Project Build: sc2020 - MK3 G60 - By sdezego

10 minute(s) of a 144 minute read

I am starting to get back into some work here. Intercooler piping is coming tomorrow, so I hope to be starting on that aspect and make this IC that I have work.

I would really like to have this wrapped up this winter... 

January 21, 2012

I finally had time to finish up some paint work that I started, well about a year ago It has been one thing after another and this morning, was the day that I had time and the weather was absolutely perfect! 68* at about 8 am with zero wind, no bugs and low Humidity (A rarity for Florida). When your driveway sometimes serves as a booth, elements have to be perfect

So, I painted my new Bumper (70mm Lip finally will go on!!!) and my spare G60 Rad support. The Rad support is important so I can take the VR one off of my car and wrap up my intercooler project (requires the VR) I started, well over a year ago...

I made a mistake when stripping the bumper and going down too far. There were a few coats over the Factory and used SEM Bumper stripper, but I should have used a softer scraper and tried to take all but the factory finish off. When you expose the bare plastic, there is a lot of prep and stuff that needs to happen to make the primer stick properly.

February 02, 2012

ok, I have some updates.

1st, I finished up the Front Bumper, Rad Support and SFT 70mm Lip sans any Wetsanding. It does not need it but I may touch it down the road. There is barely any hint of any peel at all if any, which I am very pleased with 9.8/10. I will get some proper pictures of the car when I clean it all up.

SFT 70mm Lip

Modified the G60 Support for the VR Grill. This support is only temp anyway which you will see when I post of up the IC work next. ...crappy cell phone pic

Corrado Reinforcement Lip and Lower Rad Support = 0. Me = 1. It was a hard fight, but I got every bolt in Yes, that is a new reinforcement strip, bolts and Lower Bumper Grill again, proper pics when I get it all cleaned up.

One thing I noticed when I was taking the headlights out that I don't recall when I switched to the VR Ecode Glass and Bezels a couple of years back was that the Bezels were sagging on the bot. There was a gap between the bottom of the bezel and the lens which made the lines not straight. I guess wind was getting between and worsening the fit over the years.

What can I say, when everything is now perfect up front, the little things stand out Anyway, what I did, was just carefully squeeze 3 dabs of clear RTV between the bottom of the lens and the Bezel, clamped and let it set up over night. 

Let me state first, that if you are considering using the IC as I am below, know that I bought it with only rough dims and the intention that it was only going to need slight modifications to work (yea right)...

So, in case you were asleep or just forgot from a few pages ago, I am going with a custom FMIC and using the stock bumper, stock Lower bumper Grill and unmodified Rebar. I looked at making once from scratch using a BELL or Garret Core, and in hind sight, it would have been easier in the long run (as would have AWIC)..

So here is the Plan:

• Using Stock G60 Rad becuase it is bigger
• MkIV Condenser (for reasons mentioned on prev pages)
• VR Rad support modified (very important as you will see)
• re-fabricated lower Rad support (Drivers Side where it flares outward)
• a highly Modified big ass FMIC
• unmodified bumper Rebar

NOTE, the info to follow is only for the above Configuration! VR Guys, don't try to get any ideas as you will not have the clearance if you have A/C.

Here are the Basic Constraints for this config as shown below in my highly technical drawing.

Notice there is a bit more room than one would expect between the Condenser and the Rad support when using the VR support on a G60. This is the reason I needed to paint my spare G60 one to swap on my car so I can finish the mockup on my build.

Shown Actual VR Support on G60 w/ A/C. (note: see why I needed to repaint my Ft Bumper and Rad support? )

...as compared to the same setup with the G60 upper Rad support.

Notice the Rad support come very close to the Condenser all the way across? Unlike the VR support on the G60 which has a lot of clearance all the way across (including the Center Down Strut Support which is much narrower on the VR).

This is all due to the fact that the VR Rad and Cond are angled a LOT more than the G60 to clear the motor and is much closer to the Grill.

also, FWIW note that someone did a piss poor job adding slots to accommodate the VR grill on the G60. They also had it recessed so the Grill sat flush with the G60 headlights where as if you have the universal VR support like I do (show in prev post) there are accommodations for both grills. However, when using the VR grill slots on the G60, the headlights will appear sunken and not even with the grill. Thus why I switched to VR Lenses and Bezels years back. 

Another major difference (and the need for me to absolutely need the VR support (as you will see). the the height difference toward the Pass side of the Rad/Cond pack. Because the VR is much closer to the Grill, the top of the Rad support is heightened all the way up to the Grill.

Here is a side by side comparison of the two from above pics. Note the top of the rad support just the the right of the pass headlight (Vr left and G60 Right).

...so, here was the initial fit up. I said it was big

Notice the cast end tanks and the 2.25" Core? As you will see I needed to gain ever inch from side to side so I needed to shave off those has Ribs, etc. ..and then some. And yes, the inlet and outlets are not in the correct orientation which I was aware of when I chose.

Stock G60 Rad in Factory position with the "G60ing" Spal Fan mod 

More Pics Notice the clearance on the pass side top? That is partly why the VR support was a must.

Here is the way every aspect of this whole IC project went... "almost"

I need to clearance a small section of the End tank to clear the Pass headlight. Even with the shaved castings.

Driver's side is right up to the latch spring, so no room to give.

Will post more as I progress. 

oh yea, in case you are wondering this is a VAG IC. From a Euro Audi S3 2.0t

It is a Tube/Fin as you may have noticed. There are pros and cons to both Tube/Fin and Bar/Plate IC. I decided this was best since it is basically blocking the Radiator?

I also decided I wanted the IC in front of the Condenser. Great for the IC, but maybe not so much so for the A/C