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    Thread: Another Corrado TDI (finally!)

    1. Member MikkiJayne's Avatar
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      11-12-2007 03:48 PM #1
      Hi everyone,
      Well at long last my TDI conversion is finally under way (forced by the premature demise of my 16V).
      On Friday I took the old engine out and cleaned up the bay, and also took out the dash too. Everyone has seen empty engine bays before so no pics of that
      Most of Saturday was spent sorting out the wiring, as I'm using a Golf 3 donor, and the loom needs a fair bit of fiddling with to fit in the 'Rado. The whole lot was wrapped in convoluted trunking, so it's nice and clean and I can get in to it again if needed.
      The pedal box also needs modifying, as the TDI is drive-by-wire so the TDI pedal sensor was grafted on to the Corrado pedal assembly. Also the cruise control switches were fitted to the brake and clutch pedals:

      I also cleaned up and re-greased the TDI drive shafts (axles). As you can see they're considerably thicker than the 'toothpick' ones from the 16V. They're also nearly new

      I've done a load of other prep-work over the last month or two, but I forget what it all was
      So by Sunday morning this is what I had:



      First thing on Sunday the engine went in with my 'fitting engines for girls without big strong boys and/or an engine crane' method
      The car is on jacks and at it's normal ride height. The engine is on a 6" high trolley:

      Roll the engine in to the bay:

      It's now sitting higher than the mounts:

      Fit the front crossmember and jack the car up until the front mount just fits in place:

      Once thats in jack up the car and the engine will sit down on the rear mounts. Put the bolts in and take the trolley out. Nice and easy, no struggling, and no engine crane
      I got the driveshafts and fuel lines hooked up, new short-shifter installed, and a couple of ancillaries, then ran out of daylight
      Sunday lunchtime looked like this:

      Either I have waay too much crap on my drive, or I need a bigger driveway
      By the end of today the bay is virtually done, bar radiator and intercooler

      I'm waiting on powdercoated fron subframe and rad support so I'll finish that off when they arrive [IMG]http://*****************.com/smile/emthup.gif[/IMG]
      Wiring inside tomorrow, and hopefully I should get it fired up in a couple of days
      Mikki x
      Throw an Audi engineer down a hole with a ladder and he will fashion a shovel from it and tunnel his way out

      Quote Originally Posted by shwak23 View Post
      You could always call your insurance and say that some vandals tried to swap your car to rwd while you weren't looking.

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    3. 11-12-2007 03:54 PM #2
      wow. You don't waste any time whatsoever! Looks awesome [IMG]http://*****************.com/smile/emthup.gif[/IMG]

    4. Member UTdaneVW's Avatar
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      11-12-2007 03:59 PM #3
      I am so glad to see this project coming along. The world needs more TDI Rados on the road.
      This is definitely a project I envy and would love to take on myself someday.
      You better post a video when you get this running so we can all celebrate!

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    6. Member ThaCorradoKid's Avatar
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      11-12-2007 03:59 PM #4
      Looks really good. I must be doing something wrong when I clean a bay because they don't come out like that.

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      11-12-2007 04:05 PM #5
      i would KILL to have a girl locally that had 1. the mess in the driveway you have, and 2. the knowledge to make said mess.
      [IMG]http://*****************.com/smile/emthup.gif[/IMG] on the build!!!!!

    8. 11-12-2007 04:05 PM #6
      that engine bay looks alot cleaner than when i saw it
      nice garage

    9. 11-12-2007 04:07 PM #7
      wow your working quickly

    10. Member 1967ghia's Avatar
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      11-12-2007 04:18 PM #8
      WOW
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      "He who is trained in the taking of life, is better prepared to save one"

    11. Geriatric Member GS Audio's Avatar
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      11-12-2007 04:36 PM #9
      I have to see if someone can build me a TDI Rado.
      I feel soooo left out.
      Looking good so far!!

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    12. Member MikkiJayne's Avatar
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      11-12-2007 05:14 PM #10
      Quote, originally posted by GS Audio »
      I have to see if someone can build me a TDI Rado.

      I would but I'm a bit far away
      Thanks for the comments guys [IMG]http://*****************.com/smile/emthup.gif[/IMG] This would be done by now if it wasn't 2 degrees outside (35F) and dark at 4:30
      Some pics I forgot: diy short shift, design by Dennis @ the Corrado Club of Canada...

      Move the pivot point up by an inch, and move the notches on the stick up by an inch.

      Now the stick sits higher up you need a spacer to fill the gap. I replaced all the bushes and washers n stuff, including the black plastic sleeve so I made the spacer from the old sleeve.

      Here it is assembled. The cable attachment is in the same place, but the pivot point is moved upward by an inch.

      I replaced the lever on the shift tower too, so everything should be nice and accurate with no wobbles I'll report on how it works once I get it back on the road!
      Mikki x
      Throw an Audi engineer down a hole with a ladder and he will fashion a shovel from it and tunnel his way out

      Quote Originally Posted by shwak23 View Post
      You could always call your insurance and say that some vandals tried to swap your car to rwd while you weren't looking.

    13. 11-12-2007 10:07 PM #11
      WOW! you did the swap in one weekend nice work [IMG]http://*****************.com/smile/emthup.gif[/IMG]

    14. Member EnIgMa '06's Avatar
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      11-12-2007 10:17 PM #12
      NEED
      TO
      MARRY
      YOU

      TOMORROW

    15. Member 1broknrado's Avatar
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      11-12-2007 11:03 PM #13
      Quote, originally posted by EnIgMa ’06 »
      NEED
      TO
      MARRY
      YOU

      TOMORROW


      agreed. I'm 18 next year, then i can legally marry her
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    16. Member G60ING's Avatar
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      11-12-2007 11:20 PM #14
      looking good.
      But Bolting the engine in is the easy part.
      What are you doing for the fuel tank nozzel?
      I've given up on trying to use a VW airbox.
      keet up the good progress, I looked at my B4 TDI Corrado this weekend and sorted out a couple wires.


      Modified by G60ING at 11:22 PM 11-12-2007

    17. Member abt cup's Avatar
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      11-13-2007 01:41 AM #15
      Man...way cool! ! !
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    18. Member Evil Vr6's Avatar
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      11-13-2007 01:49 AM #16
      two [IMG]http://*****************.com/smile/emthup.gif[/IMG] [IMG]http://*****************.com/smile/emthup.gif[/IMG] [IMG]http://*****************.com/smile/emthup.gif[/IMG] [IMG]http://*****************.com/smile/emthup.gif[/IMG]
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    19. Member andylyco's Avatar
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      11-13-2007 12:01 PM #17
      Quote, originally posted by MikkiJayne »
      I also cleaned up and re-greased the TDI drive shafts (axles). As you can see they're considerably thicker than the 'toothpick' ones from the 16V. They're also nearly new

      Great progress! You probably already know this, but aren't the thicker axles hollow, and the thinner "toothpick" axles solid? I *think* that's how they are in the states. Anyone care to enlighten me?
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    20. 11-13-2007 12:06 PM #18
      Quote, originally posted by andylyco »
      Great progress! You probably already know this, but aren't the thicker axles hollow, and the thinner "toothpick" axles solid? I *think* that's how they are in the states. Anyone care to enlighten me?

      Correct
      But the hollow axel will hold more torsional twist than the solid piece

    21. Member MikkiJayne's Avatar
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      11-13-2007 12:14 PM #19
      Exactly [IMG]http://*****************.com/smile/emthup.gif[/IMG] I forget how the physics works on this, but a tube can take more torque than a rod.
      If anyone knows the science behind this.... you really should get out more!



      Modified by MikkiJayne at 5:36 PM 11-13-2007
      Throw an Audi engineer down a hole with a ladder and he will fashion a shovel from it and tunnel his way out

      Quote Originally Posted by shwak23 View Post
      You could always call your insurance and say that some vandals tried to swap your car to rwd while you weren't looking.

    22. Member G60ING's Avatar
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      11-13-2007 12:26 PM #20
      the passat ones are too long for the corrado.

    23. 11-13-2007 12:29 PM #21
      Quote, originally posted by G60ING »
      the passat ones are too long for the corrado.

      Plus suspension??

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      11-13-2007 12:30 PM #22
      Quote, originally posted by MikkiJayne »
      If anyone knows the science behind this.... you really should get out more!

      explained in a cycling blog, but the same physica apply. this guy has interesting comments....
      The strength of any particular cross-sectional shape can be described
      by quantity called the section modulus, which is kind of a combination
      of the amount of material and the distance away from the bending line
      - usually taken as the centre - of the section.
      If we take a typical rear axle the OD is pretty close to 0.4 inch. A
      hollow axle has an ID of pretty close to 0.2 inch - giving a tube or
      column with a wall thickness of almost 0.1 inch.
      Using these numbers:
      The solid axle will have a section modulus of 0.00627.
      The hollow axle will have a section modulus of 0.00588
      For front axles, which are around 0.35 OD, the numbers are:
      Solid - 0.00435
      Hollow - 0.00390
      Now, of course, these figures mean that a solid axle is stronger.
      There are other factors which affect the strength of axles, of course;
      the choice of material, the heat treatment, the surface finish,
      etcetera.
      A particular effect which cannot be eliminated from hollow axles is
      that of the roughness of the inside surface of the hole. Solid axles,
      of course, do not have this, and so also do not suffer from the chance
      that a crack may start at an irregularity on the inner surface. Cycle
      axles of the highest prices (and, the buyer may sometimes presume, the
      highest quality) are finished very well on the outside surface; but
      the inside is a hidden quantity, difficult to finish and inspect.
      In the real world of cycling, there are axles made from different
      material and to different qualities. Of course it is possible to find
      a particular hollow axle which may be stronger than another particular
      solid axle - but to claim in abstract that a hollow axle is stronger
      (or even no weaker than) than a solid one is clearly wrong

    25. Member MikkiJayne's Avatar
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      11-13-2007 12:37 PM #23
      Quote, originally posted by G60ING »
      the passat ones are too long for the corrado.

      Mine is an A3 Golf donor
      About the filler neck: not sure how it works in the US, but in the UK before unleaded all pump nozzles were the same size (gas and diesel). When we got unleaded we got the smaller nozzle, and cars with cats got the smaller filler neck. Luckily for me the Corrado 16V was meant to run on leaded gas (as it was higher octane), therefore has the larger filler neck that will take a diesel nozzle
      I'm keeping the in-tank pump too since thats only a low pressure one and will help when I put the modded engine in [IMG]http://*****************.com/smile/emthup.gif[/IMG]
      So, progress today...
      I spent most of the morning adapting a mk3 Golf aftermarket aircon unit to fit the Corrado. I swapped the mk3 control box for the Corrado, and then had to tinker for an hour or two to get the fan and evaporator section to fit, as although the Golf unit is similar to the C it's not quite the same

      I've not got any of the rest of the system fitted yet, but I thought while the dash was out I might as well put the airbox in. I can finish the rest later [IMG]http://*****************.com/smile/emthup.gif[/IMG]
      Put the rest of the water pipes on, and fitted the G60 intercooler:


      Oh, and I put the wheels back on
      Not much visible progress today - mostly tinkering with things, changing fluids, stuff like that, but I got a lot of little jobs done [IMG]http://*****************.com/smile/emthup.gif[/IMG]
      Electrics tomorrow
      Mikki x
      Throw an Audi engineer down a hole with a ladder and he will fashion a shovel from it and tunnel his way out

      Quote Originally Posted by shwak23 View Post
      You could always call your insurance and say that some vandals tried to swap your car to rwd while you weren't looking.

    26. Member MikkiJayne's Avatar
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      11-13-2007 12:40 PM #24
      Quote, originally posted by mikemcnair »
      explained in a cycling blog, but the same physica apply. this guy has interesting comments....
      <snip>
      Of course it is possible to find
      a particular hollow axle which may be stronger than another particular
      solid axle - but to claim in abstract that a hollow axle is stronger
      (or even no weaker than) than a solid one is clearly wrong

      Interesting. Thats the complete opposite of how I understood it to work
      Throw an Audi engineer down a hole with a ladder and he will fashion a shovel from it and tunnel his way out

      Quote Originally Posted by shwak23 View Post
      You could always call your insurance and say that some vandals tried to swap your car to rwd while you weren't looking.

    27. Member Snowhere's Avatar
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      11-13-2007 12:40 PM #25
      Quote, originally posted by MikkiJayne &raquo;
      Exactly [IMG]http://*****************.com/smile/emthup.gif[/IMG] I forget how the physics works on this, but a tube can take more torque than a rod.
      If anyone knows the science behind this.... you really should get out more!

      Sorry MikkiJayne, but some of us do engineering for a living! But I can always relax from the stress of work by tinkering in my garage!

      Quote Originally Posted by rice is burning View Post
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