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JMC's 1.9l G60

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JMC's 1.9l G60

Post by jmc on Mon Nov 10, 2008 11:21 am

Hello all, I thought I would get some details up of my ride, and a few pics...

Gloss Black 1992 Corrado G60

Engine and Transmisson
1.9l G-Werks Red label rebore
G-werks stage 4 cylinder head
Schrick cam
Stage 4 charger with 68mm pulley
Golf G60 FMIC
Mocal 19 row 115mm oil cooler in passenger wheel arch (with ventilation fitted into the wheel arch liner)
Schrick sump and windage tray
Flowed throttle body
G-werks 4 branch manifold
Longlife stainless exhaust
70 degree thermostat
VR6 1st, 2nd and 5th gears and Peloquin in the box
Numerous maps from PSD
Power approx 230bhp, torque approx 205lbft

Wheels and Chassis
16" Compomotive MO's with 205/45 Toyo T1R's
KW Variant 1's
H&R Antiroll bars
AP Racing 315mm discs with Porsche Boxster callipers and Pagid 421 pads

Exterior
Pretty much standard other than custom front bumper to allow more air flow to the rad and FMIC
DDI blue smoked mirrors
Headlight protectors
Smoked rear lights
Uprated headlight loom and Phillips +80% bulbs

Interior
VR6 heater leather retrimmed in black leather and grey alcantara
VR6 door cards and electric mirror and window switches
Custom made centre tunnel cover in grey alcantara
Black headlining and sunvisors
Passat W8 interior light
DDI aluminium sills
All switches recoloured in red
DDI dials
Electroluminescent early style heater control
Defi AFR and Oil pressure gauges
Autometer Sport Comp Boost vacuum gauge
Extra cig lighter socket fitted in passenger under dash tray
Golf Mk4 cig lighter socket and Touran LED torch
Relocated boot light, and 3rd brake light at top of rear window
Alpine 9815 head unit
Genesis profile 4 and Precision Power 500.1 amps
Audioscape door pods and sub enclosure
Diamond M3 6.5" comps and Rainbow 10" sub

Damn me, I'd forgotten about most of that lot Laughing I will probably have to edit it as I remember more. As for plans - I currently have an empty 5lb nitrous bottle in my living room along with a load of other stuff for it waiting to go it. Also got a CF bonnet coming...

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Last edited by jmc on Thu Nov 13, 2008 9:29 am; edited 2 times in total
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Re: JMC's 1.9l G60

Post by mrbeige on Mon Nov 10, 2008 11:34 am

Has to be one of my all time favourite Corrados. Love the engineering approach to everything, and really looking forward to the results with the NOS Smile

Good work

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Re: JMC's 1.9l G60

Post by mic_VR on Mon Nov 10, 2008 11:46 am

Seconded, love this C. Always like the look of everything you're done. Good show sir! Good Job
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Re: JMC's 1.9l G60

Post by jmc on Mon Nov 10, 2008 11:50 am

Cheers guys. It has been a voyage of discovery for me has this car - I knew very little about them before buying it. Despite a few hiccups along the way (rear brake binding and red glowing rear disc spring to mind as being one of the least pleasant ones) it really has been fun. Hopefully the NOS will be even more fun Cool
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Re: JMC's 1.9l G60

Post by junkie on Mon Nov 10, 2008 12:48 pm

Any chance of getting some more angles of the front mate.
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Re: JMC's 1.9l G60

Post by jmc on Mon Nov 10, 2008 1:21 pm

Here you go Simon...

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Re: JMC's 1.9l G60

Post by dirtytorque on Mon Nov 10, 2008 1:50 pm

Hello Jonathan.
So what is involved to make a car run a chemical cocktail?
Do you need an external controller ?
What about plumbing and fittings?
Where will the bottle live?
I've never looked into it so I'm curious.
Are you fitting it yourself?
You'll have to think about taking this down the 1/4 if you go down this route mate. Smile
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Re: JMC's 1.9l G60

Post by jmc on Mon Nov 10, 2008 1:59 pm

I have bottle, progressive controller, nitrous pressure transducer (feeds back and helps control the bottle warmer to keep the pressure constant), fuel pressure transducer to make sure if it goes lean eveything switches off.

Bottle location I am not sure yet - either boot, or in that nice, ready made gap between the 2 rear seats and poking through between the front seats Cool

Have a look on the Wizards of Nos forum if you're interested. It comes with pretty much everything as a bolt in kit, and I'll be doing most of it myself. BUT I'll be geting it thoroughly checked out before using it. You're right though mate - if this goes to plan it will need quarter miling at some point.
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Re: JMC's 1.9l G60

Post by Toad on Mon Nov 10, 2008 2:22 pm

I do like that...

I just got to thinking about the extra cooling from the NOS to the charge, and just wondered if the sooner it was plumbed in the better? Or if there would be an issue with the throttle closing and a fair volume of nos/air mix left in the inlet system.

I guess the pipes run pretty cold? Could this be used to an advantage adding extra cooling to a fmic or charge cooler?
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Re: JMC's 1.9l G60

Post by junkie on Mon Nov 10, 2008 2:24 pm

Seen some skyline drag racers getting the nos bottle and blasting the intercooler to freeze it basically ready for a run.
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Re: JMC's 1.9l G60

Post by Toad on Mon Nov 10, 2008 2:29 pm

I've seen them using CO2 fire extinguishers to add a bit more cooling. Smile I like the idea of that...
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Re: JMC's 1.9l G60

Post by jmc on Mon Nov 10, 2008 3:12 pm

The pipes are nylon, so not the best for conducting heat away, but yeah, I've seen the intercooler sprayers as well.

To be honest I'm not sure I'd want to spray either CO2 (if any got into the air intake it would reduce power) or to a lesser extent N2O (potential fire risk associated with increased oxygen environment around any hot oil or fuel leak). Water seems the best (safest) bet for intercooler spray in my mind anyway.

The idea is fit the NOS and fuel inlets somewhere between the CO pot and throttle body, that way it acts to cool the air down. Then slightly more fuel can be added in with the nitrous/fuel injectors to compensate for any leaning out because of increase charge density. God, I hope that makes sense, otherwise I'll have to start from scratch again Laughing
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Re: JMC's 1.9l G60

Post by mrbeige on Mon Nov 10, 2008 3:14 pm

You'll defo need more fuel as you'll have a funk load more oxygen in the intake charge from the dinitro-monoxide Smile

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Re: JMC's 1.9l G60

Post by jmc on Mon Nov 10, 2008 3:20 pm

Yep. The nitrous system is design to input more fuel an more nitrous at the same time (it's a wet system), and keep the afr the same. Given its supercharged and there is significant air pressure in there on WOT by tweaking the fuel up slightly, it should compensate for the air/fuel/nitrous being slightly denser, otherwise (as far as my little brain can understand)it will lean out.
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Re: JMC's 1.9l G60

Post by ctwg60 on Tue Nov 11, 2008 5:37 am

Hi jonathan, nice project with the nos but I think adding fuel to the intake system before the throttle body is a really bad idea you could have fuel recirculating in your intake tract and I don't think would be good for your charger or reliable running. affraid

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Re: JMC's 1.9l G60

Post by jmc on Tue Nov 11, 2008 10:21 am

Cheers CTW. I was thinking that as well. However the nitrous and fuel are only being put in when the recirc system valve is shut off (operated via a microswitch on the throttle body). In theory (and I went through this with Trev at WoN just to make sure he was 100% on it being safe) there should be no chance of it going back through the intake system and charger, as its only in operation at WOT. Even if some got recirced though, apparently the older systems used to inject fuel and nos before superchargers (some of the older US big block engines for example). If the worst comes to the worst I'll do it as a direct injection system (after buying another charger Laughing).
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Re: JMC's 1.9l G60

Post by James H on Tue Nov 11, 2008 11:22 am

I think you'll be ok with nitrous. The injector needs to be as close to the throttle body as possible, not before the bend.
Not keen on WoN myself. Know of 2 cars this year that have had leaking WoN solenoids resulting in destruction of their inlet manifolds etc. I've been using a NOS system for 3 years without any problems. They are cheaper too!
By the way, i'm lovin' the Corrado! Cool
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Re: JMC's 1.9l G60

Post by ctwg60 on Tue Nov 11, 2008 1:38 pm

jmc wrote:If the worst comes to the worst I'll do it as a direct injection system (after buying another charger Laughing).

OK then. Very Happy Actually you could remove the recirc altogether I suppose, if you were worried. No chance of any expensive damage then.

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Re: JMC's 1.9l G60

Post by jmc on Wed Nov 12, 2008 1:25 am

Mmmh, bit scary that James. Was looking around for what systems seemed most reliable. Perhaps I should have looked harder. It's definately something I will keep an eye on though. Good to know there are other nitrous oxide users on here, if I have any questions Very Happy

CTW, I`ve run the boost delete before and it annoyed the hell out me - sounded like I had a canarie trapped just inside the engine bay Laughing so I went back to using the original pipework. As you say though, it is another option this time round.
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Re: JMC's 1.9l G60

Post by jmc on Thu Nov 13, 2008 12:13 pm

Just thought I might post this up. For those of you who want to know your air intake temps, you can relocate the outside temp sensor into a cold air feed really easily. I've done this on mine and it now gives me an idea of how the intake temps vary...

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Also if you're fitting an oil cooler in the passenger footwell, best to put some air breather holes behind it otherwise the air flow can stall.

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Re: JMC's 1.9l G60

Post by dirtytorque on Thu Nov 13, 2008 12:28 pm

some nice practical mods J.

I'll probably incorporate those. Cool
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Re: JMC's 1.9l G60

Post by jmc on Mon Jan 05, 2009 10:38 am

Just had a day out at Stealth, to get a decent map for my G60. The results have proved very interesting...

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These are powers and torque at the wheels rather than the flywheel (although out of interest it ended up being 246bhp and 222lbft at the flywheel Very Happy ).

On the graphs are 4 lines... The setup with the Piper cam (run with the bonnet up), the Schrick withe crappy map that was written for it (run with bonnet down so will be different, but included for completeness). These 2 were run at Surrey Rolling Road in August time.

Then from today at Stealth, the Schrick cam run with the Piper map (and 3 degrees advance on the timing - basically as it has been running for the last few months), and the final optimised Schrick setup. There is a huge difference, and I was amazed how much better it feels (even to me).

Some points that Vince came up with though.

The injectors are now operating at 90% so not much room to play.
The ISV is constantly leaking a small amount of boost, especially at the top end.

All in all, a great day out and dead chuffed Very Happy Very Happy
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Re: JMC's 1.9l G60

Post by junkie on Mon Jan 05, 2009 11:22 am

Brill mate, who says the piper is top endy with a loss in torque eh?
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Re: JMC's 1.9l G60

Post by jmc on Mon Jan 05, 2009 11:25 am

Yeah, the Piper is actually a pretty good cam from what I can see. Run under the right conditions it can produce a very torquey setup.
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Re: JMC's 1.9l G60

Post by junkie on Mon Jan 05, 2009 11:26 am

Yey another convert.
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Re: JMC's 1.9l G60

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