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

[RILEY UK]

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.

[RILEY UK]

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

[RILEY UK]

Hoping somebody can help out a UK guy here Needing these exact fittings pretty desperately!

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/ !

[RILEY UK]

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!

[baldone]

nice

[RILEY UK]

Thanks

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.

[RILEY UK]

Two abs wire grommets under rear seat, air lines and sensor wires run through.





Where the rear air lines and sensor wires run.



The rear strut side of things.



Fitted the build/boxing into the boot and started wiring things up!

[baldone]

[peter139]

nice build, i like your pics

[RILEY UK]

Test run video!

Clicky here! or watch below.

[RILEY UK]

Guys I've got a little issue. I left the car aired up yesterday, but when I got here today the rear was on the floor, dropped.

I aired up again to try it and its slowly gone down again!?

Can anyone advise?


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Sent from iPhone 4S via Tapatalk while on the crapper

[RILEY UK]

Another update, feel like I'm getting somewhere properly now!

Firstly, my digi pressure gauge now works when I hooked it up to the sender. Looks good as well!I think I'll paint the bezel black though, not sure yet.

I also tightened down the rear shocks properly, refitted all the rear 1/4 panels, rear speaker shelves, door sill trims, under dash pieces and hooked up the ignition live properly from the ecu to the fuse box.

And...Well, I found two good candidates for most...maybe all of the leak on the two rear struts.

Two lines on the right are feeding the front struts, the two on the left, feeding the rear. I've just recut them and refitted but couldn't test as my bloody battery went flat!

[RILEY UK]

The leaks are fixed! Just a very slight one on one of the front strut feeds which I'll sort out next time I'm up there.

I've started making a mount for the touchpad controller. Here's my old set up that I made a good while ago now...











So I picked up a spare center console, and I just trimmed a liitle plastic around the cig lighter mount and made up a piece to go in there covering the ashtray/cig lighter area.

I'm gonna end up needing yet another VDO gauge lol. But I have a 'bit of a thing for them' anyway and I've got some new options to go in the car (when I dig them out) (VDO EGT and VDO Intake temp) Not sure what config I'll go for just yet.

[RILEY UK]

Bit more done, Think I'm decided on this layout. Excuse the wobblyness, My compressor decided to stop working so I had no hole saw/drill. So I had to use a screwdriver to bore through the wood, and then a file!

[RILEY UK]

Little bit more...I tied the e-level sensors out of the way so I can get an MOT test, then I'll fit them later. Double checked all bolts etc and also carried on with the center console a bit.

Made a little bracket on the panel and cut out a notch at the top so I can pop it out easily.



Then covered. Only roughly cut in this pic!


Also picked up/fitted some new spigot rings. And then I actually drove it outside! to have a tidy up. Bloody stupidly low! I'm just happy it goes high enough really! The rear is sat on the tyres. And the front is sat on the track rods! (Goes lower again with the sebrings on) Crazy!

[madone]

Nice work, loving the Corrado, but seeing your RHD G60 is making me miss the UK, hopefully my RHD mk1 will be out of customs soon!!

[RILEY UK]

Ha, and here's me who would love to get OUT of the UK. Crap hole man.

Pretty pissed off man. Used some low tack masking tape around all of my vdo gauge faces to protect them from chipping while refitting the air ride controller, only to have it pull the frigging black paint off when removed. I've bought all these brand new and tried my best to keep em mint :-( Anyway...

I've also misplaced a new EGT gauge, just can not find it anywhere! So to fill a gap I fitted an outside temp gauge (Top left) that I had tucked away but I don't like it as it uses a different bloody bulb type and doesn't match!

The e-level touchpad brightness with ignition on and also headlights on can be adjusted by the way.

Not sure I actually like this now I've done it :-/

[RILEY UK]

It's been a while because I had a knackered rear caliper carrier so decided to upgrade to Mk4 rear brakes!

:doh: :roll: :lol:

I've just (Nearly finished) fitting the Mk4 golf calipers on the rear.
I went for:
New Handbrake cables.
New Corrado Carriers.
New Mk4 Golf calipers.
New brake pads.
New greenstuff front pads for the hell of it.
Banjo bolts.
Conversion stainless braided hoses with clear covers from on here.
And some Halfords red brake caliper paint lol. Thought I'd try something different to the hammerite I've always used before.

I've done a massive/comprehensive guide on Volksdevil here too.

New Carriers, Calipers, Handbrake cables.


Halfords brake caliper paint, cleaner/degreaser etc.


New carrier bolts, banjo bolts etc.


Conversion hoses, from on here, very nice.


Masked up all the bits where the pads will sit on the carriers (Then copper greased the masked areas), masked bits on actual calipers. Then painted and all fitted up.



The finish on the carriers was a bit rough cast unfortunately, hence a crap finish, but they will do.



And a pic fitted up from the guide I've done.

[VWBugman00]

Looks fantastic Riley! Nice work on this car. This is by far my favorite older VW. Glad to see it's getting some proper love.

[RILEY UK]

Thanks for the kind words, appreciate it

Not much managed today, just went around torquing up bolts etc and fitted spome new greenstuff pads. Should be nearly ready to complete the air ride stuff pretty soon!

[RILEY UK]

Finally got the boot build back together and near enough finished after having to dismantle it all to sort other issues.

Crap pics for now...Neons, custom led boot lights, cig lighter torch all lit up, powered up and working. All lighting goes off when the boot lid closes.

Digi volt gauge and compressor compartment temp gauge both working good. Tank pressure gauge working good.

Just need to fit some perspex in the two compartments, fit my black screw head covers, and fit my Vw badge door handles on the side compartments.







Whoops, forgot my silly crap video!

[RILEY UK]

Really can't wait to get it back on the road, just awaiting a door handle repair piece, then give the brakes a quick check over and off for MOT hopefully!

Pulled it out again today after popping on the brand spanker center caps, forgot to put the 'Borbet' stickers on them though! I can't wait to get some proper pics of it all cleaned up again, rather than dark iphone pics but I just can't help meself lol.









Boot build...

[RILEY UK]

Well I've driven it home/about a bit, although I've only just received the door handle repair piece for the MOT which I still need. Having issues getting into my unit for my tools though as the leccy steel shutter door has thrown a wobbler and won't let me in!


First thoughts from the little driving I've done...
The rebound of the suspension feels just like the konigsports did when they were new, the damping feels slightly on the softer side than the konigsports were. Basically when I saw somebody once type "Riding on air is like riding on pillows from God" Well, I'd agree with that! Very nice!


So anyway, I'm still awaiting an MOT yet before I can get a proper drive and proper pics etc. In the mean time, my kids have either become very strong...Or I'm three wheelin lol. Crazy, it can lift either rear wheel off the ground!

[Blue MK2]

Lovely looking corrado. Excellent work!

[RILEY UK]

Thanks mate!


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Sent from iPhone 4S via Tapatalk while on the crapper

[RILEY UK]

Thanks mate.


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Sent from iPhone 4S via Tapatalk while on the crapper

[RILEY UK]

Few pics from today via instagram. Next job is to get the e-level height sensors fitted, can't wait to have presets so I can properly adjust heights while on the move!

[OVRWRKD]

Perfectly done corrado my friend, well done

[RILEY UK]

Thanks man! I have a full build thread over the last 8 years at: http://www.volksdevil.com/viewtopic.php?f=6&t=149 for anyone interested.

I managed a couple shots of the boot build from inside today. Still to tidy gauge wiring (Red box in pic) and also power etc.

Nice easy access to everything though by either folding both seats or just one at each side.

[oldskoolg60]

looking good there mate

[CULVER]

very cool build!

[RILEY UK]

Cheers lads, still to fit the level sensors yet! Just can't seem to find the time!

Well anyway, I thought I'd go for some 'Vw' center cap stickers rather than the 'Borbet' stickers. Look really good in person.

[bkby69]

pm sent

once again,thanks for the quick response and the info

[RILEY UK]

No worries man, happy to help

Pics from the works website, and in the snow!

[g-rocco60]

if you don't mind me asking how you mounted your elevel sensors at each bag ? thanks