Corrado 2.0L 16v - GSXR throttle body project

@ danster

My 'Messy' comment was a little hasteful........

After looking at the alternatives, welding. extending etc etc......... Bending, for me anyway, looks like the best solution....

Going to try and bend each side by the required 4mm though.

Did you do it with the couplers in situ or did you remove them from the TB's?

Many thanks

Once again sorry for the 'Messy' comment

Ben

 

I'm going to go with extentions bolted on. Just a neat hole drilled and something like the pic below except obviously with a flat piece instead of the round cross hatched part. A pic of a tuning fork was the best thing I could find to describe the shape of the part.

 

Bigenbird, no offence taken. Because there's nowt wrong with being a messy bender!

And to be honest, the shame of owning a 16v is far more to be embarrassed about.

Looks like we need Harry Hill to finally sort out the tabs versus bending dilemma..........FIGHT!!

 

Didnt realise valvers were a motor to be embarrassed by!

Best buy a pink tent to hide my shame in!

 

No shame at all. Be proud and let your 16v sing! Lol.

Btw, this build is coming along very nicely!

Gurds

 

^^^ this. Is just a danster's thing. He has an 8v obsession

 

Spoke to the engineer last night. I'll be bringing all the bits to him this evening and he says it'll be no problem sorting it all out.

 

List of work being done by my mate.

Inlet flange being machined to flatten the rough cuts done by me. This is to get it ready for the inlet runners. Haven't decided what way I'll do these yet.
Extensions for the tabs between the throttle bodies.
New bar for the back to hold the TBs together at the new spacing.
New spacers 8mm wider for the bolt to run through and spacer the TBs.
Longer bolt made for the wider setup.
Bungs to plug the exisitng injector holes in the TBs.

The high comp pistons have been dispatched.
The block is being dropped off for the rebore tomorrow.
The crank is also being left off to be polished.

I think that's all for now.

 

Block and crank left off.

Lets talk main bearings, rod bearings, and thrust washers.

Is it best just to go for OEM standard ones?
I can see minor wear on mine. Nothing unusual, just a bit of the usual discolouration from wear. Had to be expected with almost 160K on it. Trying to gather all the bits and pieces before I build the block back up. I'll probably need to replace all the bottom end gaskets. Is there a kit part number for these or can I just buy seperately? I get trade prices on parts so I'll just be going to VW for whatever is still available.

 

When I re-built my 9a I used KS bearings from GSF. I'd imagine VW would supply the same. Mine was at 205k miles and the bearings all looked good. The crank journals were within manufacturing tolerence too! VW built these to last

 

Gave the combustion chambers and the ports a bit of a soda blast to clean them up before any more work is done. I need to get my hands on a decent die grinder before I go anywhere near it because I mashed the internals on my last one.

 

Was this the sort of thing you were thinking of for your throttle linkages? Its a little tight and fiddly getting them in.



Ben

 

Yes very similar except we'll probably recess them for the tab and the spring as well. I think it might be worth sloping off the transitions between left and right to avoid right angles. I know it's unlikely to see stress fractures but an engine bay can be an unforgiving place.

Parcel arrived yesterday:

 

Nice and shiny.

valve pockets are massive so I can't see any clearance issues here.

 

Polished crank and rebored block collected today. Will post pics later.

 

Can I be rude and ask how much the rebore and crank work cost you?

Ben

 

125 all in.

 

Here's the block and crank. As soon as I have new bearings and seals and get it flushed out hopefully it won't be too long before I have it back together.



And here's some of the wiring work all braided for running up the wings.

 

Did they not flush it out for you? How are you planning on flushing? Hot cycle in the dishwasher!

 

Nope, I'm going to use an industrial pressure washer. This is what they told me to use and just make sure I get all the oil gallerys well flushed out and all the oil holes in the crank etc.