Das $build thread$ by dasbeast3.0

8 minute(s) of a 205 minute read

Half ass polished the turbine housing. Needs more sanding/ polish work, but its good enough for now. I need to get this bomb running asap.

5/3/11

Some more pics, getting ready to fab the wastegate setup tomorrow. I marked everything exactly how it sits on the C ride and reassembled off the vehicle. Getting closer!











Got my wastegates almost done. I have to finish welding the far one tomorrow, gonna hard pipe it and use a smaller flex section, im glad to say the major pain in the ass is over with tho! It all fits and bolts up perfectly.

5/5/11

Maybe someone knows a trick to this or has good advice: I'm having a lot of trouble getting the shifter to go smoothly into all gears, I tried everything. I did the procedure VW states, lock the trans and put a pin in the shift box for placement, to align the cables. no dice.

I tried it with my own adjustments as well, I messed with it for about 4 hours and it WILL NOT adjust properly.

There's a good bit of play in the shifter, as if maybe the bushings are shot. IDK I cant seem to get it on point. I did it when the trans was on the ground, took 10 mins and it shifted smooth, no probs. once installed is when I'm having the probs. the cables seem to be about 1/2" too long, they fit but are a bit tight. they don't feel like they are binding at all though. Im hoping its just bad bushings. its the euro polo box.

I can get it to go in all gears, but if 1-4 go in smooth, 5-6 and reverse crunch. then if 5,6 are smooth, 1-4 crunch.

Got it all bolted in. Fits real tight, but it goes together pretty easily. I gotta clean everything again since its all covered in grease n dirt. and no, the oem manifolds will not be seen. I made the atp heat shield work. Drilled 2 holes where the manifolds protrude, I need to retain those 2 posts since I'll be making a turbo brace to bolt there.

6/4/11

It lives. Still a lot of work to do but im really happy to hear it run. No problems beside me forgetting to tighten a fuel fitting, I had a bad leak when i first tried to start it. Snugged it up, and she fired on the 2nd crank. It runs great though, the Holset sounds baaad.

From the drivers seat you can hear a low whistle at idle... I ****in love it.

The vid sucks and my engine bay is a mess, but ya..here it is (and yes I tripped over the car cover lol) :

http://s384.photobucket.com/user/rad...movie.mp4.html

6/5/11

The cooling system needs a ton of fab work yet. I have to make 2 "y" fittings to retain the factory overflow tank. Instead of getting crazy with t's and 25 an fittings I just ordered some SS in different sizes and am gonna weld it up. I need one Y to have 1", 5/8", and 1/2" branches, then the other needs to be 90deg. 1.25" on 2 ends with 1/4" branch in the center. Its a pain in the ass since everything is really tight as far as coolant hoses, but they gotta be there

Other than that, I need to make a new test pipe to mate my new DP to the old exhaust, install my harness for the IC water pump, mount the IC reserve tank solid to the trunk, get a new wideband sensor, clean up the bay, make a bracket for the intercooler, lots of turbo bracing, make random brackets for the i/c hoses, get axles, do wheel bearings..and lots more little ****.

6/10/11

Well, Yet again my bad luck strikes. Or, the Corrado could just possibly be cursed. Idk what it is, but the blows keep coming.

I was at work, but apparently a hailstorm came through my area and destroyed my car. My neighbor said golfball sized chunks were coming down and demolishing vehicles. All his customers cars got damaged as well. The C was covered but not thick enough to stop damage, so I have about 100 dings all over the body. The roof isnt too bad somehow, but the 1/4's, fenders, doors, and hood are pretty rough.

I called my insurance company and they will be out on Tuesday. I will get a large check and fix the car to showroom condition (possibly with a built motor). At least I get to paint it the way I always wanted to. Just gonna suck straightening all those dings, I don't wanna use filler so im gonna tap as many out as I can. Im gonna do pretty much a full resto on the body, strip it to metal, pull all glass etc. Only thing I'm not doing is the bay, I'll do that next time I pull the motor.

No I am not shaving anything, its not really my style. Only thing different that I considered was pulling the fenders, but its not very likely..I like the factory arches.

All in all.... Sweet Jesus today was brutal.

6/19/11

On a better note, body work starts this upcoming week. Insurance wants me to prove I am not going to just pocket the $, so I need to show them work being performed. No big deal tho.

FINALLY ordered DSS axles, and got my coolant system done.

Still need to work out 100 minor issues tho. My wastegate flanges warped a bit from welding, not bad, but it will be an issue down the road. I stacked a few gaskets to get a decent seal but I'm not sure how long it'll hold up. I hate doing half ass stuff but time is limited so I'll have to take a gamble on this one. If it doesn't work.. then off to the machine shop again

Also, I really need to brace the turbo somehow. Its only a matter of time b4 the manifold cracks without support. This stupid **** takes a ton of time, but I AM making progress! Axles were a major thing, at least the turd will move under its own power.

I'll have to get my ass moving and make the I/C functional...kinda need that for boost.