kr turbo build

[dubkicks 10]

Hi all,

should of done this as i was building but hay ho here we go.

 

it all started back in 2005 when i owned a 92 G60 after spending a complete fortune on it seeking more power. I took it as far as i could with the super charger but the 235bhp just wasn't enough so i ditched the charger in favor of a jabba sport ihi turbo kit which took the power to 280bhp slapped a 20vt box on it. it did high 13 second quarter miles i was well pleased. until in 2009 i wrote off my pride and joy. Any how i ripped it to bits, sold my engine but kept the turbo kit.

with the money i got for my engine and a few other bits i was able to buy a 1994 aqua blue 16v in bog standard form.

 

so the mission began, i ripped the 16v to bits the engine and box came out wiring loom, interior the lot took it to a bare shell. i started off by stripping the bay and cutting out the scuttle panel, plating and smoothing the chassis legs and bulk head. i did aim to paint the car dark burgundy pearl but have since changed my mind. [ATTACH=CONFIG]71696[/ATTACH][ATTACH=CONFIG]71697[/ATTACH] [ATTACH=CONFIG]71698[/ATTACH][ATTACH=CONFIG]71699[/ATTACH][ATTACH=CONFIG]71700[/ATTACH]

 

whilst doing the bay i started to collect parts list as follows;

like i said earlier i kept the complete ihi turbo kit which had the vf23 turbo and down pipe, greddy pro spec b boost controller, G60 wiring loom was kept along with the G60 ECU with the uprated map sensor (1.5 bar).

 

i brought a audi rs2 exhaust manifold which i cut off the 5th runner and blanked it off along with the waistgate port as i used an actuator. my mate then made up a flange to fit the IHI turbo. the finished manifold wasnt far off the G60 turbo manifold so the G60 turbo down pipe bolted straight up result.

 

i also managed to get an inlet manifold dirt cheap off flea bay from a german tuning company it is based on an rs2 inlet manifold.

 

i kept my throttle body from my G60 which bolted straight to the inlet manifold and fitted the bosch 440 injectors i had on the G60 turbo.

 

The head work was done by myself with a dremel paying attention to the plenum chamber so when the valves are at maximum lift the flow past the valves were massively improved along with the internal head work just removing the rough cast and work behind the valves. New sodium filled exhaust valves were fitted along with new stem seals and a re-skim. All done on the kitchen table much to the missus dispare hee hee.

 

i didnt use the 2litre 9a block, instead i sourced a Kr engine as these rev up quicker than the 9a. sent the block off to TSR and they bored out the block to match the wossner low comp forged pistons. I fitted the piston rings to all the pistons and fitted into the block. The crank, flywheel, pulleys and G60 clutch were also balanced by TSR to ensure a smooth engine. New bearings were fitted along with vw 16v oil pump and ARP con rod bolts and head bolts. i kept the G60 turbo sump as it had the turbo oil drain fitted and got a 1.9tdi turbo water drain core plug fitting and fitted them too along with a G60 head gasket and replaced all seals and gaskets on the block. fresh water pump and thermostat. [ATTACH=CONFIG]71701[/ATTACH] [ATTACH=CONFIG]71702[/ATTACH]

 

i also got an rs500 intercooler off flea bay dirt cheap and a mk3 golf vr6 rad but had to modify the front subframe( the part that holds the rad) to get them to fit and fitted two kenlowe blow fans as there wasn't enough room to fit the fans behind the rad instead they are fitted in front of the intercooler.[ATTACH=CONFIG]71703[/ATTACH]

 

Fitted the 20vt gearbox from the G turbo after polishing it up what a tedious job that was!

 

hid the wiring loom when refitted, running the headlight and engine loom inside the car. the headlight loom then was run under the front wheel arches and a hole cut underneath the ABS pump to run the engine loom through.

 

I made up my own 3" exhaust using bits from demon tweaks as i was getting silly quotes for doing the job. it cost me about £150 rather than the £400 i was quoted. result. and it sounds sweat.

 

I used the G60 in tank fuel pump as it was new from the G60 turbo and an additional mk1 gti pump to boost up the fuel pressure even more. i could of used the 16v pumps but were unsure of there condition.

 

The engine was done up and running after setting up the ignition timing the beast fired straight up. nice one.

 

It was then time for the chassis, new front wishbones and top mounts were fitted along with G60 hubs, wheel bearings, G brakes and brake pipes. All 4 ABS sensors were changed along with the rear brakes. the Koni sport coilovers were salvaged from the G and fitted. Best coilovers i ever brought.

I used to run 9"x15" RMs but fancied a change so got rid of them after the crash as they were bent and brought a set of 8" bmw bbs rc90 splits. my mate redrilled the hubs to take the 15mm hub adaptors. I got the wheels off the bay and refurbed myself. I had to fit camber shims to the rear to get them to fit but the handling is poo in the wet so they might not be around for long. look the absolute tits though.

[ATTACH=CONFIG]71692[/ATTACH]

 

Not really done much to the exterior, ditched the side repeaters and fitted led's in the wing mirror posts, pulled the front arches and trimmed the rears, ditched the rear wiper, fitted a single wiper conversion and custom made a bracket for the wiper motor like a mk2 golf. fitted a 90mm front spoiler and debadged grill it did have all red rears but have now gone back to standard. Going to repaint it in aqua blue and take the engine back out this year and get the bay painted back in blue rather than the dark burgundy pearl it is now.

 

I brought a Mint Black leather interior off of the corrado forum, the bloke i got it from told me it had been taken out of a low mileage 80k 16v late type that was L/H drive so the drivers seat to be now is brand new and when i turned up with my £475 he wasnt wrong both front seats were mint in fact the whole lot was mint door cards the lot. well chuffed.

 

I then got it on the road and racking up the miles taking it steady of course and turned the boost controller off whilst running it in and doing the usual oil and filter changes. After ironing out all the issues it was off to Jabba sport for a custom remap and rolling road session boy was i craping my pants when it was on the rollers waiting in the waiting room whist Mike was reeming it on the rollers. He came up and said its got 330bhp 290ftlbs torque at 1.2 bar, boy was i happy he then turned around and goes the head flows really well its got lots more to give. He then asked if he could turned the boost up to 1.4 bar i obliged reluctantly.............. well. 348bhp @ 7039rpm and 308ft-lbs torque @3902 rpm. The drive home was excellent from Peterbourgh to Poole in Dorset down the M1 Killing some Porshe carrera 4 s chewing his bumper off at 120 he then pulled in and the raddo was gone love it.

 

trust me this was no credit card build everything was done by me apart from the exhaust manifold, engine boring/balancing, the remap and drilled hubs. countless holidays have been sacrificed over the years so dont think i am made of money, like most dubbers with a passion/hobby i spose? so i am well chuffed with what i have achieved.

not all been plain sailing though the turbo bearings went so a new IHI VF34 has been fitted not bloody cheap had to take it off the road for a bit until i could stump up a grand. but this turbo suits it better as it better at the top end and should be just shy if not more of 360bhp. But thats it if i go anymore it will throw a rod as they are standard 16v ones. I know i should of fitted I beam rods but they are not cheap and i didnt expect to achieve this power.

 

I have since been up santa pod and done a 13.4 second quarter not bad considering it hasnt got a diff fitted yet and was running the bmw splits with 195/40 stretched with massive camber and full leather, needs a diff urgently! not only that since my trip to the pod it crunches into 3rd everytime not sure what box to put in it yet but i know this it aint getting polished up. thinking about a derv box? or get a vr gearset fitted into the 20vt box if this is possible? it does obviously kill tyres and does 15mpg but sod it its worth it.

 

Thanks for taking the time to read this if you want any hints or tips sod off. no only joking happy to help any dubbers with there builds.

 

a few pics to leave you with. Cheers Kev. [ATTACH=CONFIG]71693[/ATTACH] [ATTACH=CONFIG]71694[/ATTACH] [ATTACH=CONFIG]71720[/ATTACH]

 

will get some better pictures soon.

Edited January 21, 2013 by dubkicks

[dubkicks 10]

sorry i did attach more pics than this?????? will re add them later. cheers kev.

[joebloggsVR69 0]

Nice, look forward to seeing more pics :thumbleft:

[onestep 0]

Nice build dude.

Diff makes all the difference.

Good old jabba on the mapping front and high praise indeed from mike.

[Kevin Bacon 5]

Another Kev bolting turbos to his Corrado :thumbleft:

 

I think you've skimmed over the real extent of the work and made it sound easy! Having been down the same road (albeit with a VR6), I tip my hat to you sir, and the power figures are excellent! Top job!

[jonny_ash 0]

Posts like this make me jelous!! Lovely looking car with rediculous power. Would love to have seen the look on the porsche drivers face as you dissapeared down the road. Only wish I had the mechanical know how to do something like this but I can just about manage a basic service :)

[coullstar 0]

Love it, something different from the usual 1.8T conversions and credit to you for doing the work.

[dubkicks 10]

cheers chaps,

yep like wise 1.8t done to death, and the vr turbo was starting to go that way but who can blame those boys with the power achievable. It has that old school turbo feel to it because of the kr cams, bit of lag and gone. Diff and box is next on the list not sure weather to go for a diesel box or a vr6 gear set in my 20v box any pointers?

 

Thanks again Kev.

[Kevin Bacon 5]

I had a Turbo Technics 16V MK2 (Stealth Racing updated version) many moons ago and I loved it. Definitely a better engine than the 1.8T imo. Smoother and lots more character.

 

What 20V Gearbox have you got in there? The one from the Polo GTI (BJX engine code) would be perfect for your car as it runs 205/45/16s as standard, a common aftermarket corrado tyre size. The trouble with some other 20V boxes is they're geared for MK4s wearing 17s and 18s with balloon tyres.

 

If not, VR6 gears are fine, although I prefered them with the shorter 3.68 final drive from the G60 personally.

[G60 CS 0]

Ive got a g60 box with 90k on it and a brand new Peloquin that Ive been hoarding but ......

[sexybourbon 0]

Some great skills there id love a go in that i bet its a rite old hoot

[destructiv dave 0]

Mmm. Me like.

 

Me no like lack of photos though and as Kevin says, you've made that sound a lot easier than it is. I like you have gone down the old school route and have turbo'd my 9A using S2 parts.

 

Also, what engine management are you using?

[dannyboy 0]

Nice build,I was going to do 16v turbo build but parts getting hard to get hold of over here without paying a fortune.

Everyone snubs the 1.8t now cause they're bored of hearing of them but they're the most reliable engine to tune without spending stupid amounts of money

And that's not because I just have one.....

[dubkicks 10]

The gearbox code is ECW kev, i did think about a G box but 1st and 2nd are too close together poo 0-60 but then i spose the first two gears can be changed. gearbox's and ratio's are a bit much, it is running G60 management with 1.5 bar map sensor dave and will sort out some mores pics, only seems to upload about 5 pics at a time, dont know whats going on there? nothing against 1.8t's but i always felt vw should of mass produced a 16vt back in the day like the cossies and lancia deltas.

 

ar well.

[MarkFoster 0]

Really interesting read, thanks for sharing. Good to see these sort of builds still happening on the CF!

[owen g60 10]

Look forward to seeing this if your on the south coast.

[dubkicks 10]

just started to go to tidy vag at macki dees at hols bay bud if ya want too see it in the flesh, second sunday of every month Owen.

[owen g60 10]

Was that yours parked next to mine last week?

[dubkicks 10]

I was down there last week, parked on the end of a row of corrado's bud?

[owen g60 10]

Yep parked next to my g60 and David's nugget

[dubkicks 10]

thats the one, i will take you out in it next time if ya want? must say they were a pretty tidy bunch of raddos, were they all local raddo nuts?

[owen g60 10]

There's about 10 or so locals I know of and see quite a bit.

[Redfox 10]

Your Corrado looks soooooo great in this picture. Absolutely stunning AND mean ;)

Great change in BBS wheels as the normal BBS RS.

 

[ATTACH=CONFIG]71751[/ATTACH]

 

Cheers,

Redfox.

[dubkicks 10]

Cheers Redfox deeper dish than RS's staggered dish and half the price.

 

Do you all meet local somewhere Owen? good to talk cod s##t to fellow raddo enthusiast's, pub meets?

[dubkicks 10]

Took some pic's yesterday after cleaning all the salt and road crap off the raddo.

 

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got a bit trigger happy with the camera ha ha.

 

and one from santa pod.

 

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hope ya like cheers kev.

Edited February 24, 2013 by dubkicks