My Corrado Project

Well thought its about time that i started a build thread for my corrado project.... So here it is..

WARNING THIS MAY BE PIC HEAVY!

This is the shell i decided to use as i actually have 2 corrados to pick between.





Engine out


Bodywork needs some attention but it will be getting a respray anyway, The main thing is its completely solid and doesnt appear to have been in an accident etc also it was owned by my friend for the last 5-6 years so i know its a good base to start with.

Now as with all projects the plans are constantly changing but at the moment its getting an r32 engine and 4wd using a hybrid of syncro and r32 parts.

Ive been collecing parts and researching info etc for about a year now but only really started working on the car over the last few weeks, I Have not really got a planned finish date but have made some good progress so far but no doubt my enthusiam will slow down soon!

Heres a few pics of the syncro rear beam and haldex conversion.

Vr6 Syncro beam i sourced from good ol german ebay!


The beam stripped ready for cutting.


To do this conversion you need to cut off the old brackets that hold the syncro diff and make some new ones so you can fit the haldex diff.

Now cut and ready to be modified


Haldex/Syncro conversion jig



This is needed so you know the exact position where the haldex needs to sit so it can connect with the standard prop shaft.




Notice how nice the diff sits at the back of the beam, almost as if it was ment to fit there. Lol


Then i made a template out of cardboard so i had a rough design of what i needed to make




New brackets for haldex made and welded onto the beam



Rear Beam painted


Got loads more pics to come

sweet!!!! looking awesome dude.

cant wait for moar!!!!

Amazing, propper dubbing! Luke i salute you!

Cheers for the comments guys, ive got loads more pics to come jus need to find time to upload them.

Poly bushes for the rear beam and all the mounting brackets to fit it to the car


Heres some pics of the rear trailing arms being painted


new wheel bearings


I had to change the rear hubs for vr6 front ones so i could use 4motion outer cv joints, The added bonus is i can now run 280mm vr6 front brake discs at the back



Decided to paint the gearbox and rear diff silver.
Before

After

MOOOOAAARRR!!

looking good dude. well impressed witht he progress

Sneaky peak! lol




This was the 1st trial fit of the engine and as you can see it sits a little high so i had to cut the rear engine mount down by about 20mm.


Wheres my floor gone??


Rear beam and diff trial fitted


When i decided to do this project i was not intending on using an original floor pan because i was just gonna use some box section for support of the diff etc and make a false floor as its much easier and still works perfectly fine, just would not look as good....
Well the other week i went to collect some syncro parts from someone off edition38 and in his garage was this.



Yep Complete rear floor from a golf rallye, so i thought i mite aswell buy that while i was there.

hehehehe safe!

Wow some seriously impressive stuff there

Now I know where you've been these past few months then?

Have you seen the twin turbo R32 rado at NWDubs? The 650bhp one? That's got a syncro rear floor and a load of other neat bits, you should look it up sometime

Are you going to fiddle with the Haldex at all, change the bias:

http://www.r32oc.com/performance-technical/1337-whats-haldex-controller.html

Keeping it the same colour?

I'm gonna have to up my game now

Gimme a text if you're about and I'll pop over pick up a heatshield?

hat off luke impressive stuff


given me a semi x

Yep, that is some proper dubbing porn there. You have really bit into this and done something which is quite incredible. Thnaks for posting pics of the work.
A 4 wheel drive, r32 engined Corrado... That sounds like a dream car.

Fantastic work there Luke, lovely project, should be awesome.

Thanks again for the coments every1.

Ben - Yea i know rich with the 4wd r32 turbo rado i was chatting to him the other week at ace cafe, Thats a nice car!

I will have to use some form of controller to control the haldex but that one wont work as i wont have all the original oem inputs that the haldex needs to run correctly so will need to get a standalone haldex controller like this.

http://www.4motioncontroller.com/shop/products.php?version2&osCsid=2gicseqphbmb52msgsdb2mgenp25rfl3

also the rado will be getting a colour change but not 100% decided yet so mite just end up painting the inside and engine bay matt black for the time being.

Anyway more pics...
Next job on the list was to remove all the spot welds from the new floor so i can get rid of all the bits i didnt need which was a very very long and tedious job that seemed like it took forever!
But before that i had to remove all the sealant/wax so i could actually see the spot welds!







Had a little help from a friend


which actually made it quite fun but it was taking ages so i resorted to this.

Angle grinder with wire wheel attachments

For some reason i didnt take any photos of the floor fully trimmed with the spot welds drilled out ready for fitting! must of got to carried away. lol

But take my word it was a mission whoever says that the syncro floor is a straight fit into the corrado is LYING! Yea they are very similar but the golf floor needs lots of trimming and cutting to fit especially at the sides and the back where it attaches to the rear panel, Also the corrado chassis legs need a lot of cutting aswell to match the same profile of the syncro floor

here are a few pics of what needs cutting on the corrado chassis legs, they are not fully done here but you get the idea.

Nearside chassis leg


Offside Chassis leg



Here is the floor all trimmed and just tacked in place so i could make sure the rear beam and tank etc all fitted properly before the floor was seam welded in place.






Just like to add that the floor is now fully welded into place and seam sealed! But ive gotta give a big thanks to my mate matt for that as he got bored while i was at work and decided to crack the welder out so i was proper happy when i went to help him start welding the floor in to realise he had done it all already!

nice nice NICE keep the momentum up dude mmmmmmmmmmmmmmmmmmmmmmm


mmmmmmmmmmmmmm

i'm speechless (for once!!)

What a project, epic!

Wow this is going to be a breast anymore pics ?

Haha beast.

Looks like a car to me?! *giggles*

Yea got lds more pics but they are all on my old phone that is busted!! so gotta try get them off.

Not done much work on it over the last few months as been busy with other stuff, also i got a bit sidetracked and ended up buying this for the golf.....



Yea its a turbo kit for the vr so gotta fit that over winter ready for show season next year. Its second hand but was so cheap i couldnt resist!