The CorradoG60.com - Corrado G60

without question B's

 

Aye, starting to like the 'nut' style centers myself as well actually!

A few boxes!

 

So the new suspension, which I have genuine (Non scene/showy! reasons for!) Where I live has become speed bump city :-( and I'm tired of having to drive a mile to literally get around the corner. Also I can't get the car on the drive at my new place. And lastly, I'm sick of spending money on coilovers that simply don't last on our great British roads!
It's a slow burner because I rarely get any free time with work. But at least it should hopefully turn out ok.


Have spent a lot of time struggling to come up with a way to mount everything. The plan is to:
Keep the spare wheel space usable.
Mount everything with as low a center of gravity as possible.
Keep everything easy to get at to maintain it.
Keep as much boot space as possible.
Make it look sort of plain/not too showy but yet decent enough? lol.


Anyway, here's all the toys! Ill apologise in advance for all the pics...
Accuair E-Level management with 'ride height on start' function, individual controls of each corner, 3 preset/adjustable ride heights, RideMonitor™ mode adjusts as needed while driving or parked which basically means if you throw a load of mates in the car the height is maintained. 4X Corner level sensors. Touchpad with adjustable/auto dimming and warning system.


Air lift struts.











5gallon air tank



Accuair ECU and touchpad with lead.






Accuair wiring kit, and one of the corner level sensors.



The touchpad is seriously nice, superb quality!



Water trap and fittings.



Accuair power supply kit. Can see the digital gauge I also bought here.



Accuair VU4 Manifold.



Viair 444c Compressor.



That's all the kit, but I also picked up a VDO pressure gauge too for the dash, love my VDO's!



Onto the build!
I was having real problems with the skinny 5gallon tank, tried various ways but just wasn't happy with it.



So I picked up a chubby 5gallon to replace it. Can see an early template here too. Shame that I got sent the totally wrong tank, it doesn't have a damn drain port and they have done NOTHING to sort this out. But anyway...





Always start with cardboard lol!



Then cut out some wood.






And cut out some more!



Test fitting...again, and again and again...






And that's all I've managed so far...I'll try and update when I can.

Neil.

 

Little more progress managed...Compressor box made. Still unsure on how to mount the VU4 manifold and the Management.








Then I got a better seal on the compressor area, made a lip that runs around the edge so a back panel will close up against it.



Still need to finish this off. The wiring also runs behind it's own connector through a little plug I made.






And it clears at the back!



And I suppose it looks kind of ok from the front...






PS: I know it all looks a little wobbly/uneven in places, some of it is because the front panel isn't fixed yet (It straightens things up) and some I need to run over with the file to tidy edges up etc.


Neil.

 

Again, just a little progress, but it feels like I'm getting there now with starting on the wiring etc.

Picked up these two digi gauges, voltage for the management. And a temp gauge that has a little sensor wire which I'm gonna sit in the compressor compartment.


Made two lids, the flat one and an angled one, both removable.


Front pic...


Pic from behind. Need to see if I can sit the sensors upwards yet...




And front shots with the digi gauges, still need to fit my tank pressure gauge yet. Above the tank.




Picked up some of these...


Fit them into the inner of the compressor box...Pic of the rear.


Et voila...

 

Got a cool little idea for a handle on the compressor compartment, may not work yet but I'll give it a try soon.

Just another small update really, been really busy and my Dad also got threatened/assaulted so I had to 'sort that out'

Picked up a pair of neons...Never thought I'd be buying these lol.


Picked up two wiring blocks for power and earth. Also got some reusable tie wraps and mounting blocks for them.


Put them in place, although I still need to sort more wiring it's sort of coming together.


Here you can see where I fitted the two fuses as well, top right above the ecu.


The run of the wiring so far.


I then picked up some wire etc for my digi tank pressure gauge and the digi volt and pressure gauges. Also some earth cable.



And fitted my digi tank pressure gauge. It's not working though for some reason!

 

Sorted my handle idea for the compressor compartment...It's a red LED door pin lol, I'm going to connect it/power it from the compressor side of the relay for diagnostics use. Basically it will light up when the relay sends power to the compressor. It shows really weak in the pics, but it lights up a rich red!






And I started building the floor for in front of the boxing, got carried away test fitting things...






Then I started the false floor and a drivers side panel.






Picked up a couple of black piano hinges so started making a door in the side panel, needs finishing yet.








Other door done, this ones larger as there's more space behind it and I may pop my amp on there...

It all looks a bit wonky yet until I get it all tweaked/glued/screwed. Along the top above the round gauge needs trimming for example so my parcel shelf will sit back on.

 

looking good. what are you going to trim it with ?

 

Cheers mate I'm just going for the cheap and cheerful acoustic cloth in black, at some stage I'd love to get a leather retrim done, so I'd probably end up with leather on this lot too.

Picked up some push catch latches for the two doors, really good quality little things they are! Supposed to be for caravan cupboard doors lol.

Also some switches that have a little red led (Ignore the single rocker switch, I decided against it). The Idea is to have them light up when the boot is opened so you can easily find/press them. And you can see some black screw caps/covers I picked up too.

One switch powers the two red neons, and the other powers the original boot light. But I found another boot light so fitted them both, one in each side panel...Still to wire up the second one as yet...

I'm gonna try wrapping the neons in red Lamin-X to try and take away the slight pink, they do look more red in real life though.















Thing is, I must have had a brain fart when i fitted the light switches, forgot that my parcel shelf was going back in the car and they wouldn't have been easy to get to so I've relocated them today. Need to rewire them properly yet, but test fitted them with the parcel shelf in.

 

Today I did managed to run the power wire from the battery, all tied up in place and ready. Also the ignition live, compressor live, and the headlight wire for the touchpad dimming features.

I also figured out where I'm going to run the earth. So I gave the boot a tidy up as I think the next time it all goes in will hopefully be the last last/final fit before I run the sensor wires and actually throw the suspension on, fingers crossed. Just awaiting some bulkhead fittings and a replacement tank pressure gauge as the one I got is faulty.

Obviously I need to get all the boxing covered up too! Just wish I had more time man.



Also covered the two neons in Red Lamin-X today, hopefully they will light up much more red and be a bit more subtle at the same time. Can't wait to get it all covered/back in the car.





Also decided I'm going to run a ciggy lighter socket in the passenger side panel above the boot light. Picked up this mini rechargeable led torch. It's mint! Lights up a dull red when charging and is bloody bright as well!



Wanted to get a lot of the boxing etc covered today but only managed the front panel before nearly taking my finger off! Oh well...That'll do for now.

 

Have done some more covering...And also fitted a ciggy lighter socket for the LED torch, which glows red when charging. Also a pic of the second boot light on the other side.

Still need to tidy up the hinges on the doors and I'm waiting for some smart/different little push knobs for them to finish them off.

It's slowly but surely getting there, It's no show car build or anything, but as long as it's easy to maintain everything and looks boring/subtle lol.

 

looks like a very tidy build

 

Thanks mate good to hear positive feedback! I was never one for woodwork at school! lol!

PS: The Corrado now has it's own page via the works website on facebook: Please click 'LIKE' here

Will update with more soon hopefully.
Neil.

 

Well I seem to have been pretty lucky finding the Borbet B's at reasonable money, especially as I also found four brand new original Borbet B center caps! Stickers, bolts and key! I don't actually want to fit them because they look yummy! Lol.

 

Picked up some gold plated battery terminals so I know the power supply will all be clean. And my Vw door push knobs turned up too! They are basically screw head caps/covers measuring 25mm across.





Fitted! Love em. Excuse all the dust/bits of wood on the paintwork!





dynamatted the compressor box section and carpeted a little bit.


Not sure if the dynamat is a good idea or not noise wise, obviously planning to put acoustic cloth over the top too. First time using the dynamatt, it's weird stuff, got the hang of it I think.







Also my PODI digital tank pressure gauge wasn't working, not lighting up at all when powered but I split it open just now and had a look. Couldn't really see anything obvious so I just resoldered the wiring pictured.





It now lights up! But actually says FAIL!? Have I knackered the gauge!? I tried to be really careful because my soldering iron is a very high wattage one, but it looks like I may have melted/killed a resistor or something?




Boxing near finished, sorry about the poor phone pics.












All I did manage recently was to apply sealant to all the tank/compressor fittings, run a couple pieces of air line. And then I loosely connected the VDO pressure gauge, and hooked the box/tank up to the car via some jump leads. Ran the compressor and filled the tank up to 150psi.


Have left it now to see what the pressure is tomorrow. Hopefully it's somewhere still near the 150. Couldn't hear any leaks but we will see.

 

Blimey... effort and a half going into that!

Hello stranger...

 

First time Iv spotted this thread in years and I was just thinking about it the other day, glad to see the car is still pampered and thats a really nice install on the air ride, managed to keep so much boot space!

 

How do lads, hope you are both well

Aye, boot space/keeping the spare wheel usable was a priority And I want it to look as original as possible, if that's possible with this kind of thing lol

Well I just got upto my unit to check the pressure. It's dropped to 105psi.
I refilled to 150psi and ran some soapy water around the joints.
I found one leak. It's the join between two fittings just before the water trap.

Here's what all the leak free joints look like...


And in comparison, the leaky joint...Red is the leak point. Blue is ok.


So I re applied some fresh sealant after cleaning off the old, and refitted. I filled back up to 150psi and I left it again to see what the pressure was.

I'm not really too happy with the way I've mounted the water trap to the tank. Reducer from trap > 90deg > reducer into tank, it's all a bit tight so I may pick up two more of the numatics 90deg swivel elbows and run some air line between them.


After this/25 hours, the pressure had dropped from 150psi to 130psi. Better! but couldn't actually tell where any pressure was being lost so I planned to buy some more 90deg swivel elbows to mount the water trap, should get a totally leak free seal that way.

 

Near enough completed all the wiring, just the sensor wiring to run to each corner, and then connect everything up.

Managed some better fittings for the water trap, and also new ones (below red box, not pictured) for the compressor. Did a test again roughly over 20/24 hours and only dropped 5psi. But i'd had the little black pipes in and out a good few times so some fresh pipe once fitted may sort that as it's the only place I found a very slight leak.

Also fitted the rear shocks and ran the rear air lines. I ran them through the boot/trunk floor via the abs wiring grommets, and along the rear beam at each side. Jesus christ it sits low! It's sat on the tyres so I guess it's as low as it can be!

 

Fittings added to struts.


Greased up the anodized parts, and the body. This method has kept my old konigsports mint. May get pics later.


New top mounts added all around.


E-Level sensor wires, cut and tinned up with solder. Cutting them means you can route them through grommets/holes easily as the plug tends to be too big. It also allows you to shorten the wire if you want to do that.


Finished up with heat shrink, and then I taped them up nice and tight with no creases (Because I'm down like that). This soldered/taped joint will be inside the car.


Struts fitted. Air lines and e-level sensor wires have been run through. I'll try and get pics of the routing later.