[Classy]

Right about time I started a build thread seeing as it's all starting to kick off over here!

So... I'm a 20yr old third year apprentice at MB and decided to have a dig at this 20v conversion thing. Bought a 20v AMK S3 lump, complete with loom, ECU & pedal last weekend, and so the fun begins.....

A bit of history to start with... it's a 1990 1.8 8v. I bought the car off an older couple (2 years ago) who had owned it 9 years, car had 83,000 on the clock was in pretty much immaculate condition.

http://img.photobucket.com/albums/v509/crisp19888/PICT3471.jpg
http://img.photobucket.com/albums/v509/crisp19888/PICT3474.jpg
http://img.photobucket.com/albums/v509/crisp19888/PICT3473.jpg

When I got it home, decided to sort out the bodywork. It had the standard rust around the windscreen, someone had done a smart repair on the N/S rear quarter, there was a bit of rust on the tailgate also. Had it booked into the body-shop where a few quid later the rust around the screen had been sorted, with spare wiper hole smoothed, roof painted, rear quarter painted, tailgate 'frenched' & rear badges smoothed. All in all, body is now rust free and pretty tidy :)

http://img.photobucket.com/albums/v509/crisp19888/PICT3835.jpg
http://img.photobucket.com/albums/v509/crisp19888/PICT3837.jpg

Started to strip the car out a little, just un-necessary digging really, looking for more rust problems. Mainly rust on the floor pan etc. All was fine asides copious amounts of water. This started a rampage on sorting every leak out on the car, which was insane. I'm pretty sure the Mk2 is 100% waterproof now, as all the screens have been sealed, grommets replaced, light gaskets silicone sealed. Pretty much everything.

That stemmed off to something else... Because of the water ingress, all the soundproofing had become rotten and damaged & didn't really fancy putting back in the car. So I started looking at soundproofing. (During this, I replaced the exhaust as it was blowing, fitted a Jetex catback). Driving 16 miles on the motorway every day in a bare metal shell with an after-market exhaust system really spurred on the search for more soundproofing to!

Found a company in the states after mucho research called RAAMmat. Ended up purchasing 125sq ft of the butyl based soundproofing & 7 yards of ensolite (closed foam). Fitted this everywhere apart from the bulkhead and the roof! Also spent 8quid on some carpet underlay, as despite the soundproofing, the trim needed a little bit of padding out to stop rattles etc. Also wrapped the ensolite in polythene for inside the door so it doesn't act like a sponge!

http://img.photobucket.com/albums/v509/crisp19888/DSC00001.jpg
http://img.photobucket.com/albums/v509/crisp19888/DSC00292.jpg
http://img.photobucket.com/albums/v509/crisp19888/DSC00277.jpg
http://img.photobucket.com/albums/v509/crisp19888/DSC00289.jpg
http://img.photobucket.com/albums/v509/crisp19888/DSC00268.jpg
http://img.photobucket.com/albums/v509/crisp19888/DSC00263.jpg

Before I finished the soundproofing, I took the car off the road to save for 'minor' improvements :P. That was last March, in the meantime I've been driving (shamefully) in a 1.1 Rover metro :( - still it's been a cracking motor for £180!

This brings me up to the present day. Saturday I began to strip the Mk2. I have until December time this year, that's when the insurance renewal is up and want to be driving it then so I'll be taking it steady and trying to enjoy it on the weekends. Sort of lost motivation before, sure a lot of guys in the trade get sick of the sight of cars!

http://img.photobucket.com/albums/v509/crisp19888/DSC00084-1.jpg
Dirty scruffy 8v engine. Eating & leaking coolant, tappets are completely foobar'd. Anyone want this when its out? Still good working parts on it. Coil, alternator (had new reg) etc etc.. let me know.

http://img.photobucket.com/albums/v509/crisp19888/DSC00085.jpg
The engine, and workplace... tiny garage lol ONE plug socket ONE light... nightmare haha. All part of the fun though eh!?

http://img.photobucket.com/albums/v509/crisp19888/DSC00097.jpg
Tools for working. Small selection of work tools I ferry to and from, but couldn't be doing with carrying millions of sockets so just bought the Halfords set. Very nice for the money :)

http://img.photobucket.com/albums/v509/crisp19888/DSC00098.jpg
After day one, quite a slow day spent most of it sorting the space out so I create enough room to store parts coming off the car and actually be able to move! managed to get all the cables & loom disconnected from the car to body, front end loose ready for removal. Next step will be to take off the box, and remove the engine. Actually quite interesting to work on, nothing like modern day mercs :)

So that's all for now :) End goal is to get the engine in and running on OEM management at about 280bhp. Car needs fully upgrading, so wheels, suspension (complete), brakes, audio the whole sha-bang. Everything I'll be doing myself asides any body work so should be a interesting build with a decent result :)

Chris B)

This post has been edited by Classy: 04 February 2009 - 12:18 AM

[Jack Bauer]

Looks like a good clean car for a basis to start from. Look forward to this devloping :D B)

[volksbretta]

nice work B)

[Jimmy Oldskoolâ„¢]

I love Tornado red mk2's, I'll be watching the progress on this........ B)

Also, how much did the sounproofing cost you mate???

[H4YBOâ„¢]

Nice project, will keep track of it!!

[Classy]

Jimmy Oldskool, on 1st Feb 2009, 11:24 PM, said:

I love Tornado red mk2's, I'll be watching the progress on this........ B)

Also, how much did the sounproofing cost you mate???

The actual cost of the soundproofing was about £240 including shipping. I also got stung for import tax, so add another £50.
Still an absolute bargain in comparison to dynamat & second skin and had enough to go over most problem areas twice.

[Jimmy Oldskoolâ„¢]

Classy, on 2nd Feb 2009, 12:08 AM, said:

The actual cost of the soundproofing was about £240 including shipping. I also got stung for import tax, so add another £50.
Still an absolute bargain in comparison to dynamat & second skin and had enough to go over most problem areas twice.

Wouldn't have a link to where you got it from would you???

[Classy]

http://www.raamaudio...i-bin/index.cgi

Speak to Rick the owner. Probably one of the best customer services I've ever encounted, very helpful & friendly bloke. Even gave me a bit of discount because of shipping costs!

[1990G60]

Very nice looking car chris!
I cannot wait to see how this turns out!
your really making me want to move across the pond so i can see in person
-Tim

[Classy]

Cheers Tim.

Maybe one day you can pop over for a butchers & a pint :) How's the Mk2 VR going?

[goodridge]

Will keep an eye on this mate, got anymore questions just shout

John

[1990G60]

Classy, on 4th Feb 2009, 02:45 PM, said:

Cheers Tim.

Maybe one day you can pop over for a butchers & a pint :) How's the Mk2 VR going?

Actually its kind of a sad deal with my MK2. The title for it got quite messed up from the Previous owner. i ended up selling the car and hitching a ride with zack for a few weeks until i could find something i could afford. Between school and no one co-signing a loan for me i picked up a 1990 Corrado G60. The car is in VERY good shape. no rust, and the best part was the price. i got it for 1300 because it had some problems.

I spent 50 bucks on Neuspeed spark plug wires, new iridium spark plugs, disty cap and rotor and a used ISV. car runs awesome and holds boost. im getting some coilovers for it next week and doing a complete brake job.

I'm kind of glad that i sold my mk2, i hated driving it in the salt cause it was the cleanest one around. but i had everything lined up to do the swap so it's kind of a bummer.

I could actually take a trip over there this summer. i'll have some down time and some extra cash. I bet the beer over there is quite good :)

This post has been edited by 1990G60: 05 February 2009 - 12:51 AM

[Nam]

good work mate, look forwards o seeing it done

[Classy]

1990G60, on 5th Feb 2009, 12:50 AM, said:

Actually its kind of a sad deal with my MK2. The title for it got quite messed up from the Previous owner. i ended up selling the car and hitching a ride with zack for a few weeks until i could find something i could afford. Between school and no one co-signing a loan for me i picked up a 1990 Corrado G60. The car is in VERY good shape. no rust, and the best part was the price. i got it for 1300 because it had some problems.

I spent 50 bucks on Neuspeed spark plug wires, new iridium spark plugs, disty cap and rotor and a used ISV. car runs awesome and holds boost. im getting some coilovers for it next week and doing a complete brake job.

I'm kind of glad that i sold my mk2, i hated driving it in the salt cause it was the cleanest one around. but i had everything lined up to do the swap so it's kind of a bummer.

I could actually take a trip over there this summer. i'll have some down time and some extra cash. I bet the beer over there is quite good :)

What do you mean the 'title'?

Bad news anyway, still - if you've still got the engine around you could re-build it maybe do something a bit special, take advantage while it's outta the car & find another shell for it to go in? Dad's got a big enough garage either way! Has he still got that race car?

Still Corrados are nice. Assuming the G-lader says faithful to you then they can make some good power with increased boost.

Ta for comments guys. Hopefully should have a big update at the weekend. Wanna buy an engine stand for the 1.8t start stripping that, replacing gaskets/belts & checking the condition the engine. Hopefully will have the old 8v out and start cleaning up the bay as well :). Busy Busy!

This post has been edited by Classy: 05 February 2009 - 02:43 PM

[morallye]

this looks great!

Love the sound deadning and how you have covered it all up!
Its going to feel really quiet and solid I bet once you get it on the road!

Will be keeping track of this :)

[1990G60]

Classy, on 5th Feb 2009, 08:38 AM, said:

What do you mean the 'title'?

Bad news anyway, still - if you've still got the engine around you could re-build it maybe do something a bit special, take advantage while it's outta the car & find another shell for it to go in? Dad's got a big enough garage either way! Has he still got that race car?

Still Corrados are nice. Assuming the G-lader says faithful to you then they can make some good power with increased boost.

Ta for comments guys. Hopefully should have a big update at the weekend. Wanna buy an engine stand for the 1.8t start stripping that, replacing gaskets/belts & checking the condition the engine. Hopefully will have the old 8v out and start cleaning up the bay as well :). Busy Busy!

I never actually got the title for the car until the day i sold it. i didnt even transfer it into my name. Some guy from up north MN came down and looked at the car and threw me an offer i really couldn't refuse. Between bills and other stuff going on at the time, the sale actually helped me. my buddy ryan still has the motor, but i told him he could do what he wanted with it.

I actually dont live with my dad any more. im staying with Zack until i move to Denver, Colorado for a job with my uncle i got there.

As for the Rado', I checked the boost on my MFA the other day and i got a reading of 238@ redline in 4th gear. should be 13.5 lbs of boost. so very healthy :)

[Classy]

Right... not a very successful sale then.

Bet that's fun staying in the mad house with Zack lol. What job you got?

Didn't think MFA gave boost readings, 238 certainly doesn't sound like a boost reading ;)

This post has been edited by Classy: 07 February 2009 - 08:05 PM

[Classy]

Small update guys:

Bit pissed off with today... spent a lot of time getting not a lot done. Just having to contend with dodgy bolts and fixing other things along the way. Got to the garage at 1'o'clock after popping to machine mart to buy some spline tools for the drive shafts. Ended up leaving about 5.30/6.

So in the end I managed to drain/disconnect the PAS lines.
Took out the drive shafts WHAT A MISSION! This took most of my time, having a few bolts sort of fall to pieces! Also had to find a way of putting the brakes on ridiculously hard so I could undo the hub nuts. And not having a lot of head room to work. What I thought would be a hour MAX job took like 2 hours maybe even 3.
Drained the gearbox.
Removed the front end completely. (Spent additional 30 minutes repairing those ridiculous bolts that hold the bracket on to the bumper.)
Started to disconnect the gearbox from the engine, then the f*cking MRS shows up and within 20 minutes is moaning she's freezing and hungry so had to pack everything up and go home :@! Think I'm going to take the engine & gearbox out together as well now.

Only 1 picture today. Hoping to have an early start tomorrow. Want the engine/gearbox out! So hopefully big update :)

http://img.photobucket.com/albums/v509/crisp19888/DSC00100.jpg

[Classy]

Good day today :) Objective completed at least! Started a bit late as well again today... finished earlier though for the Sunday roast ;)

Removed downpipe & engine mounts from the engine - Used about half a can of butane gas and penetrating grease managed to not snap any exhaust manifold/engine mounting bolts. Christ they were tight!
Loosened PAS bracket
Removed the front supporting members

Removed the engine :)

http://img.photobucket.com/albums/v509/crisp19888/DSC00103.jpg
Crane in the position!

http://img.photobucket.com/albums/v509/crisp19888/DSC00106.jpg
Engine out. Note ghetto engine hoist :) Also took me 10 minutes to move the crane 180* because not enough room to turn it lol!

http://img.photobucket.com/albums/v509/crisp19888/DSC00110.jpg
Two engines together. Bit more space to get the car back in.

http://img.photobucket.com/albums/v509/crisp19888/DSC00113.jpg
Empty bay :mellow:

http://img.photobucket.com/albums/v509/crisp19888/DSC00117.jpg
Check out the gap :lol: :blink:

http://img.photobucket.com/albums/v509/crisp19888/DSC00111.jpg
The old 8v motor. 92k on the clock. All parts available if anyone is interested!


So next is to get the 20v on a stand and start stripping it. Begin sorting out the wiring loom in the mk2. Most of it is intermingled with chassis loom as well, so will need to start cutting the protecting hose to find the right wires to keep - Also need to clean the bay, although I'm heavily considering getting it sprayed! Need to find out some costs ^_^

S'all for now B)

[kav1187]

Looking good mate. I remember being at this point last year...fun times ahead :D

I wish I'd gone for the TT or S3 engine now.

I find a lot of the jobs I've done have taken a hell of a lot longer than anticipated! Really simple jobs like routing the wiring loom etc took ages. It's all worth it in the end though :)

Keep up the hard work and also the updates.

Kav