30k Mile Build Thread...

[SLC4EVER]

Indeed. It is a complete 1-6 Gemini gearset and diff I am in the process of transferring over to the CDM cases.

[RedYellowWhite]

Gemini 6 speed setup? With matching diff?

Indeed. It is a complete 1-6 Gemini gearset and diff I am in the process of transferring over to the CDM cases.

^^ My goodness .....and

[SLC4EVER]

This had me worried at first...that lock washer is c-clipped as well as being splined on the ID and OD. It looked to be forced in place from the last assembly.



Being that replacement parts are extremely hard to come by, drilling was not an option.

So I had the shop make me a little puller and thread the washers in place. Worked well and saved me from busting a vein. LOL

[TheBurninator]

That is some scary looking spline damage!

[SLC4EVER]

Totally custom, unobtainium shaft bolts...



I looked into duplicating the washers and bolts prior to coming up with the puller.

[SLC4EVER]

That is some scary looking spline damage!

Yeah, thankfully they cleaned up well and were salvageable. Ya never know what ya got buying used until you really get in there.

[SLC4EVER]

Even the reverse idler is beef cake.

Stock vs. Gemini

[SLC4EVER]

Everything looks to have been pretty low mileage and not totally beat on...besides the lock washer. lol



I'm tempted to pull the races from the syncro cases and run them in the CDM. Obviously I would still need to check pre-loads.

[SLC4EVER]

[tachycardia]

Friggin bitchin!

Productivity in the water filtration design biz just hit an all-time low.

Powdercoater just called and asked if I could vouch for your mental health.

[SLC4EVER]

LMAO! I am working, I swear.

Seriously, this powder should be an interesting choice. I'll either love it or hate it and redo. Hopefully I don't don't opt for a redo.

[SLC4EVER]

Needed bracket for R32 a-arm swap. The R32 a-arm doesn't have a bung for the sway bar end link. The TT a-arm does, but it is also on the front of the a-arm. Corrado's are on the back of the a-arm.



This mounts to the bottom of the a-arm sandwiched under the ball joint nuts. (ball joint on top of a-arm, bracket underneath).

[iAco]

Pardon my ignorance, but whats the deal with this transmission set up? A quick google search says it's a VWMS gear box? What are the advantages to using this gear set?

[SLC4EVER]

Advantage for me is better drive out of a corner. It's a close ratio six speed. The 6th gear ratio for example is the same ratio as a CDM 5th. The 1st gear ratio is much taller than a CDM.

The other advantage is the whole assembly is much stronger than a OE VW assembly. Gear teeth have a stronger profile. They also are not swept like the OE teeth.

Going to have a little bit of a whine, but not too much that it becomes annoying like a dogbox would.

Still up in the air about which diff to use. Gemini plate diff, or Peloquin torsen diff.

[MikkiJayne]

Thats a nice trick with the sway bar bracket Does that mean you can run the alloy control arms?

[SLC4EVER]

Hahaha, trust me I thought about it. As far as I know though the alloy arms have a different rear bushing and mount all together. Would take pretty extensive fab work to the k-frame. Unless you know of a model that uses the same design, but in alloy? If anyone would know, you would.

[TheBurninator]

Hahaha, trust me I thought about it. As far as I know though the alloy arms have a different rear bushing and mount all together. Would take pretty extensive fab work to the k-frame. Unless you know of a model that uses the same design, but in alloy? If anyone would know, you would.

To my knowledge the TT's never had aluminum arms, they were just the standard cast pieces the R32's got

[SLC4EVER]

That was my understanding as well. I believe Mikki is referring to the Mk2 TT which is all alloy including the knuckles and subframe. It's a thing of beauty for sure. Common upgrade for the Mk6 GTI guys.

[TheBurninator]

That was my understanding as well. I believe Mikki is referring to the Mk2 TT which is all alloy including the knuckles and subframe. It's a thing of beauty for sure. Common upgrade for the Mk6 GTI guys.

Ah yes. That setup is more like the old vw mk1 arms. Much better design IMO. Allows for a proper pivot point.

[MikkiJayne]

Is that cast control arm steel then? Thats the piece I'm talking about, but I've seen one that looked like unpainted aluminium so I assumed they all were...

[SLC4EVER]

Yes, it is cast steel. Even so, it's not much heavier than the stock Corrado arm.

[MikkiJayne]

Now I can't find a single pic of an unpainted one It must have been a mk2 TT one I saw.

I'll get my coat

[SLC4EVER]

You got me all excited that an alloy version exists.

[TheBurninator]

Now I can't find a single pic of an unpainted one It must have been a mk2 TT one I saw.

I'll get my coat

That the arm you were thinking of?

[SLC4EVER]

Yummy.

[SLC4EVER]

Downloaded Gear Speed Calculator for my EVO. Not getting much done tonight. Sweet little app.

Trying to decide on a final drive. All stock VR, built for the twisties.

Choices are:

5.166
4.21
3.93
3.53

[MikkiJayne]

That the arm you were thinking of?

I don't think so. I've seen those before and knew about the different rear bush. I was absolutely convinced I'd seen an alloy arm that would fit the 'rado but with no sway mount. It must have been the steel one though, since I can't find any pics of anything else

[SLC4EVER]

"Tinker night" while i wait for things to show up.

Have a little twitch in your VR steering that you just can't pinpoint? Make sure the backlash in the rack and pinion is adjusted out.



Grabbing both sides of the rack and twisting it back and forth I could feel more play than I was comfortable with. Adjust the center bolt until the play goes away. It didn't take much, about a 1/8 max in my case. Re-grease the rack with a good grease and install new boots.

[sdezego]

I didn't realize you were going to get all crazy with a Gemini

I was originally thinking 30k including the car, but now I am thinking 30k + the car LOL

[SLC4EVER]

I didn't either!

Well, it was meant to be 30k miles build thread...now I'm not so sure. LOL

[SLC4EVER]

Use this wherever there is electrical contacts. I like to clean the contacts first with a clean copper or brass wire brush. Makes for very reliable contacts.



#1 location on the late interior....blower fan control switch.
#2 location on any VR Corrado...MAF connector.
#3 location on any Corrado...ignition switch.

[SLC4EVER]

Worked late...so I made some design changes.

Indexing retro-fit-able camber plates. I'll end up turning them 90 degrees and use them as caster plates.

[pileofredparts]

the gearbox got me interested

[yellowslc]

Vw calls for a special steering rack grease.. I still have some! Hit me up and I'll send it out.

[DUBZAK]

Choices are:

5.166 Out of Gear at 120?!?!?!?
4.21 Out of Gear like a Stock VR6 @ 147
3.93 My choice (Perfect Balance if the rest of the gearing is right)
3.53 Boosted yes, NA no.

What are the Stack Ratios?