Project Build: sc2020 - MK3 G60 - By sdezego

12 minute(s) of a 278 minute read

Did a little bit more work tonight and finished up the MkiV Condenser install. (don't mind that PS pipe as that will likely be going).

Next up should be IC fitment. I am really on the fence about this...

February 01, 2011

Using the MkiV harness and ECU is not a bad way to go (especially if a stock tune is fine). I am just strongly against the "chip Tuners" and the price they charge... AEB head is great, but plenty of power to be had from small port head. I would get what is readily available at a good price.

Well, after putting the front end together on the mock setup, taking detailed measurements and trying to fit my Precision Core under the stock bumper, I have come to the definite conclusion (I think), that my only solution for a good IC is:

1.) AWIC

2.) Build a custom FMIC

Guess which one I am going to undertake

My constraints (which did change from the start where I planned on running my Dietrich RS) are now to use the stock bumper, get proper air flow for IC, Condenser, oil cooler and Rad, and look as close to stock as possible. That means to even run the Lower bumper grill as well. I in no way want to hack up a stock bumper and try to stuff a core in there that is wedged to the rebar and blocks all proper air flow.

I did some research on some cores with my measurements and I have a few options. I just need to decide, bite the bullet and build. Bell cores are hella expensive, so I may need to try and set up a reseller account through my brothers shop. Or find a comparable efficient core.

Stay Tuned..

Shawn 

February 02, 2011

The closest part of the Rad support. I have some better pics I will post up. The Vr support is narrower (allowing more room) between the Condenser and the support itself, but either one would need to be modified. I will mod and reinforce.

Yea, a factory front mount would be ideal and most are pretty inexpensive brand new, but the problems with the ones that I have searched (2.0t, Saabs, Volvos, etc) is that they are either too tall, or the outlets are positioned to face rear and come in either over the top or sides of the rad and point back. This might work with a narrow radiator (i.e. like the Rallye golf FMIC), but as you know, with FL heat in the summer, a black car and A/C to boot, you need as big of a rad as you can get. So, I am not downsizing that.

What I foresee, is a FM similar in size to the ones you mentioned (large surface area), but the Inlet and Outlet will come off in the same plan as the IC but head out toward the right and left tow hooks. Then pipe around and up as usual.

I have the design already finalized in my mind and it will definitely work nicely. I just need to find and buy the right core to get started.

A 2.5" core looks like it would be perfect, but I could squeeze a 3" core in there if need be. Bell doesn't have a 2.5", but they have a 2.25 and a 3". The Difference in flow is very small (only 25cfm).

February 09, 2011

Took a break on the intercooler briefly since it requires spending a lot of money I pretty much have it all mapped out though and it will be slick.

I really hate rebuilding axles and packing CV joints, so glad they are done and on! Redline CV2

About 1/2" clearance between the CV joint and the trans cup now.

...kind of blurry, but oh well.

April 05, 2011

Things have been progressing, but haven't posted much progress as things that have been completed are all over the place and nothing significant lately other than wrapping up Megasquirt3 and getting a final tune on my current setup.

I'll give a small update though:

I made the decision to ditch the really nice precision IC Core that I bought a long while ago when the intentions were to run the Dietrich RS front (tells you how long this project has been culminating). I purchased the new IC core (not yet disclosed) and started mocking it up. Some Corrado owners may find this interesting, but I will leave it a that for now. I can only say that it is a very large area core that will look factory and still allow A/C an a full Rebar. Upper Rad support trimming is still TBD.

I have also been porting and rebuilding one of my spare chargers among other things.

I am at the point where I really want this done and in, but my time has been limited to work on this as usual. Money making jobs have to come first and these are outside of by daily job and Family life.

Not to worry, progress pics soon

I have been also working on refinishing my spare bumper so I can get it on to show off your 70mm lip Got a new lower grill, new steel lower support trim , etc. 

April 10, 2011

As usual, I have 20 things going on at once, but I did work on the IC setup quite a bit the other night as Lee mentioned. I don't want to post any pics yet though, but will soon.

The reason is that I need to complete refinishing my spare bumper, and shoot my spare upper Rad support so that I can swap them on my car now and take the Vr Rad Support that is currently on my car. ..plus add my SFT 70mm lip on I need this to complete the IC mockup.

Unfortunately, the IC is much tighter than I expected. So MUCH so, that the small diffs in the VR upper Support are required for use and there is also a lot of creativity needed to get this thing to work. Not to mention a lot of cutting here and there (but no mods to the rebar ). I am now confident that it will work, but realistically to try and repeat this solution for others, is not be the best route.

The avenue I almost went down with a Custom Garrett or Bell core and fab up end tanks would have been a better route and could have been made to work with only trimming the down strut on the upper Rad support when using the VR support with the G60 Rad/condenser setup. 

April 12, 2011

Crappy weather, so no work on painting the front bumper and rad support to swap so no pics on the IC mockup, but here is one one of the G60 on the Bridgeport opening up both intakes.

September 09, 2011

Yea

Well after all of the work or replacing the single Fuel Pump swirl pot bladder rubbers, the FP itself decided to take a crap LOL... I decided to go all out and be done (hopefully) once and for all.

Added from this thread -> http://forums.vwvortex.com/showthrea...-small-project

• IE Surge tank
• Bosch 044 Fuel pump
• Stock G60/Mk2 VDO transfer pump (did calcs and flow rate is more than sufficient)
• Custom Made Mount plate, Fuel Filter mount, etc
• '02 Audi S4 Fuel FIlter
• 14mm x 1.5mm to -6 AN Adapter Fitting (Fuel Filter Inlet)
• 12mm x 1.5mm to -6 AN Adapter Fitting (Fuel Filter outlet)
• M5 and M6 nuts for 044's elec terminals (yes, diff sizes)
• Banjo fitting for 044 outlet using the 044 Check valve
• 6' Aeroquip line and lots of various AN fittings
• Earls 5/16" compression fittings to -6AN for adapting to Stock Nylon lines (must get brass insert from hardware store)

Transfer Pump test fit isolating rubber (Buna-N) was trimmed before install

Test Fit before assembling

to feed this..

Setting up Fuel filter layout.

Heat Shield action

The welds are not as bad as they appear in most the crappy cell phone pics, however, I noticed just as I was finishing that the car seats that someone stacked on my Tig must have slid and cracked the flow meter which was leaking pretty good... I hadn't Tig'ed on it in months and didn't notice/fix it until I was almost done, so they are certainly not my best either.

So, for the Factory nylon line to -An, I am using the Earl's Compression fitting, with a separate insert to prevent the line from collapsing. I have used these before, so I know they work well.

Note: the factory line has a brass insert to prevent the hose clamp from crushing.

However, in this pic the is a 3/16" drill bit that barely fits in.

Using a custom insert (from a hardware store, but the flange end must be trimmed) with the Earl's, the inner Diameter is increased to 7/32"+. Not that I Personally really need the extra flow, but I am sure someone who needs the extra flow for E85, etc could spare the expense of running all new lines.

A pic of the whole thing.

The amount of $ that ended up in this is just retarded, but I guess if I never have to revisit it again, it is all worth it...