NewportEdition G60

[velly_16v_cab]

more pics of the corrado I've added to the photo thread

http://www.vwwatercooled.com.au/forums/images/imported/2008/02/IMG_9229-1.jpg


http://www.vwwatercooled.com.au/forums/images/imported/2008/02/IMG_9220-1.jpg


http://www.vwwatercooled.com.au/forums/images/imported/2008/02/IMG_9206-1.jpg


http://www.vwwatercooled.com.au/forums/images/imported/2008/02/IMG_9155-1.jpg


http://www.vwwatercooled.com.au/forums/images/imported/2008/02/IMG_9122-1.jpg


http://www.vwwatercooled.com.au/forums/images/imported/2008/02/IMG_9104-1.jpg


http://www.vwwatercooled.com.au/forums/images/imported/2008/02/IMG_9214-1.jpg


http://www.vwwatercooled.com.au/forums/images/imported/2008/02/IMG_9171-1.jpg

[DubSteve]

Velly those pics aren't any good mate...... Build up thread please:D

[velly_16v_cab]

i will find the build up of it.....

[velly_16v_cab]

quote="ewang33"

I bought the car back in October just after selling the valver, and I've just been too busy with freelance stuff to do any work on it. (reason for the site not being updated.. sorry people :cry:)

Anyways.. spent the last few months getting the new garage sorted. Lick of paint, sorted the leeks out and security issues.. so finally started to pull the charger apart to see what the damage was.

New garage.. secret location :oops:
http://www.vwwatercooled.com.au/forums/images/imported/2008/02/IMG_8567-1.jpg
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http://www.vwwatercooled.com.au/forums/images/imported/2008/02/IMG_8561-1.jpg
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Blown charger:
http://www.vwwatercooled.com.au/forums/images/imported/2008/02/IMG_8588-1.jpg
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Found this on the underside.. it had also blown a hole in the main chamber:
http://www.vwwatercooled.com.au/forums/images/imported/2008/02/IMG_8598-1.jpg
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Found out what happened soon as I removed it.. looks like the toothed belt just failed and caused havoc inside.. I see why G-werks use 12mm belts!
G-lader owners check your belts NOW!
http://www.vwwatercooled.com.au/forums/images/imported/2008/02/IMG_8578-1.jpg
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Looking at the crap left in the pipes I'll need to pull the intercooler too..
http://www.vwwatercooled.com.au/forums/images/imported/2008/02/IMG_8584-1.jpg
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[velly_16v_cab]

Other than that the rest of the car is pretty mint..
http://www.vwwatercooled.com.au/forums/images/imported/2008/02/IMG_8547-1.jpg
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http://www.vwwatercooled.com.au/forums/images/imported/2008/02/IMG_8543-1.jpg
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http://www.vwwatercooled.com.au/forums/images/imported/2008/02/IMG_8542-1.jpg
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http://www.vwwatercooled.com.au/forums/images/imported/2008/02/IMG_8541-1.jpg
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http://www.vwwatercooled.com.au/forums/images/imported/2008/02/IMG_8538-1.jpg
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Between getting the site sorted for 2007 :roll: I'll post pics as I go along. After the new charger goes in it's onto the brakes and suspension.

[velly_16v_cab]

quote="ewang33"

weekend update..

Someone please remind me why the @$%? I'm doing this??

Charger, brackets, rad and everything else forward of the engine block is out. I only meant to swap the friggin charger out?! But you know how these things end up.. "I'll just clean this.. then that.. ohh there's some rust there.." oh crap!

http://www.vwwatercooled.com.au/forums/images/imported/2008/02/IMG_8674-1.jpg
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http://www.vwwatercooled.com.au/forums/images/imported/2008/02/IMG_8668-1.jpg
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http://www.vwwatercooled.com.au/forums/images/imported/2008/02/CRW_8681-1.jpg
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http://www.vwwatercooled.com.au/forums/images/imported/2008/02/IMG_8704-1.jpg
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After pulling the bumper, I can't believe what I found?? I guess being parked up in a damp garage for a year has done it no good. The rad support or cross member has completely rusted through. Basically I need a new one, or second hand and restore it. It's too far gone to fix.

According to ETKA there's two types, early and late. I'll need to check my chassis number...
http://www.vwwatercooled.com.au/forums/images/imported/2008/02/CRW_8684-1.jpg
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http://www.vwwatercooled.com.au/forums/images/imported/2008/02/CRW_8687-1.jpg
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It's this bit:
http://www.vwwatercooled.com.au/forums/images/imported/2008/02/radSupport-1.jpg
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I hate this bolt!!! Rounded out completely.. The only one that defied the air impact wrench! Should be fun getting this out..
http://www.vwwatercooled.com.au/forums/images/imported/2008/02/IMG_8713-1.jpg
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Charcoal canister.. big, ugly but leaves a lovely hole for a CAI 8)
http://www.vwwatercooled.com.au/forums/images/imported/2008/02/IMG_8701-1.jpg
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More fun to come.../quote

[velly_16v_cab]

quote="ewang33"
Not much to update other than 3 weekends worth of solid cleaning, scrapping and painting.

Then there's the endless task of listing all the seals and gaskets I need. Not to mention rounded off or snapped bolts!

Just started to detail the other side of the engine bay.

Next job is sorting all the wiring out.. well.. replacing all the cloth tape that has perished over the years.

Still waiting on that cross member :evil:

Pix aren't too good this time.. cold!!

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http://www.vwwatercooled.com.au/forums/images/imported/2008/02/IMG_8640-1.jpg
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http://www.vwwatercooled.com.au/forums/images/imported/2008/02/IMG_8641-1.jpg
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http://www.vwwatercooled.com.au/forums/images/imported/2008/02/IMG_8642-1.jpg
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/quote

[velly_16v_cab]

quote="ewang33"

A bit of an update on the Corrado saga..

Finally got the brackets and charger back from G-Werks, fitted them last weekend. All the refurbed pulleys are back on and torqued up, and all the front suspension has been overhauled with new wishbones, bushes, balljoints etc..

Still waiting on the pas pump bracket from G-man, and also a new charger oil feed and intercooler. I still need to find a new clutch pipe, apparently it's obselete from vw?!

Still to do.. once the engine is all hooked up and front end back together, I'll be stripping the rocker cover and inlet manifold for a fresh lick of paint and to degrease all the throttle body. Should be good to go after some new rear brakes, shocks, and a damn good clean.

I did plan to have it ready by this weekend.. but apparently it takes 5 weeks to rebuild a charger?!

As you can tell, I'm still not entirely in love with the Corrado. Kinda like the fit bird that works on the tills in Tesco, you would! But you just can't see yourself loving her. Maybe I've just lost my passion for power driving around in a pos Polo for 6 months?!

Anyway.. on with the show..


Shiney pulleys which no one will ever see..
http://www.vwwatercooled.com.au/forums/images/imported/2008/02/IMG_9916-1.jpg
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Cleaned up alternator and another pulley (shiney stainless bolts)..
http://www.vwwatercooled.com.au/forums/images/imported/2008/02/IMG_9914-1.jpg
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New charger and brackets..
http://www.vwwatercooled.com.au/forums/images/imported/2008/02/IMG_9910-1.jpg
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What a mess.. I hate the 8v engine bay..
http://www.vwwatercooled.com.au/forums/images/imported/2008/02/IMG_9907-1.jpg
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Close up of the most stupidly expensive thing ever (£400 to have G on the side?!)..
http://www.vwwatercooled.com.au/forums/images/imported/2008/02/IMG_9903-1.jpg
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/quote

[velly_16v_cab]

quote="ewang33"
I swear I'm gonna end up torching the friggin thing if things don't start going my way soon :x

So to add to the problems so far.. 3 month charger rebuild, rusty rad support issues, front bearing problems, snapped bolts, rounded nuts.. etc etc..

Picked up a set of new front calipers from GSF. After 2 sets of brake pads not fitting I finally realised they're 16v calipers?! So GSF had to trace my old exchange calipers back for reference. VR6 and G60 calipers are the same! Although all are labeled Lucus/Girling 54's. The caliper width is different.

Then last weekend I set about cleaning all the charger pipes and hoses. Whilst degreasing and jet washing them, the gauze in the end of the boost return pipe managed to work itself loose and proceed to fly off into the undergrowth.. AR5E!!.. So I spent the afternoon cutting my way through the brambles and nettles trying to find this bstrd piece, knowing full well it was either unavailable or cost £104 from VAG. Could I find it? could I funk!!

Another weekend with nothing constructive done and the show season slowly drifting away..

Rant over for today.

Anyone have a boost return pipe lying around?
/quote

[velly_16v_cab]

quote="ewang33"
With all the parts finally in front of me I quit cleaning stuff and made a big leap forward last weekend to get it running. I'm just waiting on one intercooler bracket now from G-werks, they lost the one I left them so they've ordered a new one from vag.. one less bracket I have to strip and paint anyway. :up:

After triple checking every pipe and most bolts I filled it with liquids and gave it a go. Took a few attempts to get going, timing was out at the dizzy and I hadn't plugged in the alarm. Luckily I decided not to rip out the original alarm loom before start up, I'll need to pull all that out and replace it with a new one as the remote fob and key have gone missing at some point.

It runs though! Albeit a tad lumpy and the idle is all over the place.. a few hours reading the Bentley and scouring the forums for fault finding write ups and fingers crossed it'll be good enough for a trip down to G-Werks for a final tweek.

I think the alternator has seen better days after being stored so long, if anything at all it's reading near zero on the ammeter.. so thats another 100 bucks I haven't got.. brilliant. :???:

The charger is loud as a mo fo without the airbox installed, whistling and whining like something annoying.. love it!

Just the back shocks, brakes and bearings before being mobile again after over a year in storage.. even German cars don't like sitting doing nothing half their life. When I'm happy it's running ok it'll be back in the garage for an interior strip and major paint detail. The back seat still has a big rip in it, the stereo is none existent and the old alarm needs replacing properly. Besides, the interior needs a good scrub and taking it all out is the only way really.. just seats, carpet and door cards though.

Hopefully this will be the last update before getting it back on the road!

Some pix...

Arse shots:
http://www.vwwatercooled.com.au/forums/images/imported/2008/02/IMG_0757-1.jpg
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http://www.vwwatercooled.com.au/forums/images/imported/2008/02/IMG_0751-1.jpg

Lets hope it stays this way for a few more years..
http://www.vwwatercooled.com.au/forums/images/imported/2008/02/IMG_0737-1.jpg
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http://www.vwwatercooled.com.au/forums/images/imported/2008/02/IMG_0736-1.jpg
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http://www.vwwatercooled.com.au/forums/images/imported/2008/02/IMG_0734-1.jpg
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A couple of lights and a grill to go..
http://www.vwwatercooled.com.au/forums/images/imported/2008/02/IMG_0729-1.jpg
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Rear axle overhaul..
http://www.vwwatercooled.com.au/forums/images/imported/2008/02/IMG_0723-1.jpg
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http://www.vwwatercooled.com.au/forums/images/imported/2008/02/IMG_0721-1.jpg
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Wish it would stay that mileage!
http://www.vwwatercooled.com.au/forums/images/imported/2008/02/IMG_0741-1.jpg
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/quote

[STV4SYT]

Awesome find, looks like the typical out of control rebuild.

[KI11Z]

gotta love fresh paint! :cool: and if its not then he must never drive it :rolleyes:

nice example!

[velly_16v_cab]

its been well looked after hence the milage :D

[DubSteve]

Any more pics from it Velly it looks awesome:)

[velly_16v_cab]

i am sure there is a few more...i will find them later fella

[aussieg60]

Good stuff, the bay looks brilliant, cleaner than mine :D
What gauze were you talking about in the boost return pipe :confused:

[ausgolfer]

now he needs to get some more enjoyment out of it buy putting a 1 in front of the numbers on the odo....;)

[Bubu]

Sweet... :cool:

[aussieg60]

i am sure there is a few more...i will find them later fella

Any more pics for an update ?

[velly_16v_cab]

the car is running ant at most of the shows this year...i will dig through our site and add his photos to this thread

[velly_16v_cab]

next part of the story....

Here we go again.. 3rd time lucky to get the thing back on the road.. After the head gasket gave out on the way back from G-Werks last March.

Finally got the head back from the machine shop at Oselli (http://www.oselli.com).

It needed a bit of welding on a few of the coolant galleries to stop the risk of the gasket going again.
I had it mildly ported and polished throughout, matched inlet manifold, new valve guides, triple lapped valve seats and a good de-coking.

Well.. it looks clean.. see how it performs now:
http://www.vwwatercooled.com.au/forums/images/imported/2008/06/IMG_0112-1.jpg
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http://www.vwwatercooled.com.au/forums/images/imported/2008/06/IMG_0110-1.jpg
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http://www.vwwatercooled.com.au/forums/images/imported/2008/06/IMG_0106-1.jpg
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http://www.vwwatercooled.com.au/forums/images/imported/2008/06/IMG_0102-1.jpg
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http://www.vwwatercooled.com.au/forums/images/imported/2008/06/IMG_0100-1.jpg
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http://www.vwwatercooled.com.au/forums/images/imported/2008/06/IMG_0093-1.jpg
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Matched inlets:
http://www.vwwatercooled.com.au/forums/images/imported/2008/06/IMG_0124-1.jpg

New heavy duty layered gasket:
http://www.vwwatercooled.com.au/forums/images/imported/2008/06/IMG_0119-1.jpg

New valve guides:
http://www.vwwatercooled.com.au/forums/images/imported/2008/06/IMG_0141-1.jpg

[velly_16v_cab]

Fully built up and ready to go back on:
http://www.vwwatercooled.com.au/forums/images/imported/2008/06/IMG_0137-1.jpg
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http://www.vwwatercooled.com.au/forums/images/imported/2008/06/IMG_0136-1.jpg
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http://www.vwwatercooled.com.au/forums/images/imported/2008/06/IMG_0133-1.jpg
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The block isn't too bad after a few hours de-coking, although there is some weird staining in cylinder bore 1?!
I figure this is just where it's been standing for a while. The other bores are pretty fresh..

http://www.vwwatercooled.com.au/forums/images/imported/2008/06/IMG_0082-1.jpg
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http://www.vwwatercooled.com.au/forums/images/imported/2008/06/IMG_0075-1.jpg
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http://www.vwwatercooled.com.au/forums/images/imported/2008/06/IMG_0072-1.jpg
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show pics will be added tomorrow.....

[aussieg60]

Sweet as, looks real good. Are they not standard exhaust gaskets ? They are all linked, new part, superseding the single gasket per exhaust port ?