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GrahamU

GrahamU's 2.0 TFSI with DSG - not for the purists :)

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Well it was on the road for a whole 3 months....... then the end of the gearchange cable broke and fell of, had to manually stick it into third and drive home.

 

Time for some changes:

 

First is the mk4 golf gear shifter upgrade

with the engine run in its time to fit the k03s

When driving it sounded like the diff bearing was noisey so an gearbox change aswell

Uprate the exhaust as I'm still running the standard 16v exhaust

Couple of changes to the cluster 😉

Maybe re-upholster the recaro seat centers (I have 2 spare mk5 GTI rear seats with interlagos material to use)

mk4 golf rear calipers and gonna look at rear bushes

 

 

My first thoughts on the gearbox were to fit an 02s 6 speed and I thought I'd got one till I got it home and found it had a gear missing, bloody ebay seller swore blind it was a 6 speed and would not pay for shipping/transport costs to have it back so I have a 2011 mk6 Golf LHE 5speed diesal box - decided to give it a go unless I find a 6 speed before I fit it all back in.

Got to make the speedo drive come of the ABS but hopefully that wont be to much hassle.

 

this is the broke cable

52652372662_06877e6fb0_z.jpg

and here she is looking all sad and in bits again

52653346153_6e65f1406c_z.jpg

52653135824_00178686d9_z.jpg

 

Just a couple of jobs and have it back out for summer

Edited by GrahamU

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Mate, I have been looking high and low for a bonnet in Black berry for 5 months and there you go.....cheap as chips off eBay ;)

 

Seriously though, if you haven't painted it yet (and it is in good nick paint wise) then if you want to sell it to me for a profit and buy another, let me know.

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Hi Hof,

 

Unfortunately the bonnet has a few scratches which didn't bother me as I intended to spray it. I do now have a red bonnet so I will be selling the black berry one

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Got another chance to get an afternoon in the garage today.

 

I've given up for now trying to find a 6 speed 02s for a price I want to pay so here is the 0a4 5 speed I have from a 2012 golf

52653346138_5314176d2f_z.jpg

built 02/11/11, nice...

52652372642_e25d57ae90_z.jpg

Had to make a braket to fit the rear mount, took a little while as I hand cut it from 6mm steel but it seems ok.

52652372632_e4ba01f0c8_z.jpg

now fitted to the engine along with the k03s

52652863226_a81bebf268_z.jpg

 

Gear ratios/revs/speed for this box are

 

Final-----1st Gear 3.778----2nd Gear 1.944----3rd Gear 1.185-----4th Gear 0.815----5th Gear 0.625

3.64-----Revs----Speed----Revs----Speed----Revs-----Speed----Revs----Speed----Revs----Speed

 

-----------500--------2

-----------1000------5

-----------1500------7

-----------2000------10-----------------------------------------------------------------------1959-----60

-----------2500------12

-----------3000------15-------3251-----32

-----------3500------17-------3500-----34-------3902-----63

-----------4000------20-------4000-----39-------4000-----64-------4434----104

-----------4500------22-------4500-----44-------4500-----72-------4500----105-------4964----152

-----------5000------25-------5000-----49-------5000-----80-------5000----117-------5000----153

-----------5500------27-------5500-----54-------5500-----88-------5500----128-------5500----168

-----------6000------30-------6000-----59-------6000-----96-------6000----140-------6000----183

-----------6500------32-------6500-----63-------6500----104-------6500----152-------6500----198

 

1st, 2nd and 3rd look to be ok but 4th and 5th may be a little tall.

1959 rpm @60mph will mean no more reving the nuts of it on the way to work (better than the old 3000rpm @60mph)

 

Got to wait till next weekend to carry on.

Edited by GrahamU

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More playing in the garage today.

 

So, stage 2 of the speed drive, now I think I know how many pulses it takes to run the speedo I have found a sensor that will do the job niceley

 

http://uk.rs-online.com/web/p/magnetic-pickups/2355706/?searchTerm=235-5706&relevancy-data=636F3D3126696E3D4931384E525353746F636B4E756D6265724D504E266C753D656E266D6D3D6D61746368616C6C26706D3D5E5C647B337D5B5C732D2F255C2E2C5D5C647B332C347D2426706F3D313426736E3D592673743D52535F53544F434B5F4E554D424552267573743D3233352D353730362677633D4E4F4E4526

 

As my rado doesn't have ABS fitted, my plan is to fit this sensor in the hole for the ABS sensor then modify the ABS ring so give the correct pulses to run the speedo.

 

Started by working out the spacing for the ABS ring and removing the bits I dont want

52653301870_b681b6793f_z.jpg

Then weld up the holes in the remaining tabs to make solid areas for the sensor to pick up on

52652372607_2d455749c5_z.jpg

Finally, drill the hub I have and fit the ABS ring to it

52653346098_b12cbe81f0_z.jpg

I now need to paint it and get a bearing to refit the hub (Thought I had one in the garage but it turned out to be for a Mk1 😞 )

With that done I thought I'd start making my exhaust, when it was on the road last year I was still running the 16V exhaust but with the bigger turbo I thought it needs to be bigger.

 

Had a few bits lying around from the many exhausts I tried on the old Bora so cobbled this together

 

old 16v next to the larger bore

52652863186_acb386c1b0_z.jpg

52653135749_f9deea9d5f_z.jpg

 

 

Still need to finish of the tail pipe when I decide how I'm gonna do it

Edited by GrahamU

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Well the engine is back in

52652863171_fb3ee539f0_z.jpg

Been playing some more with the cluster, almost there now:

 

cut the tracks that went to the speedo and tacho motors then re-wired them to swap their positions

52652372557_0228367588_z.jpg

Then downloaded some images of standard dial faces, resized them to fit the new positions and printed them onto some sticky backed photo paper. Stuck them to the dial faces and got this:

52652863126_c1dc3e29ed_z.jpg

During the time the cluster was in bits I managed to break one of the needles so I converted the needle from a mk4 to fit by gluing part of the corrado needle to the underside of the mk4

52653301800_6922c7bc08_z.jpg

52652372522_e346d51f36.jpg

then fitted it all together

52652372507_85937d0517_z.jpg

52652372497_bac956b792_z.jpg

 

 

Not 100% sure on the needles and the fuel/temp gauge is now a different colour but its almost right

 

Next will be the SWG scuttle cover panel when it arrives 🙂

Edited by GrahamU

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After doing a bit of decorating today I had a bit of spare time so I fitted the oil cooler sandwich plate I'd been waiting for, filled it with liquids and turned the key and it started straight of

 

was quite impressed and happy.

 

Just a couple of jobs left and it will be on the road again

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The rado hit the road today, did its first 50 miles of the year

 

And it looks like a got my calculations for the speedo drive correct I'm glad to say, just need to align the speedo needle a bit better as it reads 10mph to high instead of the standard 5mph.

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Decided today I would change the colour of the rear number plate panel from red back to black, whilst I was doing it I thought I would also paint the corrado emblem

52653346023_644aac3256_z.jpg

Then onto the polishing, got one side done-ish

52652372452_5df69cde0e_z.jpg

 

who says you cant polish a turd...

 

 

Plan to paint the wheels white next

Edited by GrahamU

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Painted the wheels today 😄

 

Don't think they look to bad, was only done with cans but I like it so will get it powder coated when winter comes back

52652372447_faa3521dd5_z.jpg

 

Edited by GrahamU

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Thanks Mark,

 

I wasn't 100% sure it would work myself but when I bought them the wheels had been rubbed back by someone using his teeth and sprayed black, I sprayed them silver for a while but thought I'd try white.

 

I can get them prept and coated properly now I know what colour I want.

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Well 500 miles is all the diesel gearbox lasted....

 

Broke the syncro on 3rd on my way home tonight.

 

Knocked it down from 5th to 3rd to give a little squirt of power and there was a loud crunch, now it crunches everytime I go into 3rd in both up and down the box unless I let the revs drop right down.

 

I wasjust beginning to have fun aswell.

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Right then, got myself another gearbox from a mk4 1.8t (EVS code) the gearbox has now had the driveshaft cups changed to be 100mm, the linkage on the tower is now changed to be the pin style rather than the ball joint type and its been filled with oil.

 

Its now fitted to the engine and back in the car.

 

I spent a couple of hours yesterday in the rain going to a breakers on the other side of Norwich and looking at all the shift cables and different brackets to fit the cables before realising all the stuff I'd read about a 6 speed cable shift not fitting a 5 speed was bollox and all I needed was the right mounting bracket.

 

The bracket and cables are now fitted but this causes an issue with the 3" tip I have fitted so tomorrow I'll be making some spacers to move the cable bracket to the side a bit and then removing the metal cooling pipe that feeds the heater and cutting it down.

 

then its just a case of fitting all the ancillaries again and hoping it all lasts longer than a few weeks.

 

At some point in the future I plan to strip the 16v box I have and the mk6 golf diesel box and swap some gears about. I've never stripped a gearbox so that will be interesting :)

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Excellent work! Well done for getting stuck in and all the best for the gearbox strip down. I think that would be beyond my skill level fiddling with that, although I can't say I've ever attempted it. Got nothing to loose if its a knackered one worth not much at all anyway I suppose, so good luck and look forward to the updates! :thumbleft:

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Bloody Corrado's........

 

Spent the day putting it all back together then I try to start it and nothing...........

 

Ignition switch is knackered now.

 

 

 

And to top it all I found a hole in the Sill under the wing

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Got a start button today so I can start it when the ignition fails, fitted it and the thing started of the key again, typical

 

Then went to a family BBQ

 

Got back home and went straight into the garage.

 

Had it running for a while and it boiled up, bit of an air lock I thought, so let it cool and tried to get the air out, run it again and it boiled up again.

 

Had a closer look and found the small inlet into the expansion tank was blocked.

Unblocked that and tried for a third time. It lasted quite a while longer before boiling up again

 

It was 10 o'clock tonight by then so I gave up before the wife ripped my balls off.

 

I have a couple of hours to get it sorted in the morning before going to watch the BTCC

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And the problems just keep coming.....

 

Now it turns out the gearbox I put in jumps out of 3rd gear as the clutch engages unless you hold it in place, seems to stay in gear once the clutch has engaged.

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This afternoons progress

52653135639_3b69d9ee27_z.jpg

52653135634_33bb23d080_z.jpg

 

 

Virtually everything from under the bonnet removed and one wing and door off

 

Next is the other wing, door and the dash out but that will have to wait as I off to watch the truck racing at Snett tomorrow

Edited by GrahamU

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Some more pics

 

Bit of a hole at the bottom of each A pillar/sill

52652863006_da70f05898_z.jpg

Other wing off

52653301720_3413d6d260_z.jpg

and the dash out

52653135609_3c844ed0ce_z.jpg

 

Edited by GrahamU

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