TDI RatRod (full thread)

[PRA4WX]

That's right, the pile of junk knocking on the door of 300k miles got it's debut today at the Ozarks Mountain Region SCCA chapter autox.....it was an ABSOLUTE BLAST!!!! Finishing first in class wasn't too bad either! i got really lucky to win.....and not by much at that, at just over 4 tenths of a second. :bang: The car plowed and rolled all over the course, but with a couple runs down i started to be able to get the rear end to come around. It really was a riot to drive! Met some great people out there who were totally helpful! Not to mention a really nicely done Audi TT. :-)

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[PRA4WX]

Well lots has happened since that post. The Rat Rod is gone but it's essence has since been imparted to the Pale Horse, and now a new Rat Rod has come along in the form of another tornado red VAG product-a corrado! I'm very excited as one of the first cars i drove was a G60. This one needed/needs attention but will serve commuter/autoX duty.

It is a 1990 G60 with a 2870 Lysholm. Don't know who if any around here have any familiarity with these guys be it PG's or Lysholms but thought i'd throw my difficulties with it out here for input. Here is the deal.....I've got a Lysholm newly fitted, recently went to a 55mm pulley (live at ~ 5k feet above sea level) and am only seeing 11.3 psi max at ~redline in third and fourth gear pulls. I've pressure tested intake plumbing, and it will hold 15psi solid for more than a minute. New BBM billet tensioner cap to make sure of no belt slip. Any thoughts? Johnny says that he loses 2psi going from sea level to Bend OR @3500 ASL. Sounds logical that i could lose 4 or so at 5k ASL. BBM's site claims around 17+ for the 55mm, 18+ on the 53mm, and 22+ on the 50mm. Wondering what charger guys experience at altitude as if this seems normal. Seems a bit excessive to me but i dunno with chargers.

Oh, and some pics to come.

[PRA4WX]

[PRA4WX]

Well it's alive.

[mr_aj_johnson]

That took a little bit of time . This just gonna be an autox/corner carver or what's the next step?

[PRA4WX]

Just a little:

Not big enough


VR6 clutch to go with single mass flywheel


Little porting
New seal while in there

AFN EM

Cheap coil overs

Head after decking and valve job

GT2260VK


Pedal clusters

Sorting wiring

Cam comparison, 276 TT G60, stock 1Z, and Stage 3 Kerma

Hold it together

New HG

Wiring

more wiring

more wiring

Bosio Race 520's

New cluster in place (although the final with MFA and boost, egt, etc, yet to come)

Malone handling the software (egr delete, VNT conversion, R520's, etc)

Lift pump fuel pressure reduction

Drop in cam needed some clearancing

VNT GT2260VK and AFN fits, but BARELY



No egr, and it didn't clear so hamfisted something

Originally

Mo betta

Aaaand more wiring

In place and starting to work and charge pipe routing

Slight improvement over the stocker




Jimmy, these look familiar?? :wink:

Making G60 AC and power steering work with the 1Z

Death by wiring

Ventilation

Chasing wiring ghosts

[A20V200]

Looks good, what a cluster F*&k of wiring, better you than me..how's it run?

[PRA4WX]

That took a little bit of time . This just gonna be an autox/corner carver or what's the next step?

It took me a little bit! :wink:
Commuter travel car/weekend autoX and track car. I'm still getting it road worthy. Hasn't left the garage yet. Still working on sorting cruise control integration, have to wire in the final lift pump control circuit, bleed brakes/clutch, re-torque ARP's, build final down pipe, etc before i can start driving it.

Looks good, what a cluster F*&k of wiring, better you than me..how's it run?

Starts right up and idles/runs beautifully...but haven't driven it yet.

[mr_aj_johnson]

Good work! Make sure to give an update on fuel mileage too. looks like a good all purpose car.

[PRA4WX]

I'll try and report the mileage is see. To be honest, if i were to get nothing better than 30mpg, i'd be satisfied. I'm shooting for an average in the 50's with the ability to touch 60mpg if driven carefully.

[MikkiJayne]

What did you do to that doodad from the pump? I can't tell from the picture - it looks like you extended it somehow?

[PRA4WX]

It's a small plate added to the case pressure relief valve. They tend to "pop" with revs, and this plate prevents that. Case in point-the donors had popped and the previous owner was un aware. You can tell by the small black portion you see exposed from the valve in the first picture. That black tip should sit flush with the valve body.

[Mcstiff]

Cruise!? AC?!!

Can't wait to check it out

[MikkiJayne]

It's a small plate added to the case pressure relief valve. They tend to "pop" with revs, and this plate prevents that. Case in point the donors had and the previous owner was un aware and it is the small black portion you see exposed in the first picture. That black tip should not be exposed but sit flush with the valve body.

Interesting thanks. I'll have to check that out

[psychorallyfreak]

Chasing wiring ghosts

Can't say for sure, but I think it's the white wire. :tard:

Looks like quite the undertaking!

[PRA4WX]

It's a small plate added to the case pressure relief valve. They tend to "pop" with revs, and this plate prevents that. Case in point the donors had and the previous owner was un aware and it is the small black portion you see exposed in the first picture. That black tip should not be exposed but sit flush with the valve body.

Interesting thanks. I'll have to check that out

You can glean some info here:
http://forums.tdiclub.com/showthread.php?t=206384

[PRA4WX]

Cruise!? AC?!!

Can't wait to check it out

Not yet, but working on it! :wink:

[MikkiJayne]

Ah right I never rev mine hard tbh since it just goes flat at 4000.

[PRA4WX]

Well it left the garage under tdi power for the first time. Any number of issues to sort/wrap up but it's running and driving.

[PRA4WX]

Corrado 2+2??

Took a spin to the bike shop last night. Can't wait to have the down pipe/exhaust on and turn it up a bit. Even at only 5psi it moves all right. Popped an intercooler hose last night. May have to rework the junction where the intake side turns down and connects with a lower hose. You can see said junction here:

With some tweaking it joins better now......but i'm not totally happy with it

[Mcstiff]

3 across in a CQ fits better! Can you shove a CQ seat bottom in there?

[PRA4WX]

3 across in a CQ fits better! Can you shove a CQ seat bottom in there?

I am going to give it a shot at some point! :wink:

[PRA4WX]

It's exhausted now. While on the lift getting the exhaust done the infamous corrado radiator neck broke completely off w/o room to reclamp enough to even limp home. So this is the rig we came up with to get home:

Finally have given in and a billet replacement is in its way. I was looking forward to beginning to drive it......

[PRA4WX]

And that problem solved:


On to the next. Took it out last night for a quick spin to get the wife some cider. Boosting to about 10psi. First two gears easy throttle but enough to see about 5lbs. Did a stronger pull through 3rd two times up to and backed off at 10psi.....everything good to go. Runs out pretty good too. I'm excited! Turn around to head back and decide to do one more 3rd gear pull from cursing at 2k rpm. Back off before 4k, and on decel the engine shuts down. Add throttle, and it comes to life but its running weak. Have to stay in the revs to keep it running when off load, on load can only use light throttle or it bogs and dies. It would die at idle. I would then crank, crank, crank, and some throttle and it would come to life. Managed to nurse it home. Sounds like fueling to me........ Lift pump is still running, no air in line, no fuel leaks-okay so that all seems good. I've put off changing the fuel filter-it has the filter from the donor and i don't know how long it had been in service-but was planning on it anyway. Gonna pull the lines after and at the filter and verify i still have good fueling from the in tank and through the filter. Maybe clogged filter? Water?
Any of this tell the experienced tdi'er something? Sound like fueling?

Have an exhaust leak somewhere in the at the back of the head.

Noticed some exhaust track from the #4 injector as well. Retorqued it. How common is blowby at the injectors? No fuel was leaking from the injector tops but a couple were slightly wet at the line and nut junction. Retorqued the lines.

[PRA4WX]

Made the first road trip today in the tdi to meet a friend with a super proper TDI swapped MK2 GTI. Drove Pikes Peak. The tdi RatRod ran well.








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