GrahamU's 2.0 TFSI with DSG

[GrahamU 5]

Todays main job was to fit the moonroof

 

First job, colour the sliding cover black to match the rest of the interior

 

I was going to recover it but it didnt easily want to come out of the frame so I got sprayed

 

 

Managed to get it fitted reasonably well but I did need a washer between the frame and the roof as it was sitting to high

 

 

 

 

Moved onto the climate control problem, started by cutting 2 perfectly good dash centres, one early and one late, which turned out to be a mistake

 

 

After cutting I trial fitted and realised the difference in the dashes to allow for the larger heater control is taken up the height of the vents

 

 

 

So the moral of the story is check everything properly, the measure twice and cut once

 

I have now wasted 2 good dash parts which seem to be worth a fair bit on ebay :(

 

 

I now need a new plan of attack for this

[GrahamU 5]

Oh yeah, and I got a copy of the pic from the photographer

 

[GrahamU 5]

Took a little trip to Hertfordshire at the weekend where I part ex'd some black doors and tailgate for my red doors and tailgate (thanks veedub-Dave) so that will make it easier to spray, the insides are good so just a blow over for them.

 

Tailgate is now sprayed,

 

Stripped it all yesterday, welded the wiper hole and went over with a scim of filler then sprayed it today

 

Edited April 12, 2016 by rado20vT

[Cressa 44]

Good luck with it all. The roof is a good read and would be a great fix solution for all our fragile units

 

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[Vrt 10]

Wow just went thru your thread. Great work. I wish I had body shop skills

[GrahamU 5]

Been quite some time since I last updated this, mainly because I have been away for about half the year last year and till now this year, so not much has happened since my last update.

 

But today I ventured out into the garage to see what I could do.

 

Started by flatting the tailgate, I still need to do the rest of the car but I need to move it first :(

 

Flatted it with 1500 then 3000 and 6000 and got a good finish from that, need to polish it now

 

 

Then moved onto one of the doors, stripped it first and then rubbed it back ready to be sprayed

 

 

So with summer coming I'm due a load of holiday so I'm getting back in the mood for working on the old girl

[GrahamU 5]

Out of the 4 day weekend I managed to get some time in the garage on Monday afternoon so I turned to the wiring for the central locking unit.

 

The original idea, about a year ago, was to sleeve the wires in some good quality thinwall DR heatshrink and put on new crimp terminals. Unfortunately, after a year of sitting around, I spent 2hrs looking for the connector, I then gave up trying to find that one and spent another 30 minutes finding another connector from an old harness.

 

Still, its done now and has nice new shiney terminal on it :)

 

As most of my afternoon was wasted I thought I'd finish of with removing the rubber guide bits from the spoiler so I could stick them in the dishwasher to try and clean. The screw were not tight as It was removed before to spray it and I knew it had to come of again but as I unscrewed the right side I heard a clunk as I removed the screw and found the plastic area around the nut inserts had broke off.

 

Tonight I superglued the plastic back together and then reinforced them with high strength DP490 glue

 

 

 

 

I dont think it liked being neglected for a year :(

[Spuddy 10]

Nice to see a glimmer of Progress graham! (hi on here btw)

I had the same issue with spoiler mounts, but luckily mine cracked slightly and just lost the insert so managed to get a nut and washer inside the boot to sort it.

Mine has liked sitting in bits for 2 months let alone a year!

 

Hope you have more luck next time you set upon it!

 

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[GrahamU 5]

Hope you have more luck next time you set upon it!

 

Cheers Spud

 

 

More time to work on it today, this getting to be a habit :)

 

Got the new crimp terminals on the left side tailgate harness

 

 

So got the carpets in the boot

 

 

 

The spoiler is back in, checked to make sure it works and all wired up. I also put in the electric tailgate release back in

 

 

 

I also started putting the windows back in

 

 

Hoping the wife is in a good mood tomorrow so I can get out there again :)

[Spuddy 10]

Cheers Spud

 

 

More time to work on it today, this getting to be a habit :)

 

Got the new crimp terminals on the left side tailgate harness

 

 

So got the carpets in the boot

 

 

 

The spoiler is back in, checked to make sure it works and all wired up. I also put in the electric tailgate release back in

 

 

 

I also started putting the windows back in

 

 

Hoping the wife is in a good mood tomorrow so I can get out there again :)

Did you get the rear windows bonded in yourself?

 

Hateful to get out, that's why I paid someone else for a change haha

 

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[GrahamU 5]

Did you get the rear windows bonded in yourself?

 

Hateful to get out, that's why I paid someone else for a change haha

 

 

Yes mate, removed them myself now putting back myself, hopefully no leaks :)

[GrahamU 5]

I want to update the rear brakes so I made a start after seeing this on vortex.

 

http://forums.vwvortex.com/showthread.php?5407910-mk4-rear-brakes-on-mk3-No-drilling-and-welding

 

I looked at getting the complete rear brake setup from a Polo or lupo but thought there must be a slightly cheaper way to do it that will allow more people to do it.

 

I started with this rear drum from a 1.4 polo for £20 of ebay

 

 

stripped it down

 

 

Will use the stub axle and the hub/bearing carrier although I may modify the backplate aswell as it is just bigger than the disk

 

 

Next bit I need to decide how I want to do it, the stub axle, being from a drum brake has no way to fix the caliper, but I will machine down the old Corrado stub bolt it in place to fit the caliper, I think I need to get some carriers from a mk4 golf or make a spacer to fit the Corrado carriers fit.

 

I'll update this after I get the part machined

[Bauhaus 3]

That's an interesting way to do this, I did something similar but used Lupo stub axle back-plates, MK5 polo 6N2 stub axles and 4 stud hubs, MK4 golf anniversary caliper carriers and Seat Leon Cupra R calipers which clamps on to 256mm discs,but I recon your way will be more cost effective.

 

Are you running 5 or 4 stud wheels ?

[GrahamU 5]

That's an interesting way to do this, I did something similar but used Lupo stub axle back-plates, MK5 polo 6N2 stub axles and 4 stud hubs, MK4 golf anniversary caliper carriers and Seat Leon Cupra R calipers which clamps on to 256mm discs,but I recon your way will be more cost effective.

 

Are you running 5 or 4 stud wheels ?

 

The lupo and polo parts dont seem to come up often and when they do the sellers seem to ask a premium price so I'm hoping this will work and gives another option

 

I'm running 4 stud and the hub I have is 4 stud, the disk is a spare I had in the garage which is 5 stud, I can either re-drill or buy some polo disks or maybe I'll go overkill and fit some 256 vented to go with the 305mm fronts :)

[Bauhaus 3]

The lupo and polo parts dont seem to come up often and when they do the sellers seem to ask a premium price so I'm hoping this will work and gives another option

 

I'm running 4 stud and the hub I have is 4 stud, the disk is a spare I had in the garage which is 5 stud, I can either re-drill or buy some polo disks or maybe I'll go overkill and fit some 256 vented to go with the 305mm fronts :)

 

256 rear vented is what I'm running, I used 16v front discs for this and they fit and work perfect, I will have to start build thread and post the pics.

[GrahamU 5]

256 rear vented is what I'm running, I used 16v front discs for this and they fit and work perfect, I will have to start build thread and post the pics.

 

I like your style :)

 

Get that build up

[GrahamU 5]

At the moment I am putting my Golf R in the garage overnight which means the corrado is against the racking and its a pain to get to anything along that side so today was another little sideline project to allow me to move the car

 

 

 

 

Only got enough to do the rear wheels but that makes things alot easier

 

I then spent way to long trying to work out what was wrong with my rear seat belts because they would not pull out when I took them out of the box only to find that if you bolt them in place they magically work perfectly :)

[Spuddy 10]

You know you can buy those wheel trolleys for like 50 quid for a set of 4.. 😉

 

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[odub 0]

Shouldn't you be working on the car instead of making skids?

[Spuddy 10]

Shouldn't you be working on the car instead of making skids?

Any excuse not to do it eh 😉

 

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[GrahamU 5]

You know you can buy those wheel trolleys for like 50 quid for a set of 4.. ��

 

 

I thought they were 50 and pair, But why spend 50 quid when I can make them with bits lying around the garage for free :)

[mic_VR 3]

Too right mate. Look really good, and useful as hell I bet.

[GrahamU 5]

Decided to kinda follow Bauhaus's idea of the 256 rear disks but rather than buy another set of rear calipers from a TT or CupraR I wanted to keep the mk4 calipers I have already.

 

A little surfing of the net and I found that some of the mk3 golfs had 256 solid disks on the front and they are 4 stud, winner :) and the motor factor across from my work (Exhaust unlimited) gave me some discount so they were £25 the pair.

 

 

 

I took the corrado stub axles to a local engineering company to have the stub removed and leave the back plate but they told me it would be better for me to remove the stub with a saw or grinder as that is what they would do and I would be paying them to do it, so I'll cut it of and take it back to be machined flat although it looks like I'll get a new plate made for the larger disks

[Pat. 10]

Looking great! How has the paint come up? I am debating on cellulose or 2k paint when I get to mine, has your paint hardened well? My father sprayed his 1930's ford with 2k and it seems quite soft, scratches easily?

 

The brake idea is good, what's stopped you going 5 stud out of interest? (For the greater array of oem/aftermarket brake upgrades etc)

[Bauhaus 3]

rado20vT Glad you found it useful mate, also if using solid discs the Polo 6N2 (I used 9N) stub axles have cast in lugs to mount your caliper carriers to, not tried it myself but considered it before going with vented discs. The link below shows what I mean, it all lines up but may need tweaking to accommodate a larger disk.

http://img.photobucket.com/albums/v624/bluecorrado/20170430_024523.jpg