when it's so filthy, it's absolutely thick with dust but what the hell...

 

 

 

 

 

 

[Riley 0]

Finally got around to fitting the front height sensors for the air ride. Real pig of a job! A LOT of measuring, moving, tweaking, measuring, moving, tweaking!

 

Found it really hard to get a good position for the sensors without fouling any of:

Wheels, brake pipes, ABS wiring, Strut bracket for ABS wire, driveshafts etc.

 

And then trying to actually get the full sweep of the sensor without over extending it...Nightmare of a job.

 

 

This is mounted with tape...checking sensor travel.

 

 

 

 

[Riley 0]

After mounting things with sticky tape, and triple checking everything...I made up some brackets to mount the ball stud for the sensors to the wishbone.

 

 

[Riley 0]

Some pics...Again, absolutely filthy and moved for only the second time in 3 years!. But finally the whole Accuair E-Level with I-Level WIFI is complete!

 

 

 

 

 

 

 

 

 

 

[Riley 0]

And here's a quick/shaky video...I'd literally just finished fitting everything up here, had been up there a good few hours with nothing to eat. So I knew I felt shaky lol. I was just determined to get it finished!

 

 

[Tigerfish 10]

That's cool. Didn't realise the air shocks moved that quickly

[rolex 0]

You gotta be happy with that mate, looks awesome.....I understand your pain! mine hasn't moved in 3 years and ive only (just) worked on her for 3 days!! I may start a build thread, that'll make you feel better!

[Riley 0]

'99 Pages and the Corrado still ain't gone':bonk:

 

Ha, I'm just very 'Meh' about it now, have been for a while tbh. Too busy with 'Life stuff' to have any time for it sadly.

 

Just another random pic...I started throwing a site together just for the Corrado too but I'm struggling to get it fully up to date.

 

[Riley 0]

Oh hi page 100:cheers:

Well, the road tax is due on the daily IS200...So I may look at getting the Corrado on the road and tax that for 6 months instead. Lot of hassle swapping insurance over though etc, so dunno if I can be bothered tbh! Hard work with the kids to run about as well.

 

 

Hmmm.

 

Still been fired up now and again...Can't believe it's been sat in my unit for four years!:shrug:

[video=youtube_share;QlrWEhBKCYA]

Edited June 30, 2016 by Riley

[Riley 0]

Thought I'd replace the window regulator rollers and make up some new water barriers for the doors while I'm at it.

 

 

Bought some new foam surrounds for the inner door handles, can see the new window rollers here too.

 

 

Cleaned the door up and replaced the window rollers first.

 

 

I bought some plastic sheet. (Forgot a pic) I think the 'spec' was something like 250mu / 1000g.

Cut it out roughly to shape.

 

 

And bought some 'Auto Mastic' on a roll, which seems to be awesome stuff! Very similar to the original Vw stuff.

 

 

Went ahead and applied it along with the plastic sheet.

 

 

 

 

Obviously made flaps etc for the wiring and whatnot.

[Riley 0]

Then I wanted to take it a step further and thought about some form of sound proofing, to get a nice solid sound from the door.

So I bought some good quality floor underlay :lol: Gold backed stuff, thought it would give an extra bit of waterproofing, and the thickish foam would add some density for sound.

 

 

 

 

What I wanted to do here, is apply another bead of mastic, just inside the previous bead so that for future removal, I'd only have to remove the plastic sheet and not the flooring underlay. So I ran roughly cut/hung it in place and then ran another bead of mastic.

 

 

 

 

 

 

And this is where I'm up to...Had to leave the unit so didn't have chance to throw the door card back on.

 

 

 

 

[Riley 0]

I've just decided I may refurb the Borbet B. They're alright, but the coloured bits are dark grey rather than black, and the dishes are lacquered (As per factory), but I'd like to go black 'n' polished.

 

Oh, and I've got to quickly learn how to weld! :shock:

The front Airlift struts have a well known issue (They all suffer with it) where the body spins and wraps the airline around the strut! Pretty ****ed off to find out about this problem with such expensive kit! Need a little 'L' bracket popping on.

[Riley 0]

Been doing quite a bit of tinkering lately...Just a few random pics before I get to the details.

 

 

 

 

 

 

[Riley 0]

So I gave it the usual service...

New W6DPO Plugs, Oil, Dizzy cap, rotor arm, blue temp sender etc etc. Then came the fuel filter...I've changed it before and I knew the bolt for the clamp was tight back then, so thought I'd buy all new fuel filter bracket bits.

Had a bit of fun sourcing them all from different places. :bonk:

 

Apparently I've bought the last five speed clips WHT002257 from Vw, only needed two but thought I may as well take what they had. I doubled up on every other part anyway...

[Riley 0]

Oh, and as I've replaced the fuel return line (Blue) in the past...Thought I'd replace the fuel feed while I was it it. (Fuel tank to filter).

 

The bits for the fuel filter bracket. :lol: And the fuel feed line.

[Riley 0]

The part numbers for the fuel filter bracket bits, and the fuel feed line:

 

 

• Fuel filter main bracket/retainer - 535 201 505 (535201505)
  
• Fuel filter bracket rubbers - 191 201 274 (191201274)
  
• Fuel filter bracket steel inserts - 191 201 278A (191201278A)
  
• Fuel filter bracket speed clips/nuts - WHT 002 257 (WHT002257)
  
• Fuel filter bracket ring - 251 201 679 (251201679) - Ended up with/got sent wrong one!
  
• Fuel filter bracket threaded plate - 251813599 (251 813 599)
  
• Fuel filter bracket hex bolt - N0 103 484 (N 0103484)
  
• Fuel filter bracket nut - N0 111 849 (N0111849)
  
• Fuel feed line, tank to filter - 535 201 293D (535 201 293D)
  

[Riley 0]

Some of the parts...

 

 

[Riley 0]