G60 Conversion

RichG said

pazwaa said

Possibly a daft question, but what is a fluid damper?  

Matt

Good question

On the crank of a G60 there is a harmonic damper which balances out the crank and reduces vibrations and resonance from the G60 supercharger.

I couldn't rescue mine so fitted an alloy pulley from Bartek. I've heard that in the long run this may cause stress on the crank.

The fluid damper is a pulley with an inertia ring inside surrounded by silicone fluid and laser welded shut. When the engine is rotating the interia ring helps balance out the vibration o the crank assembly. 

Thanks rich    all clever stuff.

Been busy tweaking and fettling I have fitted my fluid dampr now and very impressed with how smooth the engine feels. Removed the crank bolt easily with the VW tool literally undone with one swing of my bar.

The reduction in vibration is dramatic, hardly anything at all now with genuine mounts all round.

I got busy making up my supercharger bypass pipe, I couldn't fit my bartek kit as the radiator is very close to the boost return outlet. I bought a metre of stainless 1.5mm 40mm pipe and I had some 3mm stainless plate. I used the blanking plate I had as a template and cut the same in the 3mm plate, hard work on stainless this thick 
I carefully cut the stainless pipe at an angle that would clear the radiator, pretty much as extreme as I could make it without it overlapping the plate. I then stainless mig welded it in place and a local engineers firm tig welded it for me.

Check out how close it is to the radiator  but does the job and reduces the engine noise dramatically.


Oh and sorted out a gearbox Needs a jolly good clean

blimey theres a few pipes in that engine bay

jellybelly said

blimey theres a few pipes in that engine bay

Yeah I know what your saying lol, the g60 was never a pretty engine bay and with the boost pipe system going back to standard with uprated gear it takes up a lot of space.

Definitely opportunities to reroute and tidy up in the future 

Does anyone know if I'm missing something on my gearbox where the speedo cable goes? On my 02j box I had a threaded part I could attach a 1.3litre cable but not sure about this one.

Cheers

Rich

CTN box. Is that the one from a Mk3 diesel? I've gone with an ASD but I think the CTN is meant to have slightly better ratios.

Your missing the speedo sensor (like the one shown in the link). If you have one of those you unscrew the electrical connector off the top and the cable screws on in its place

http://www.corrado-club.ca/mods/tranny_fluid_change.html

MR_LONG said

CTN box. Is that the one from a Mk3 diesel? I've gone with an ASD but I think the CTN is meant to have slightly better ratios.

Your missing the speedo sensor (like the one shown in the link). If you have one of those you unscrew the electrical connector off the top and the cable screws on in its place

http://www.corrado-club.ca/mods/tranny_fluid_change.html

Yes that's right from a diesel. Managed to get it for a good price without scene tax

Thanks for the link. I will get one of those. Might even have one spare in my CDA 02 box.

I want to make sure this box doesn't shed its paint after 5 mins. Last box I cleaned pretty well and acid etch primed it, then aluminium coloured paint. 

Perhaps the paint was the problem. I did the rocker cover and inlet manifold the same way but with vw reflex silver and that's holding up.

Anyone have any tips on this?

Nice work on the charger boost return pipe! Do you think there will be any issues with contact between the pipe and radiator due to engine movement?
  I've been thinking about doing the same on mine but I've probably got less space than you :/.

daniboy123 said

Nice work on the charger boost return pipe! Do you think there will be any issues with contact between the pipe and radiator due to engine movement?
  I've been thinking about doing the same on mine but I've probably got less space than you :/.

Hi Chap,

I rev'd the engine a few times and it rocks backwards towards the windscreen away from the radiator The pipe does have a slight notch in it which is under the silicon pipe so it's more forgiving.

I can now hear the fuel pump under the rear bench now its quieter Might need to quieten that down

Very nice mate love the work you've put into it liking ya bypass pipe I'm planning on doing the same but in ally 

Be here now said

Very nice mate love the work you've put into it liking ya bypass pipe I'm planning on doing the same but in ally 

Cheers chap, the main boost return pipe is alloy. The charger section is only 4 inches long and I chose stainless because if I used alloy the outlet plate would need to be at least 10mm thick to not distort with the heat welding.

 I only had a gap of 35mm so stainless was a no brainer as I could have a smaller outlet plate of 3mm.

Had a bit of time to sort out the remaining boost system.

I've plumbed in the ISV and removed the filter so it's now back to stock:


I also ported my custom boost return outlet as I thought it might be a bit restrictive.

Before:

After:

Hmmm which alloys should I get refurbished? Garage is a bit over run with them at the mo!

Le Castellet's with alloy centres polished up?


Or BBS Sebring alloys in anthracite?

Hi Rich, pic links are currently broken, but anthracite Sebrings get my vote!   

Some rubbish photoshops:


Sebring's in standard silver (couldn't tint them anthracite for some reason)

 

Or leave it alone:

 

Leave it alone 

Matt

Agree, leave it alone! Pete.

Leave alone! If you fancy a change then anthracite sebrings but definitely not the chrome Le crapdalettes!! lol