corrado 20v turbo, finally finished

[20vturbo 0]

after finishing my first project a 1994 golf mk3 i have decided to move on to bigger and better things. i recently purchased a 1990 vw corrado 1.8 16v. over the next 2 years or so i have the following mods planed.

 

1.8 20v turbo conversion

garret gt28 turbo upgrade

bmw 535 inter-cooler

remove door bump strips

qpeng diy engine management kit

porsche boxster 3.2s calipers

recaro front seats

custom carbon fiber interior trim

kw varient 3 coil-over suspension

17" bbs rc's

strip and re under seal the under neath

body shell re-sprayed inside and outside in bmw csl grey

i have probably forgot a hundred other upgrades but thats all i can think of for now

all work will be done by myself including the engine conversion, re-spray, drive-train, and custom carbon fiber parts.

all ideas and advice are very welcome.

 

the old lump

 

 

time for some surgery

 

 

quick power wash

 

 

the new lump 1.8 20v turbo agu from a 2001 golf gti with 76,000 on the clock

 

 

test fit

 

Edited June 22, 2012 by 20vturbo

[20vturbo 0]

inter-cooler from a BMW 535

should be big enough

dimensions 700mm long, 130mm high, 110mm thick

 

 

 

 

dash taken out. mk4 shifter installed not an easy job

 

 

 

qpeng diy kit with 2 stage boost control

have to say qpeng are great, brilliant service and very quick postage.

 

 

got the engine wired up and it started first turn of the key.

[20vturbo 0]

brand new genuine porsche boxster 3.2s calipers soon to be finding a home on project raddo.

 

 

 

[20vturbo 0]

i spent the last 6 or 7 evenings making a rotisserary (spelling)

 

 

 

 

 

dont worry the g clamp isn't permanent

spent a few hours yesterday and got the underneath striped down and gave it a quick clean

 

 

 

[20vturbo 0]

half way through takeing the under seal off i decided to do some rust repair before i go any further. the less time the floor pan is exposed the better.

i have one of the things for jigging the car taken off so far. it was starting to rust under neath so i had to take it off.

 

 

 

next i takled the rust in the sill where it had hit a kerb or somthing and was left to rust

 

 

 

 

[20vturbo 0]

then i took the mount for the fule tank filler neck off to do some repair. the side i have done on the left looked the same as the right when i started.

 

 

 

these arrived a few days ago. replacing all bushes with powerflex. not cheap but there worth it.

 

 

still cutting and repairing rust. i had to cut be bottom of the wheel arch off. inner and outer skin.

 

 

[20vturbo 0]

the back of the arch wasnt looking to healthy either so some more angle grinder action.

 

 

 

repair half done

 

 

got the repair on the back of the arch done

 

 

then i cut off and rewelded the lip on the inside of the arch. its kinda hard to see in the pic.

 

[20vturbo 0]

next i started to deal with the rust on the back of the car.

 

 

 

 

 

 

what i cut out. i think i can see some metal in there. no just rust :lol:

 

[20vturbo 0]

took the rocker cover off to have a look a the cam shafts and followers. every thing looks like its just after coming out of the factory :D

 

 

 

while i had the rocker cover off i decided to throw it in the sandblasting cabinet. i am not going to leave it like this but was sick of it being filthy.

 

 

put it back on to keep the valve train nice a cosy.

 

 

next for the sandblaster. the intake manifold. ill use this one for now but maybe down the road ill put a fancy one on

 

[20vturbo 0]

finnaly got a chance to do some work. i hate being so busy

 

all welded up with some isopon on top

 

 

then some filler

 

 

bye bye rust, one corner done

 

 

and the other

 

 

bottom of the arch done

 

 

lip gone

 

 

dont think it kept the water out

 

 

problem fixed

 

 

some rust converter/primer on the fuel tank bracket to keep it rust free after sand blasting

 

 

 

bracket tacked in place

 

 

bracket welded on and seam sealer on to keep the water out of the joint

 

 

hands now in tatters. i think they need a vacation but theres no chance of that happening :lol:

[20vturbo 0]

put rust converter/primer on all the spot welds. i have noticed this is where all the rust starts. right in the middle of the spot weld. then i cleaned the arch and primed it with acid 8. then i masked it up and put on the seam sealer. looks pretty good if i do say so myself :D

 

 

 

you can see holes in the bottom right were i took off the fuel tank filler neck bracket. i have it repaired and just need to weld it back on.

 

 

got the rest of the under-seal taken off. horrid horrid job

 

 

 

then i sprayed on some rust converter just to make sure it dosent start rusting again.

 

i haven't primed the front chassis legs because the werent perfect and i dont want to rush it so 1 liter and 3 coats of acid 8 got put on. so happy its in primer :D

 

 

[20vturbo 0]

i have the front inner arches nearly finished

 

 

 

i only meant to give the bay a sand down and prime it but before i knew it the whole thing was back to bear metal.

only had one patch to do under the battery, its a common place for rust, battery acid likes to eat metal :(

 

 

 

 

[20vturbo 0]

got the engine bay finished.

before

 

 

and after

 

 

 

 

 

finally got some underseal on, ill let the pictures speak for themselfs

 

 

 

 

[20vturbo 0]

got the rear axle and front sub frame blasted. then i primed it with jenoseal and top coated it with special high gloss paint. before i painted the front sub frame i seam welded the whole thing.

 

 

 

 

 

 

 

 

got the powerflex bushing in the rear axle and put it on the car. i sand blasted and powder coated the mounts.

 

 

 

i sand blasted, seam welded and powder coated the front wish bones. then i fitted the powerflex bushings.

 

 

 

 

[20vturbo 0]

i striped the steering rack and then sand blasted it. after that i primed it and sprayed it black.

 

 

 

 

 

 

the track rod arms got the same treatment.

 

 

i powder coated the pipes and then put it back together.

 

 

 

 

[20vturbo 0]

havent got much done lately due to christmas but i finnaly got it off the frame.

 

took a few pics before it came off the frame

 

 

 

 

got the engine up on the stand and took the sump off to have a look

 

 

[20vturbo 0]

got most of the interior stripped out

 

 

got the sound deadening striped off the passenger foot well. just have to clean it up with some thinners.

 

 

some more parts arrived today :grin:

 

3" intake

 

 

2.5" outlet

 

 

oil return flange

 

 

sump flange

 

 

oval to round 3" stainless pipe for the exhaust

 

 

bonnet lifter

 

[easypops 8]

Quality work there mate.....great pics too :notworthy: :D

[R1chy99 0]

If I wore a hat I'd take it off to you :notworthy: I'd LOVE to have that kind of ability. Looking forward to the finished article.

 

Rich

[C488ADO 0]

WOW!

 

not afraid of getting stuck in are ya!!!

 

widh i had that sort of time /patience and knowledge.........

 

what colour is it going??

[dukest 0]

amazing, want to do mine next?! :grin:

[nmahi 0]

awesome pics, write up and build, cam wait to see more........shame ur not keeping it sliver.

[junkie 0]

Blimey im shocked.

 

I like the comment " i just made a rotiserrie " :D

[Danny B 0]

Jesus christ you're a superstar.....quality work, wish I had the knowledge, ability, desire, effort and garage :lol:

[VAG-hag 0]

What a build thread!! Fantasticos 8) 8) :clap: