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    Thread: Yes another Corrado Build.

    1. Member vwflygti's Avatar
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      08-18-2011 11:21 PM #1
      I have everything listed of my build on my website, which was started last year for my S4 build. Website is www.buildmys4.com

      Figured I would start one here as well...

      *First let me start by saying hello as I'm new to the corrado forum. I have always wanted one since I was 16 and have come accross one I just couldn't turn away.

      Car started as a G60. Now I'm doing the typical aba16vt. Running 9.1 comp ratio since it's a daily. Looking at the precision 5857 .63 ar as a turbo with a t3 flange.

      Here is the story, thanks for tagging along, hope to have it running in the next 3-4 months...
      10-4-10



      Last Thursday I got a 1990 vw corrado.  It is white with the red dot interior.  All the power items still work perfect, the sunroof, the wing, the windows, the mirrors, etc.  The motor has some issues that need to be straighted out.  Cylinder 1 and 2 have a bent valve which is the cause of the 0 compression.  So I bought a new cylinder head and head gasket kit along with timing belt and everything needed to do the job.  




      Some exterior pictures:




















      Some dirty interior Pictures:









      Some motor shots:










      The bent valves, here the lifters are stuck down:














      10-11-10




      Today I took some time to tear down the motor and see what is salvageable. Looks like the cylinder head is in need of a full rebuild, valves, guides, lifters, etc.  So I'll be using a new cylinder head I purchased.




      The two stuck valves...






      Looks like a buildup of oil/anitfreeze in the cylinder.  Possible overheat... (Before and after shots)






      The new head that will be installed...






      And a new box-o-parts:









      3-12-11

       

      Well back in the fall Pete and I tried to get the corrado running so I could use it as a G60 daily driver.  The visual damage to the engine was the cylinder head haveing two bent valves and didn't appear to have any damage to the bottom end.

       


       

      So the bottom end was cleaned all up, checked the deck for any major warping and everything looked good.  So we begain installation of the new cylinder head.

       




       


      Everything went together pretty easy, had it done in an hour or two. 

       

       





       




      Everything was done and ready to run.  Filled the car with fluids and cranked her over.  After a few small adjustments of the distributer and she lived once more.  Everything was assembled with assembly lube for first start.  Problem is we had no oil pressure.  So we shut it down right away!

      What we found wasn't pretty!

       




       


      The oil pickup was totally melted! Over heat was obvious.  I had another used G60 oil pump laying around so we quick swapped them out and bolted the pan back up.  Tried starting the car again and had good oil pressure.  Later when it was dark we went out for a drive, and car was running half decent for sitting for 2-3 years.  Until the we started hearing "The Knock".  Yes indeed the bottom end started knocking.  With it being so dark we packed it in for the night and I looked further into it the next day.  Outcome was new motor.... :-(

       



       

       

       

       


       

       

       

      *Here lies the problem, I'm never one to just put a stock motor back into a car if you dont know me!... ;-)

      3-15-11



      So the fun begins.  Right now the car is sitting outside and part collection is the priority for this project.  Been hitting up a bunch of "u pull it" yards trying to gather up all the parts I will need to make an ABA/16v turbo motor for this car.  Seems to be a very cost effective solution to put some serious hp down in a shoe box. :-)




      Parts collecting with Pete:






      Joe jumped in as well:









      Got the bottom end back to the house and started stripping it down to clean it up.  The aba pistons are coming out and 9a pistons are going in.  As far as the rods go, we'll see what kind of deal I can find on some...









      3-21-2011

      Started ripping the motor out today. 



       

      Motor out and dirty engine bay:






      3-22-2011

      Went and got a bunch of 16v stuff yesterday from someone off the vortex:

       












      4-3-11

      These past couple of days were spent cleaning up around the garage and pressure washing the engine bay of the corrado.  Just some shots of some stuff:




      Pressure washing the car:








      Transmission back in the car ;-)






      Both motors up on stands, ready for some work:











      5-3-11

       

       

      Ripping down the old G60 motor for parts...

       





       



       

      Got to cleaning the block and trans today, what a greasy mess!



       



      Last edited by vwflygti; 09-30-2011 at 09:19 AM.
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    2. Member vwflygti's Avatar
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      08-18-2011 11:22 PM #2
      5-25-11

      Got the block painted:                                The turbo manifold came in also:







      The ABA rods now have new bushings pressed in and machined to fit the 9a pistons:






      Some random gaskets and such that came in:






      Honed the block also:








      Started with the clean and prepped block...                



       

      Got the bearings installed with the plastigage to see if the tolerances were good. Needed .02-.06mm.

      Came in around .051. Thumbs up...


       

      Plenty of assembly lube and set the crank...                And torque it all together, 48 ft. lbs + 1/4 turn...



       

      Putting new hardware in rods...                Rods ready for install...


       

      8-2-2011

      Got to working on the motor a little more today.

      Pistons and rods are in:



       


      Head is bolted on:



       

      The cylinder head turned out great, thanks DEFIV:

      Ferrea race valves:



       

      Some pictures of the port work:

       


       

      Some shots of the motor as of today:

       





       

      8-17-2011

      Got some Girling Dual Piston calipers from an audi for the corrado, should work nicely!



       

      Started cleaning and rebuilding the front sub frame, rubber bushings are being a pain!



       

      Also got a OBD1 vr6 Throttle Body with a TPS sensor, should make for a nice install...



       

      Got some more stuff done on the motor this past week. Mounted a 35mm tial wastegate.







      Last edited by vwflygti; 08-18-2011 at 11:31 PM.
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  • Member Corradoman8's Avatar
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    08-19-2011 12:07 AM #3
    Looks good! Alpine white is my second favorite Corrado color. It comes in a close second to Diamond silver

  • 08-19-2011 01:28 AM #4
    subscribed, keep posting man this is sweeeeet!

  • 08-19-2011 01:28 AM #5
    oh yeah checked your site... your audi.. GAAAHAAAA ooooomaaaazing

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    08-19-2011 03:45 AM #6
    Nice

    Engine work looks spot on
    Any plans for it other than the motor swap?

    Quote Originally Posted by dogger View Post
    ... (Corrado) might be the greatest collection of bad VW ideas ever put into one car.
    My Corrado (sort of) build thread / On Database
    My MK1 build thread
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  • Member vwflygti's Avatar
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    08-19-2011 07:49 AM #7
    Quote Originally Posted by ctk9000 View Post
    oh yeah checked your site... your audi.. GAAAHAAAA ooooomaaaazing
    Thanks, audi is a lot of fun.
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    08-19-2011 07:49 AM #8
    Quote Originally Posted by RedYellowWhite View Post
    Nice

    Engine work looks spot on
    Any plans for it other than the motor swap?

    Thank you, other than the motor just keeping it simple. Prob some suspension and wheels. Not big on aftermarket body components.
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    08-19-2011 09:45 AM #9
    Quote Originally Posted by vwflygti View Post
    Thank you, other than the motor just keeping it simple. Prob some suspension and wheels. Not big on aftermarket body components.
    ^^ me too


    Hope at least you're repainting the bay since you have the motor out and all
    Quote Originally Posted by dogger View Post
    ... (Corrado) might be the greatest collection of bad VW ideas ever put into one car.
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    08-19-2011 09:48 AM #10


    In for this one.
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    Quote Originally Posted by pileofredparts View Post
    Do you guys remember the time that Ryan kid started mixing and matching rods and end caps and then his motor wouldnt turn over? I do

  • Member vwflygti's Avatar
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    08-19-2011 09:55 AM #11
    Quote Originally Posted by RedYellowWhite View Post
    ^^ me too


    Hope at least you're repainting the bay since you have the motor out and all
    Hm, funny you posted this. I've been going back and forth, I was going to strip the engine bay more and do a quick spray. But I would love to make this car black some year, so have been going back and forth wether to go black engine bay now or stay white and go black later. Seen a silver engine bay also I liked.

    What do you think?
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    08-19-2011 10:02 AM #12
    Quote Originally Posted by vwflygti View Post
    Hm, funny you posted this. I've been going back and forth, I was going to strip the engine bay more and do a quick spray. But I would love to make this car black some year, so have been going back and forth wether to go black engine bay now or stay white and go black later. Seen a silver engine bay also I liked.

    What do you think?
    Can't really help you with what colour to go for (*cough, go for oe white, cough* ), its your car - your decision in the end, but all I'm saying is that it would be a shame for all the nice engine work you're doing to put that nice/fresh/clean engine into a dirty/messy bay
    Quote Originally Posted by dogger View Post
    ... (Corrado) might be the greatest collection of bad VW ideas ever put into one car.
    My Corrado (sort of) build thread / On Database
    My MK1 build thread
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  • Member vwflygti's Avatar
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    08-19-2011 10:04 AM #13
    Quote Originally Posted by RedYellowWhite View Post
    Can't really help you with what colour to go for (*cough, go for oe white, cough* ), its your car - your decision in the end, but all I'm saying is that it would be a shame for all the nice engine work you're doing to put that nice/fresh/clean engine into a dirty/messy bay
    Haha, cheers! White it is....
    *Thanks to redyellowwhite for choosing the car color! lol
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    08-19-2011 10:22 AM #14
    Quote Originally Posted by vwflygti View Post
    Haha, cheers! White it is....
    *Thanks to redyellowwhite for choosing the car color! lol
    LOL

    I'm probably a little biased in favor of white tho (or red or yellow)....get the username now?
    Quote Originally Posted by dogger View Post
    ... (Corrado) might be the greatest collection of bad VW ideas ever put into one car.
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    08-19-2011 10:23 AM #15
    Nice work!

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    08-19-2011 11:02 AM #16
    What model Audi did you get you dual piston set up from?

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    08-19-2011 11:38 AM #17
    Quote Originally Posted by Corradoman8 View Post
    What model Audi did you get you dual piston set up from?
    The gurling 60 dual piston calipers came on a bunch of older Audi's. The ones I got mine from was the older Audi coupe with four lug and electric locking rear differential.
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  • 08-19-2011 01:07 PM #18
    Go blue. <3

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    08-20-2011 09:28 PM #19
    Quote Originally Posted by ctk9000 View Post
    Go blue. <3
    Car or engine bay?
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  • 09-09-2011 07:31 PM #20
    Quote Originally Posted by vwflygti View Post
    Car or engine bay?
    both!?!?!?!

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    09-29-2011 08:13 AM #21
    Back to working on the Corrado.

    Machined down the crank pulley.                                Pulleys line up nice now.




     

    New Short Runner intake.







     

    VR6 TB


     

    SRI on motor.

     




     

     

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    09-29-2011 08:45 AM #22


    ^^ Nice progress man
    Quote Originally Posted by dogger View Post
    ... (Corrado) might be the greatest collection of bad VW ideas ever put into one car.
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    09-29-2011 10:28 AM #23
    Thanks man, still waiting for some guy to send me some dam timing belt covers! Been waiting on the canadian for two months.
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    11-13-2011 10:56 PM #24
    Got some updates for everyone following....
    Got the turbo, Precision 5857 .63a/r exhaust .70 a/r comp:




    Ceramic Coated Mani and Hot side:


    Turbo mounted up:



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    11-14-2011 07:59 AM #25
    Nice!!!

    Ceramic coated white - I would have never guess it
    Quote Originally Posted by dogger View Post
    ... (Corrado) might be the greatest collection of bad VW ideas ever put into one car.
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    11-14-2011 09:00 AM #26
    Quote Originally Posted by RedYellowWhite View Post
    Nice!!!

    Ceramic coated white - I would have never guess it
    haha, yeah i'm sure. Decided to go dark gray, like a gun metal color in the engine bay as well. Doing the factory corrado wheels in the same color. Brought them to work to sand blast them today. I'll throw some pictures up later...
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    11-14-2011 12:03 PM #27
    Nice work!
    -Joey

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    11-14-2011 02:02 PM #28
    wow looks really good!! i miss my G60.
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    11-14-2011 08:45 PM #29
    Nice work indeed, also nice selection on parts

    Question, where did you get that turbo manifold?
    Quote Originally Posted by crazynorweegian View Post
    Good luck, might want to get vaccinated for "while-I-am-in-there" syndrome.
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    11-14-2011 09:24 PM #30
    Looks similar to the cast ones they sell on eBay.

    Chad get one of these...

    http://www.ebay.com/itm/turbo-manifo...item3a618b4e97


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    11-14-2011 10:09 PM #31
    Quote Originally Posted by dogger View Post
    Looks similar to the cast ones they sell on eBay.

    Chad get one of these...

    It does look similar, but I haven't personally seen one with the wastegate flange located on the driver side... Seen those tubular mani's and not a fan, would locate the turbo too damn high IMHO, SPA mani's are doable, but...
    Quote Originally Posted by crazynorweegian View Post
    Good luck, might want to get vaccinated for "while-I-am-in-there" syndrome.
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    11-14-2011 10:17 PM #32
    Quote Originally Posted by Sr. Karmann View Post
    Nice work indeed, also nice selection on parts

    Question, where did you get that turbo manifold?
    It is an eBay one. If you keep an eye out you will find them occasionally with the wastage to the driver side. I'm sure you could get a little quicker spool time with an equal length mani. But I have my reasons for going cast.Main one was it cost under$50. And this was supposed to be a budget build for a daily driver.
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    11-14-2011 10:18 PM #33
    Quote Originally Posted by dogger View Post
    Looks similar to the cast ones they sell on eBay.

    Chad get one of these...

    http://www.ebay.com/itm/turbo-manifo...item3a618b4e97

    $700 is more than I paid for the turbo! Haha
    CHECK OUT MY BUILDS AT WWW.BUILDMYS4.COM
    2000 AUDI S4 RS6/54MM BILLET WHEELS
    1990 VW CORRADO ABA/16VT PRECISION 5857 .63 A/RCORRADO BUILD THREAD

  • Member Sr. Karmann's Avatar
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    11-14-2011 10:20 PM #34
    Quote Originally Posted by vwflygti View Post
    It is an eBay one. If you keep an eye out you will find them occasionally with the wastage to the driver side. I'm sure you could get a little quicker spool time with an equal length mani. But I have my reasons for going cast.Main one was it cost under$50. And this was supposed to be a budget build for a daily driver.
    Quote Originally Posted by crazynorweegian View Post
    Good luck, might want to get vaccinated for "while-I-am-in-there" syndrome.
    tek-euro.com SpoonFedTuning

    my Corrado's specs on corrado-database / My Corrado Build Thread / My Cabby Build Thread / My Boat Build: 18' Powerplay w/5.7l V8

  • Member Sr. Karmann's Avatar
    Join Date
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    91 Corrado 2.0l 16v on MS3X, Parked like Jurassic... 83 Cabby 1.8l 16v... 88 Powerplay XLT-185
    11-14-2011 10:30 PM #35
    Quote Originally Posted by vwflygti View Post
    $700 is more than I paid for the turbo! Haha
    Fosho, had to sell off my 5857 recently, but will be purchasing another one when the time comes, curious to see some #'s on your setup. What's your plan for engine management?
    Quote Originally Posted by crazynorweegian View Post
    Good luck, might want to get vaccinated for "while-I-am-in-there" syndrome.
    tek-euro.com SpoonFedTuning

    my Corrado's specs on corrado-database / My Corrado Build Thread / My Cabby Build Thread / My Boat Build: 18' Powerplay w/5.7l V8

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