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Discussion Starter · #522 · (Edited)
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 -> New 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)



Click to enbiggen







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




Test Fit before assembling



to feed this..













Setting up Fuel filter layout.




 

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Discussion Starter · #523 · (Edited)









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...






 

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Orig owner 90 g60, 02 allroad 6SP M w/ 3rd Row, 07 3X White NB Vert, 09 Escalade ESV Plat to tow em
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DIR1X

Do it right 1 time. Most of the stuff you need to get this stuff done isn't available off the shelf or at the hardware store. Working on my long forgotten grey market 914-6 or 67 bug was just maintenance or repair compared to the Corrado. It's truly amazing how you have to engineer so many work arounds to make just one modification. Nice work Shawn. Appriciate the pics & build thread!!

 

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Discussion Starter · #532 · (Edited)
I finally had time to finish up some paint work that I started, well about a year ago :rolleyes: 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 :p

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.

sorry for the cell phone pics (clickable)




















 

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I finally had time to finish up some paint work that I started, well about a year ago :rolleyes: 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 :p
There's something to be said about driveway shoots, AWESOME! :beer:
 

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Discussion Starter · #537 · (Edited)
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 👍

All pics clickable.











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 :screwy: Yes, that is a new reinforcement strip, bolts and Lower Bumper Grill :cool: again, proper pics when I get it all cleaned up.









 

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Discussion Starter · #539 ·
:beer:

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 :p 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. :thumbup:
 

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Discussion Starter · #540 · (Edited)
Custom FMIC Fitment

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? :) )






 
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