gaz205t 42 Posted March 17, 2015 Report Share Posted March 17, 2015 (edited) Ok so thought I might as well start writing my build thread for the Rado. I know a boosted VR6 engine isn't anything new or special these days so not sure how much interest this will generate. May as well share my experience. First thing I wanted to do was get the Rado tested, just so there wasn't any hassle of getting the car through the test after the conversion. Plus means it's legal to go out and map it when I'm at that stage. She passedwith a advisory on a foosty clutch pipe. So we're good to go. Not really got much done. Time isn't on my side with work, a house and a seven month old. My plan is to change the valve stem seals when head is of to put on de-comp plate and change shells at same time. Just the cam sprockets to take off and head bolts to undo then whip her off. Edited March 17, 2015 by gaz205t Russvrt 1 Link to post Share on other sites
gaz205t 42 Posted March 17, 2015 Author Report Share Posted March 17, 2015 (edited) Machined myself a 3" v-band flange and machined the exhaust housing so it locates. Edited March 17, 2015 by gaz205t cactusjackslade and Russvrt 2 Link to post Share on other sites
daveyboy 897 Posted March 17, 2015 Report Share Posted March 17, 2015 You got a lathe and machine centre in your garage or is that at work? Link to post Share on other sites
Gwr corrado 189 Posted March 17, 2015 Report Share Posted March 17, 2015 Fair play mate , love to be able to do stuff like that , I have bother washing the car gaz205t 1 Link to post Share on other sites
gaz205t 42 Posted March 17, 2015 Author Report Share Posted March 17, 2015 You got a lathe and machine centre in your garage or is that at work?Haha I wish!! The perks of being a machinist. Link to post Share on other sites
Neil20vtc 44 Posted March 17, 2015 Report Share Posted March 17, 2015 Great work so far fella, good that your able to machine stuff yourself gaz205t 1 Link to post Share on other sites
daveyboy 897 Posted March 17, 2015 Report Share Posted March 17, 2015 Haha I wish!! The perks of being a machinist.I served my time on cnc's sometimes I wish I was still in engineering for those perks gaz205t 1 Link to post Share on other sites
gaz205t 42 Posted March 26, 2015 Author Report Share Posted March 26, 2015 When I put my decomp plate over this oil way seal on the block face, do I need to put something on the head side to seal?? Something like a fibre washer? Link to post Share on other sites
Sump_slammer 23 Posted March 27, 2015 Report Share Posted March 27, 2015 Pritty sure thats part of your old gasket, dont leave it in dig it out and throw it away. Link to post Share on other sites
c00k 435 Posted March 27, 2015 Report Share Posted March 27, 2015 Get a mk4 2.8 24v gasket. Split gasket in half, totally cover it in copper grease, (Like you would paint it, you can buy spray version of copper grease) Both sides, of both parts once split apart. Put one part on top of plate, put one part below plate. Link to post Share on other sites
gaz205t 42 Posted March 27, 2015 Author Report Share Posted March 27, 2015 This is my decomp plate (in the photos) It's the plate and Multi steel gasket all in one. Link to post Share on other sites
gaz205t 42 Posted April 2, 2015 Author Report Share Posted April 2, 2015 Little update, done a little profile matching between the manifold and the exhaust housing, a bit anal but why not. The head has been off and valve stem seal's have been changed. Cleaned both head and block faces then put on the decomp plate and refitted and torqued down head. Next I put the cams and sprockets back in and timed it up. Gave the cam cover a quick paint and and lay it on top for now. Still waiting on a replacement chain guide as mine is Broken, then I'll get the timing cover back on. Profile matchingLet the excess oil drain out Stripped the headGave it all a good clean and inspectionSpacer plate I got from Germany with multi layer gaskets Built head back upCleaned up block faceGot a bit excited and bolted on my turbo and short runner to see what kind of room I have. I don't have a lot of room between the bulkhead and snail, plus no room for compressor inlet pipe because of servo reservoir. Thought about swivelling turbo up a little but have no bonnet clearance. Waiting on exhaust parts to arrive now. D11PS 1 Link to post Share on other sites
gaz205t 42 Posted April 2, 2015 Author Report Share Posted April 2, 2015 Another pic of the profile matching, wasn't enough space on the last post. daveyboy and D11PS 2 Link to post Share on other sites
jonmir 10 Posted August 16, 2015 Report Share Posted August 16, 2015 Excellent gaz205t 1 Link to post Share on other sites
gaz205t 42 Posted August 21, 2015 Author Report Share Posted August 21, 2015 (edited) Hard to believe its been four month's since my last update! Not a lot done to be honest, considering the length of time. Been busy with the house and garden as it's the right time of year for all that jazz. Really need to pull my finger out if I want this project finished or at least on the road by the end of the year.Ok a little update. Changed my broken chain guide and put side cover and can cover with new gasket back on.Fitted new big end shells. There was nothing wrong with the original ones.Machined a couple oil return and External wastegate flanges. Edited August 21, 2015 by gaz205t daveyboy and Bealieboy 2 Link to post Share on other sites
gaz205t 42 Posted August 21, 2015 Author Report Share Posted August 21, 2015 Link to post Share on other sites
gaz205t 42 Posted August 21, 2015 Author Report Share Posted August 21, 2015 Link to post Share on other sites
gaz205t 42 Posted August 21, 2015 Author Report Share Posted August 21, 2015 Don't worry, I have done a little more haha. Will get pics uploaded asap Link to post Share on other sites
gaz205t 42 Posted August 21, 2015 Author Report Share Posted August 21, 2015 ff with the old s/s powerflow system. Link to post Share on other sites
gaz205t 42 Posted August 21, 2015 Author Report Share Posted August 21, 2015 Bought 3 meter length's of 3 inch stainless exhaust pipe from eBay. Also orderd two 90 bends, one a tight, and six 45 bends. I found that was maybe a bit excessive. Also bought 3" v-clamps and flanges, a joiner and clamp, and a 4" long flexible. I then started mocking and tacking up the downpipe. Bealieboy and daveyboy 2 Link to post Share on other sites
gaz205t 42 Posted August 21, 2015 Author Report Share Posted August 21, 2015 Fabricated together the backbox using a 5" silencer and some of the 3" straight pipe.Mocked up and tacked the rear section.Things really start to tighten up when using 3" stuff D11PS 1 Link to post Share on other sites
Bealieboy 1,625 Posted August 21, 2015 Report Share Posted August 21, 2015 Very nice fabrication, certainly no seagulls hovering round your workshop to help with the welding! D11PS and daveyboy 2 Link to post Share on other sites
Neil20vtc 44 Posted August 21, 2015 Report Share Posted August 21, 2015 Progressing nicely mate, what angles did you use for getting over the rear beam? Link to post Share on other sites
Vag-hag 147 Posted August 21, 2015 Report Share Posted August 21, 2015 Awesome skills mate. Everyone loves a vrt D11PS 1 Link to post Share on other sites
gaz205t 42 Posted August 21, 2015 Author Report Share Posted August 21, 2015 Center section.Ready to tig up. bennyk 1 Link to post Share on other sites
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