20v corrado

[DANG60 0]

Hey all. Been on here a few years and never put a thread on my old G60 Ill put a few pics up of that and my current 20v project. Im just copying and pasting the thread from another forum. I do apologise about the sizes of some of the pics.

 

Hers a couple of my old one.

 

 

 

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and the new one, well not so new

 

 

 

 

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Decided i wasnt really happy with the car. Enjoyed the summer out of it and decided to make some improvements.

Got some cheap brembos to overhaul but think im gonna get some new ones now but worth it just to check they fit under the wheels. They do just :clap:

This was her before any work commenced

Next up wasnt really happy with the qpeng ecu that was on it so sourced a new DTA ecu from badger five and got it running in a fashion lol

engine coming out

 

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Then i bought some bits from integrated engineering in the states

it mostly consits of forged rods supertech valves and valve train, calico bearings and a few other bits for the engine build

 

I sourced a large port head and took it to a machine shop have new guides fitted valve seats cut and check the head was flat etc.

Got it back and fitted all my valves and new springs etc

 

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Also set about swapping over the conrods

[DANG60 0]

Took the rotating assembly to be balanced and also the block to be honed etc

Had the crank pulley dowelled to the crank

 

Bores of the block have been honed

 

Had the full rotating assembly of the engine balanced which includes crank, rods, pistons, flywheel, pressure plate.

Also had new rings gapped to the bores and then fitted to the pistons. If you can remeber the brown staining on them from the pic before and this is what they look like now. pretty much like new.

 

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part of the new clutch which was also balanced

 

and a few more of some bits i have aquired since the last update

KW V3s

New engine mounts

New suspension bushes

also new anti rollbars

 

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at the moment ive just been stripping the engine bay so that i can grind back some bits of rust and have it painted then hopefully i can built up the subframe with new bushes ect and bolt them back in ready for the engine. Also gonna try and tidy up the wiring as its a mess, its a cobination of messy vw wiring and un needed wiring from the engine conversion.

 

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So as of about 5 weeks ago the car has been in a unit. I started to strip the underseal off in the usual places where there are known to be problem areas. i.e under the front wings, inside rear arches etc.

I was happy that it wouldnt go any further and i would just treat the problem areas and job done.

 

So the car basically went from this:

to this:

 

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then to this:

 

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what have i done? lol. I decided, well i was pursuaded to put it on the spit and take all the underneath back to metal a) to make sure it was all ok and b) i would be able to paint it and put all my own protection on it.

 

Two friends loaned me the spit and we set about getting it on, I say we but in reality i just watched and cringed as my car was lifted about like a rag doll and my two friends just got on and got the job done.

Sorry i know its rather alot to digest in one go, future updates will be a bit more gradual lol.

[Trickygti 0]

Great project you've got there. Those conrods look a lot more capable than the stock items, what sort of power will you be looking at when its finished?

[dragon green 5]

Wow !

Did you find any rust on the underside ?

Very impressive work

[DANG60 0]

Cheers tricky, yeah the new rods are a bit more up to the job I hope. When its finished im hoping it will be somewhere between 350 - 400 bhp.

 

I havent finished removing all the underseal yet dragon green. But so far ive found a few small patches of surface rust under places where the underseal seemed to be still intact. I would say though for a 16 year old car there isnt much at all and i just hope thats the case for the full underside. There were a few bits that needed welding right at the front of the sill but i belive thats a common place for them to go.

Edited December 4, 2011 by DANG60

[daves16v 1]

You own my 1st Rado, nice to see it again and being cared for.

[CazzaVR 0]

Wow, that's one hell of an overhaul! Superb work. Pretty terrifying seeing your mota in that state I should imagine! It's gonna be amazing when it's all back together. What 1.8T engine is it?

[DANG60 0]

Cheers guys. I can't tell you how many times I've questioned myself as to wether I'm doing the right thing. Hopefully once all the hard work is done it should just be a matter of keeping on top of it.

The engine is an Aum code from a 2002 golf gti.

Tbh I wish I hadn't sold the last one so that's why this one gone this far as it was the next step I would have taken with the old one.

Dave do you have any old pictures of it?

[daves16v 1]

Dan, yes I do, PM me your email address and I'll send em over.

[Wild-Animal 0]

Keep the pictures coming : ) its good to see such the attention to detail

[Portent 0]

Very nice indeed. I love the wheels :)

[DANG60 0]

Thanks chaps, hoping to have the majority of the underseal off by the end of the week.

Portent- thanks mate the wheels are just lensos so nothing special really

[DANG60 0]

Well here's a couple of boring updates hopefully a couple of exciting ones will be along shortly.

So the car had all its underseal stripped off and all the rot was welded up. There wasn't a great deal tbh. Good job as I've never welded a car before.

Then on parts of the car where there were small amounts of surface rust I used por15 metal ready and then por15 paint over the top. This is supposed to convert rust and protect it. However I soon found once the full car was painted that in places I could peel the paint off in sheets. This was no good, the metal ready is supposed to convert the rust and etch the surface to mak sure there is a good adhesion of the paint.

So the car started to look like this

Unfortunately I then spent the next two weeks stripping all the paint back off.

 

I got my new Bosch 044 fuel pump and surge tank from Ie engineering.

Pic of the surge tank. It's gonna go in the same place as the original inline 16v fuel pump.

 

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Where metal ready was applied to the rust, once the paint had been removed it was obvious that the por15 wasn't that Good as under the paint the treated parts remained rusty.

Somebody recommended some deox gel by bilt hammer so I gave it a try.

The below part is the front of the sill underneath. The picture shows what it was like after the area had been cleaned up and treated with the bilt hammer stuff.

Then acid etch primer was painted over the parts that the rust had been treated like so.

I have nearly treated all the rust. I just applied some deox gel to the area and then wrapped it in cling film so that it didn't dry out.

 

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It's pretty much at the stage where it needs painting. I bought all my paint last week so that's this weeks/weekends job.

I'm going to spray acid etch primer on the rest of the underneath followed by normal primer followed by stone chip - think this is going to be painted on smooth then followed by the colour Which is very very close to this colour.

 

The last bit for now is I've separated my pistons and rods. Rods are getting sent back to integrated engineering to be rifle drilled. School boy error as I never realised they came like that from the factory and thought if they were supposed to be like that then it wouldn't be an option when buying rods.

I was assured that it only matters if doing loads of miles but it was bugging me so thought I'd get them done whils in bits.

 

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Few pictures from today's antics. Etch primed then primed. Seam sealer hopefully tomorrow.

 

Starting to feel like its getting somewhere now.

 

Hopefully get my subframes powder coated and rebus he'd in the next few weeks then need to start working out my brake and fuel lines.

[aide 0]

wow. really impressive work, probably a bit late now, but a solution called vactan does a good job of converting rust that cannot be removed. keep the pics coming.