Hello,
I would like to show you my baby ..... it is Vw Polo G40 '94. I bought it 3 years ago. It was fully stock.
Modifications done: - polished G60 RS charger,
- german toothed pulleys (28 tooth charger pulley at the moment), additionally I have 22 and 24 teeth charger pulleys,
- custom charger bracket,
- custom chip,
- G60 injectors,
- Bosch W4DP0 spark plugs,
- ported head,
- aluminum air intake 77mm => 70 mm by the charger,
- air filter K&N,
- polished rocker,
- polished Polo GT inlet manifold,
- polished de-wedged throttle 48mm
- IC from Audi A3
- 4-2-1 exhaust manifold
- Jetex exhaust system – 2,5”
Suspension: Koni + H&R kit 80/60, front and rear brace bar
Wheels: PLS Hockenheim,
- front: 8,25" ET 6 – outside rim 3"
- rear: 9,25" ET 6 – outside rim 4"
- tires Continental 175/50/13
Body: removed rear wiper, smaller mirrors
Interior: - 3 VDO gauges: oil temp and pressure, voltage
- AG SM Peak boost gauge
- modified clocks
- steering wheel: Raid HP 28 cm
- shift-light
Plans: new CatCams camshaft 267/281, 250kPa or 300kPa map-sensor, 24 or 22 teeth charger pulley and custom remap. After that I will search for a new body, I want the Polo mk1.
I bought the car in 2008, below photos:
Chart from the rollers. Stock car: 0,6 bar of boost:
Result: 106.6 HP, 153 NM
Next I have done following modifications:
- charger pulley 65 mm + SLS chip,
- FMIC from BMW
- de-cat
- Polo GT inlet manifold
- de-wedged throttle body (48 mm)
- rear and front brace bar
Unfortunately I did not measure power after these modifications. I sold the G40 charger in winter 2009 and it started .... :-)
Polishing:
new charger ...
Refreshed wheels:
Mounting the G60 charger:
and it's ready for 2010 season:
At the end of 2010 season I have added: toothed pulleys, 4-2-1 exhaust manifold and Jetex 2,5” exhaust system.
In 2011 I worked under the air inlet, new IC. I've wanted as much as possible of aluminum.
Pipe from the charger to IC
Almost finished, you can see the new headlights, air inlet on the bonnet to the IC
Clocks at night, the red LED light below the VDO oil temp gauge is shift-light, useful thing ...
It is not a full story, but the most important informations.
75 mm (28 teeth) charger pulley produces 1,35-1,4 bar of boost.
Next week I will check this setup on rollers.