Project Corrado

[Leeboy]

Some will know that I have/had a VW Corrado which I have previously spent effort on overhauling the engine bay. I was selling it last year and finally a mate at work brought it just before Christmas 2007. However a week later, the ignition switch ceased to work so he had to have it repaired much to his bemusement. Then worse still, early January the clutch disintegrated. In the end I brought it back had it towed to JKM to be fitted with a new clutch and came to the conclusion that I was not meant to sell it .

So after a bit of a break and the prospect of warmer weather, Project Corrado is underway. My first intention was a track day car, full stripped, plexiglass windows, roll cage throttle bodies etc, but this was going to be too expensive. And besides it wouldn’t be worth much in the long run, so instead it has become a restoration project.

So what needs doing or has been done already?

The car has done 179.5K miles but still runs nicely and happily produces its full factory power quota (as determined at JKM’s rolling road). Gearbox is losing its hold over first gear synchro but I can live with this for the time being.

Previously the engine overhaul included new head gasket, fuelling bits, coolant pipes, lots of other bits and pieces plus a damn good clean up and paint.

Outside, things could be better. Initially when I got the car, a set of clear and red tail lights were installed – much better than the originals particularly for a dark coloured car, oh and I splashed out on some new original fog lights as these were completely shot. Otherwise the body work is original and as ever with Corrados, it seems to have attracted more than its fair share of stone chips, scrapes and dents. There is also a bit of a rust problem with the rear panel.

The interior had a steam clean and this did wonders. There are a few small fag burns here and their and the drivers seat bolsters are a little tired, but otherwise it is very good for the miles.

So here are a few pics of the exterior, interior and engine as is:

From the front – note a bit of a dent on the bonnet front edge and wing


From behind with the new crystal lights


In the boot plus the rusty bit, I’ve established that rear panels are still available from VW at a price of £374 inc VAT !


Then to the interior
Interior dash and very polished steering wheel!






Then to the engine which has previously had attention (still leaks a bit of oil from the crank case breather and cam seal:






And so for the first significant task – the front suspension, I’m going to drop the front subframe, replace control arms, roll bar, callipers etc using new rubbers throughout. So bits are coming off already.


I have no significant automotive experience so this could get interesting at times. Expect this project to be atleast a couple of years in the making, so check back for regular up dates!

[Lummox]

Keeping an eye on this one.

Those hubs and brakes I had would have been perfect for you.

[VRStu]

Engine bay looks sweet Lee.

I do have a little soft spot for the Corrado although never got to own one.

[Tom_vRS]

Nice wee project - the 16v being very underrated imho!

I too have a serious softspot for them - would love a blown VR6!

[TeflonTom]

Originally Posted by Leeboy

I have no significant automotive experience so this could get interesting at times.

you'll be fine nice little project you have there.

if you get really stuck with anything give me a shout, i'd be happy to lend a hand

[Leeboy]

Bit of an update on progress.

Pending the purchase on an 18mm socket (I'm finding I need to buy appropriate tools as I go along , this size needed to release the main bolts holding the subframe to the body), the front sub-frame complete with steering rack, track control arms, hubs, drive shafts, roll bar etc should (fingers crossed) be removed this weekend. All necessary bits have been parted from their neighbours as required, however I hope the steering rack easily parts company from end of the column - I've removed the pitch bolt and will get a screwdriver in the clamp to spread it a bit. Other than that, fingers crossed my make shift engine support does the job (though I've got a jack and block under the sump to take a bit of the weight!)

Once this assembly is off, it will be stripped with the subframe painted up nice and shiney - I have thought about getting it shot blasted and powder coated, but it isn't in too bad a condition so maybe a bit of a paint with a brush and then sand back and cut 'n' polish up would allow better future use of money.

Before this goes back in, I have decided that the engine can come out next (after all it is now only a case of drain the cooling system, remove the radiator and front slam panel, followed by unplugging of electrics and release the front engine mount. Only problem I have is that I have no hoist to lift out the engine, though I can buy one from Machine Mart from £70 - unless anyone on the south coast has one they can lend out for a little while!

Will get more pics up once the sub-frame drops out.

[Hedge]

Not wishing to drag this off topic at all but 18mm sockets are a bit like hens teeth.
It's the same size as the nut inside a TFSI fuel pump.

[TeflonTom]

Originally Posted by Leeboy

I have no hoist to lift out the engine, though I can buy one from Machine Mart from £70 - unless anyone on the south coast has one they can lend out for a little while

i've got one.... have you got a van??? actually it might fit in the back of the felicia

[Leeboy]

Originally Posted by Hedge

Not wishing to drag this off topic at all but 18mm sockets are a bit like hens teeth.

Quite, unless you go for a bit tool set, most socket sets jump from 17 to 19mm missing the size required in this case. Anyhow, socket now secured - the village where I work has one of those good old fashioned hardware stores where you can pretty much buy everything and anything!

[Leeboy]

Originally Posted by TeflonTom

i've got one.... have you got a van??? actually it might fit in the back of the felicia

No van, a Superb with non folding rear seats isn't going to help. I could borrow my other half's Fabia with the seats down, if your hoist folds flat? Perhaps looking to borrow it in a month or two if available. Thanks kindly for the offer, particularly as engine hoists are twice the price I originally assumed - the price I was thinking of was more in line of that for an engine stand.

[cheezemonkhai]

Originally Posted by Hedge

Not wishing to drag this off topic at all but 18mm sockets are a bit like hens teeth.
It's the same size as the nut inside a TFSI fuel pump.

Halfords sell them as part of their professional range.

I've got a 1/2" drive 18mm socket.

[TeflonTom]

Originally Posted by Leeboy

if your hoist folds flat? Perhaps looking to borrow it in a month or two if available.

yes it folds up, i'll measure it to see if it fits in the felicia... after all i dont care if i ruin the interior anyway

in a month or two is fine, i'm going to be using it next week tho for some reason so any time after that is ok

[gadgetman]

I idlised the VR6 corrado in college.

Spring yellow was such a fitting colour. Love the green on yours tho!

[Lummox]

Sounds cool.

But one thing to point out (you probably know already). If you have the subframe off there isnt anything holding the engine in anyhow.

[TeflonTom]

Originally Posted by Lummox

Sounds cool.

But one thing to point out (you probably know already). If you have the subframe off there isnt anything holding the engine in anyhow.

i was thinking exactly the same thing

[Leeboy]

Originally Posted by Lummox

Sounds cool.

But one thing to point out (you probably know already). If you have the subframe off there isnt anything holding the engine in anyhow.

Don't be too alarmed, engine/gear box supported from above with a home made support resting on a couple of wooden blocks resting on the inner wing runners.

You'll be glad to hear that the complete subframe assembly came off with no issues, although even with a 24" breaker bar, the N/S rear track control arm that goes right through to the chassis rails did prove rather stubbon!

[Lummox]

I thought you would have constructed something to hold the engine up

[Leeboy]

As suggested, subframe now removed and as of this evening dismantled. Photo prior to spannering apart:

[GarryC]

Looks good mate

Im helping a mate do a Corrado Project also. Started life as a G60 but now running a GT30 Turbo, 1.9 but still 8V, although they are dinner plates, lol. Been off the road for 2 years now but should be running this friday. The Emerald ECU landed today which will help, lol.

Wicked car mate. Looking forward to seeing it progres.

Regards

Garry

[AndyG_1979]

Much to the annoyance of SWMBO this thread had made me start trawling Auto Trader

Always wanted one of these but could never afford it so ended up with an XR2i many years ago..

Keep up the good work