My Nugget - USA G60 - more new bits

[Henny 0]

yeah, you don't need the K&N... that's a vent pipe from the fuel tank... there's a handy little hole in the inner wing that you can feed it down into from the bay so that it vents to atmosphere... in over 8 years of running my G60 I never had a problem or any smell of fuel caused by having binned the carbon cannister and having threaded the pipe into that hole... :)

 

There's a thicker pipe that needs to be plugged which, if you blank it with a short pipe, will cause a rather irritating whistle... simply leave a 12" bit of the original pipe attached to it and put a bolt in the end of it with a jubilee clip to seal the pipe onto the bolt. This will stop it from whistling... :)

 

Oh, and if you go to a motor factors and get a diesel blanking plug, this will seal the nipple on the back of the throttle body perfectly and look neat too! ;)

[GlosterOx 0]

fantastic.. car looks great!

 

i've actually got an original LHD double gauge holder somewhere.. Were you thinking of one of these or adding the 3 gauge holder from the audi's?

 

oh really, where the hell did you find that? i spotted them in the original brochure and they look spot on. I have a audi set up which i was thinking of putting in but id rather the 2 pod set up, am considering making a holder myself as well.

 

I am based in Stroud, i usually go along to the E38 meets up at the air balloon and the mk2 golf owners meets so some of you may spot me. Who else is local??

 

dave

 

Me, live in Gloucester but work in Thrupp - Just bought a VR6 and will have a 2.0 16V to sell in the near future. We sometimes meet up @ the air balloon too, so keep a look out on the forum!!

 

Ian.

[kerrly 0]

been doing some more cleaning this evening - beggining to get carried away but feel its worth it.

So, i tackled the rear of the interior and the boot area as the boot was full of a billion leafs and the remains of a last years christmas tree and all sorts.

 

 

after plenty of washing, drying and polishing the results

yes the boot floor really is that much brighter yellow after being polished.

 

and i bit if the overall interior.

 

Really happy with how its looking now, just got to put the knee bar and lower dash trim back on the drivers side after removing them to do the ignition switch - a job i will never learn to enjoy.

 

next task is moving onto cleaning the underside of the car - my goal is a yellow underside covered in clear waxoil to keep it sweeeeeet but that is likely to be a job for october time when the car comes off the road.

 

dave

[kerrly 0]

also thanks to BUSTER-G40 for this pic he took at Polo Show a couple of weeks back

[kerrly 0]

well the scrap yard turned up a little gem today... a set of of 16x7 speedline turinis in pretty dam good condition with 195/45 tyres.

 

Personally i think they are a good modernisation of the sebring style.

 

 

The problem now is they really do highlight the rather high suspension so something will have to be done about this, im also thinking about trying my BBS RZs on it to as my brother has just done this to his mk2!!

 

 

DAVE

[Danny B 0]

This is really cool, some quirky features that set it apart in the UK.

 

Love the seat belts, theres something strangely comical about them :)

 

EDIT : oh also the new wheels freshen it up nicely, good choice IMO

[n3p 3]

Love it, nice seeing the subtle differences! I actually prefer the side indicators, and the seats look pretty good. Much prefer the early interiors for some reason - think they look 'meaner', lates remind me too much of a mk3 I used to drive.

 

Yellow still looks in good nick, too. Will be keeping an eye on this thread :norty:

 

Nick

[kerrly 0]

right, now i have a real problem. At the moment the car has the speedline alloys on, which i like but are not perfect -id like to refurb them. So today whilst massively hung over from having had far too much beers at a local beer fest i decided to start painting...

 

The set of Sebrings i had on the corrado originally are now BWM grey mettalic

 

and a set of BBS RZ 15x7 BMW fitment have also arrived (£23 bargain on ebay) should have them finished painted by thurs/fri but missing a centre gap:cry:

 

so what to wear to edition38 at the weekend

 

DAVE

[psiburr 0]

"cant wait to get rid of carbon canister and all the associated pipes etc that go with it. Should neaten the bay up a bit and allow me to run a cold air feed directly into the bottom of the box."

 

Is this cold air feed something you need to buy or Bodge ?

[kerrly 0]

yo,

the cold air feed is just a rather large diametre section of flexible piping that will go from behind the bumper/inside the inner wing (havent decided yet) and the feed up into the large hole that the carbon canister lives in at the moment - imagine this hole empty

 

and a chunk of

 

Doubt il get a chance to do this before E38 as spending loads of time cleaning at the moment, trying to make the most of the engine bay at the min.

 

DAVE

[kerrly 0]

here it is with it current BBS RZ wheels, they are a shadow chrome so look dark with only have a slight sparkle to them. On Friday the car was treated to a full wash wax an polish as part of my efforts to ensure my paint survives the winter but by the time id taken these pics id covered 350miles. Hopefully tomorrow i can scan in the high res pics i took + the pre respray pictures with the white wing mirrors lol

 

The sun was just starting to set so there were some rather unusual lighting conditions..

[Adski 0]

Really nice!

 

Going back a few Posts, i have just taken the charcoal filter out of my G60 to do a Cold air Feed, :clap:

[kerrly 0]

Really nice!

 

Going back a few Posts, i have just taken the charcoal filter out of my G60 to do a Cold air Feed, :clap:

 

Yo,

 

To be honest no i have not had a chance to remove the charcoal filter yet. Been ironing out little niggles like a split fuel line, a couple of crap vacuum pipes and rattling exhaust heat shields and other exciting things.

 

The car is likely to come off the road end of this month so the major work can begin then.

 

dave

[kerrly 0]

last pic for a while - this is winter mode with 16 inch TSW Venoms on. They were previously on my bros mk2 golf an painted bright red which really didnt work with he yellow :tongue:

 

 

The car is now off the road for some major surgery consisting of refurb'd subframe, brake system and suspension plus a freshly painted slam panel, under the bonnet and new VW badges

[Kempy 0]

still jeolous of your seat belts :)

[kerrly 0]

Hi, not had many updates recently mostly as the car has been off the road. I wasn't 100% happy with the original respray as it didnt include the front slam panel, behind the rear lights and inner doors so i have had those done now. Next plan is to begin giving the engine bay an overhaul especially since the front end is already off an i need to buy a new air conditioning condensor.

 

 

got a new slam panel which has been resprayed and looks a million times better than the original one which wasn't painted during the first respray.

 

new panel "resting" in place to check colour match

 

and then i fell into the trap of whilst im here lets do.......

1) re route the wiring harness through the chassis leg and prepare the inner wings for a repaint

 

now im going to go all out and have the inner wings repaint, the cross member + rad support, subframe, driveshafts powder coated and then start on the engine which will be repainted as per factory colour scheme.

 

hopefully the real progress will start being made one i get the Air Conditioning condensor removed which is being a PITA right now as one of the bolts is so mangled it needs to be chopped out but i only have a few Cms to work in

 

dave

[kerrly 0]

Well it's been a while since i have done any updates mostly because there hasn't been much to report but now there is. After having the car resprayed i was never completely happy with the front end so it's all come apart.

 

got a new slam panel which has been resprayed and looks a million times better than the original one which wasn't painted during the first respray.

new panel "resting" in place to check colour match

 

and then i fell into the trap of whilst im here lets do.......

1) re route the wiring harness through the chassis leg and prepare the inner wings for a repaint

 

now im going to go all out and have the inner wings repaint, the cross member + rad support, subframe, driveshafts powder coated and then start on the engine which will be repainted in silver except the block.

 

hopefully the real progress will start being made one i get the Air Conditioning condensor removed which is being a PITA right now as one of the bolts is so mangled it needs to be chopped out but i only have a few Cms to work in :(

 

dave

 

---------- Post added at 12:53 PM ---------- Previous post was at 12:52 PM ----------

 

Did a bit more work over the weekend. It doesn't look like a massive amount has changed as i've spent a fair bit of time organising the parts i remove into BIN, REFURB and REPLACE and lets just say the shopping list is getting longer - mostly due to me bing a fussy bugger an wanting it spot on.

 

So, last update was preping passenger side chassis leg an reroute wiring, now it's time for the drivers.

before

after

 

Finally managed to get the air conditioning condensor off and radiator in order to drop the cross member tomorrow as its being powder coated.

 

next job tomorrow is to strip all the wiring loom with the plan being,

1) route the headlight loom through the chassis leg and out the front like on other side.

2) route the live/earth cables for the battery halfway through chassis leg so they come out of chassis leg up behind the battery mostly out of view.

3) route the radiator/fan/Air Con looms through chassis out the side near where a PAS bottle would be on a MK2

4) extend starter/alternator wiring so it can be run closer to the block out of view

 

Then when i've had enough of wiring, I want to test fit a 1.5L washer fluid bottle from a Seat and start thinking about a bracket to relocate the air condition control box.

 

Once the wiring is hidden im going to begin prepping the chassis legs for painting work and remove the inlet manifold/rocker cover an everything metal to be polished.

Dave

 

---------- Post added at 12:54 PM ---------- Previous post was at 12:53 PM ----------

 

Well Edition38 proved to be a very worthwhile trip as i finally have myself a genuine USA specification rear number plate holder - after over a year of trying.

 

Here it is with my cars original dealer transit plate from when my uncle bought the car new.

 

All i need now is a custom made USA Pennsylvania style plate but with my UK number plate on it which I can use at show/events

[G60MAT 0]

Looks great, always like the US look, try Plate My Ride for your plates! ;)

 

http://www.platemyride.com/

[Kempy 0]

you know your seatbelts, if all the parts are still available, I checked etka and got all the part number. Would you think a retro fit would be on the cards?

 

cheers kempy

 

I just love those seat belts sorry lol

[mrginge 0]

There are a LOT of parts linked to the electric seat belts so buying it new bit by bit would be a nightmare. To be honest you could be better off asking on VWVortex if someone in the US wants to trade as there seem to be a lot of yanks who want Euro spec

 

dave

[Jim Bowen 1]

"Did a bit more work over the weekend. It doesn't look like a massive amount has changed as i've spent a fair bit of time organising the parts i remove into BIN, REFURB and REPLACE and lets just say the shopping list is getting longer - mostly due to me bing a fussy bugger an wanting it spot on."

 

I'm doing the same sort of thing now, started off doing one thing and can't stop myself moving on to the next bit, thinking to myself "may as well, while i'm here"

 

missing driving it now

[kerrly 0]

The corrado was put on hold for aaaages whilst I waited for a brand new air conditioning condenser and pipework to be made - it all had to come from the USA. So I mocked up the front end with the radiator as well to ensure it all fits.

 

 

I was going to leave it like this and continue putting the front end on. However there is surface rust on the battery tray and a few scabs on the other side as well so for now I am doing some touch ups so that the car should be finished for the mk2 national meet....

 

Yesterday I sanded/prepped/primered the chassis leg areas that had some surface rust , then it began raining :-(

 

So I worked on the underside, no before pics but everyone knows the underside of a 20year old car is black and dirty.... well after many hours with the wire brush, more hours applying sealer and more prep i was able to get the first of several coats of paint on today!!! The plan is, another couple of coats of yellow followed by clear wax oil.

 

 

I also did a few more jobs on the bay,

DItched this horrible plastic box

 

Replaced with custom alloy outlet

 

Now i just need a silicone hose to link the charger and intercooler

 

once that is in place, the chassis legs painted it is time for the freshly painted front end :D

 

The final jobs now are:

1) continue finishing the underside, remove exhaust and paint centre of the car.

2) repaint the back axle - il cheat and paint it on the car this time.

3) replace front suspension struts/springs inc lower arms, anti roll bar bushes, steering rack bushes, track rod ends etc

4) refit drivers side doorcard after fixing the electric window

5) MOT & TAX

 

Dave

[kerrly 0]

bit more painting. Note the paint is still very fresh and still needs to be flatted and final coat.

 

 

 

 

 

[kerrly 0]

finally, some new parts.

It's been ages since I updated this as i have been collecting parts and building a mk2 Polo bready with my bro http://www.clubpolo.co.uk/forum/index.php?showtopic=270397&st=0

 

After waiting patiently a chap in the U S of A was able to assist me on ebay.com to get some items posted.

 

Things coming up next:

- Weitec 30mm springs

- Koni TA shocks

- new brakes, refurbed callipers

- all new suspension, steering and ARB bushes/arms/mounts

- removal of fuel tank & back axle.

- paint the rear underside section of the car

- decat

 

It will probably end up being more as my objective is to maintain the car to a high standard.

 

---------- Post added at 12:48 AM ---------- Previous post was at 12:39 AM ----------

 

Here is the engine bay after a lot of cleaning. The rocker cover and other components have now been polished.

 

I still need to sort a piece of pipe to link the charger outlet to the intercooler but im hoping Forge can help me out there. In the meantime I will keep it stock in order to run the engine for the MOT.

[kerrly 0]

After the huge disappointment of not having the car ready last year and the last minute crap with having the wrong headlights and not being able to MOT the car i have now sourced a perfect set of headlights and all the other lights so that i have a full set of unchipped/cracked lights for the front end.

 

Got rather lucky on Ebay an found a unused Corrado G60 subframe for less than what i was going to pay to have mine powder coated. It will also have all new bushes and new engine mounts prior to fitting and will be joined by the new suspension components already purchased.

 

 

Hopefully if everything works out i should have a rather nice looking stainless steel exhaust and decat and a rear axle (which will be rebuilt) this weekend.

 

Then a rather large box from a well known VW parts specialist with new discs & pads plus flexis all round.

 

Last on the list is to repaint the boot floor/spare wheel well, remove and paint all the heat shields for the exhaust and repaint the fuel pump housing and do a fuel filter and the underside ought to be as good as new.

 

Fingers crossed it should be ready soon.... so long as i dont get shafted like last week when i booked a couple of days off and it snowed :-(