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UK Corrado G60 - E-Level Slow Build - Too many pics...

35K views 113 replies 26 participants last post by  RILEY UK 
#1 · (Edited)
Thought I may as well start a thread on my air ride install. It's a slow burner because I rarely get any free time with work :thumbdown: But at least it should hopefully turn out ok, Hope so anyway! Sick of coilovers! :thumbup:

Also posted on the Vw Corrado G60 Forum

Check the links in my sig to see the Corrado in question.

Have spent a lot of time struggling to come up with a way to mount everything so that I can still have decent space and still use the spare wheel, I never actually run the pare in the car but I tend to throw it in there for MOT.

Anyway, here's all the toys :thumbup: Ill apologise in advance for all the pics, I always tend to take plenty incase others see something they wanna ask about etc...





















Can see the digital gauge I also bought here, bagriders sent me the wrong one, it was supposed to be black but it's alloy/silver. :thumbdown:






That's all the kit, but I also picked up a VDO pressure gauge too. :thumbup:


Onto the build! I was having real problems with the skinny 5gallon tank, tried various ways but just wasn't happy with it.:thumbdown:


So I picked up a chubby 5gallon to replace it :thumbup: Can see an early template here too. Shame that bagriders sent me the totally wrong tank, it doesn't even have a damn drain port and they have done NOTHING to sort this out. :thumbdown:



Always start with cardboard:laugh:


Then cut out some wood.




And cut out some more!


Test fitting...again, and again and again...






And that's all I've managed so far...I'll try and update when I can.

Neil.
 
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#53 · (Edited)
I do like the detail:p

Picked up some gold plated battery terminals so I know the power supply will all be clean. And my Vw door push knobs turned up too! They are basically screw head caps/covers measuring 25mm across.



Fitted! Love em. Excuse all the dust/bits of wood on the paintwork!

 
#57 ·
Thanks mate:thumbup:Have got some black screw caps for the screws (Bottom left of pic) :thumbup:

Still awaiting hearing back on some fittings to finish it all off! :( But I went crazy and bought some new wheels today after a supposed wheel specialist ruined my beautiful Borbet A's that I've had from new. :(

 
#59 ·
Well not much done due to having the bad news that my Auntie passed away yesterday :-( Always feel kinda numb when someone passes away, hate how you just have to somehow carry on...My head wasn't really on it today but I dynamatted the compressor box section and carpeted a little bit.

Not sure if the dynamatt is a good idea or not noise wise, obviously planning to put acoustic cloth over the top too. First time using the dynamatt, it's weird stuff, got the hang of it I think.



 
#63 · (Edited)
Ahh well, I actually thought it was for noise enhancement for car audio, was thinking any compressor noise would be forced to the boot/trunk away from the passenger area. Oh well...lol.

Haven't managed to touch anything else really. So a pic or two on the Borbet A's that a wheel refurb company have ruined (My fave wheel of all time!) and on the new wheels (For now anyway) Borbet B.







 
#64 ·
OK so my PODI gauge wasn't working, not lighting up at all when powered but I split it open just now and had a look. Couldn't really see anything obvious so I just resoldered the wiring pictured.



It now lights up! But does this actually say FAIL!? :confused: Have I knackered the gauge!? :( I tried to be really careful because my soldering iron is a very high wattage one, but it looks like I may have melted/killed a resistor or something?

 
#68 ·
Well I'm still awaiting some fittings... :( I've struggled for time etc of late anyway.

Love the progress mate :)
I'm only down the road from you too, would love to see this and take some pics once it's done :thumbup:

Love those 'B's btw, which company wrecked the others? Bad news bud
Cheers mate. It was TWS as Manchester. I just can't seem to find ANYBODY that is good at their job these days, no matter the industry they are in. Hence I very rarely have anybody else touch the car. Everywhere I take the wheels, people are pulling their faces about doing them, I'll probably just do them myself again so I know they are done right. Just time issues really.
 
#69 ·
Well I've been really busy with other things so haven't really done anything.

All I did manage recently/today was to apply sealant to all the tank/compressor fittings, run a couple pieces of air line. And then I loosely connected the VDO pressure gauge, and hooked the box/tank up to the car via some jump leads. Ran the compressor and filled the tank up to 150psi.

Have left it now to see what the pressure is tomorrow. Hopefully it's somewhere still near the 150. Couldn't hear any leaks but we will see.

 
#71 ·
Well I found one leak. It's the join between two fittings just before the water trap.

Here's what all the leak free joints look like...


And in comparison, the leaky joint...Red is the leak point. Blue is ok.


So I've re applied some fresh sealant after cleaning off the old, and refitted. I filled back up to 150psi and I've left it again to see what the pressure is tomorrow. I'm not really too happy with the way I've mounted the water trap to the tank. Reducer from trap > 90deg > reducer into tank, it's all a bit tight so I may pick up two more of the numatics 90deg swivel elbows and run some air line between them.
 
#72 ·
OK guys, after 25 hours, the pressure has dropped from 150psi to 130psi.

Is this kind of drop normal? Bad? Or should I be aiming for totally leak free before I get it all in the car? I'd like to think so?

I only managed a quick look today and couldn't actually tell where any pressure was being lost :confused:
 
#73 · (Edited)
Hoping somebody can help out a UK guy here :thumbup: Needing these exact fittings pretty desperately! :thumbup:

I need the following:
3X Numatics 90deg swivel elbows - 3/8 NPT Male X 3/8 PTC.
1X Numatics Straight - 3/8 NPT X 3/8 PTC.

EDIT: Never mind, sorted via https://www.newmaticsinc.com/ !:thumbup:
 
#74 ·
After a torrid time with my ex not letting me see the kids etc, I'm back on it.

Near enough completed all the wiring, just the sensor wiring to run to each corner, and then connect everything up.

Managed some better fittings for the water trap, and also new ones (below red box, not pictured) for the compressor. Did a test again roughly over 20/24 hours and only dropped 5psi. But i'd had the little black pipes in and out a good few times so some fresh pipe once fitted may sort that as it's the only place I found a very slight leak.

Also fitted the rear shocks and ran the rear air lines. I ran them through the boot/trunk floor via the abs wiring grommets, and along the rear beam at each side. Jesus christ it sits low! It's sat on the tyres so I guess it's as low as it can be!

 
#76 ·
Thanks:thumbup:

Been a bit lazy with pics lately, so...

Fittings added to struts.


Greased up the anodized parts, and the body. This method has kept my old konigsports mint. May get pics later.


New top mounts added all around.


E-Level sensor wires, cut and tinned up with solder. Cutting them means you can route them through grommets/holes easily as the plug tends to be too big. It also allows you to shorten the wire if you want to do that.


Finsihed up with heat shrink, and then I taped them up nice and tight with no creases (Because I'm down like that). This soldered/taped joint will be inside the car.


Struts fitted. Air lines and e-level sensor wires have been run through. I'll try and get pics of the routing later.
 
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