Club G40 Forum

Hi All

So here is quick update of the last 8 months of G40 ownership:

Was on the look out for a mk2f polo after my last vehicle didn't fulfill certain criteria.
(http://i959.photobucket.com/albums/ae75/physicsfool/car_zps2df4cb76.jpg) (http://s959.photobucket.com/user/physicsfool/media/car_zps2df4cb76.jpg.html)

I bought this G40, having viewed it 4 hours previous, not a shred of service history and taking it for a test drive. No idea why anyone would put a supercharger on a 1.3 8v but it drove nicely and bloody quick.
(http://i959.photobucket.com/albums/ae75/physicsfool/89437D23-B10B-4EFD-80D0-D13B5EEE1E62_zpsmr73nmda.jpg) (http://s959.photobucket.com/user/physicsfool/media/89437D23-B10B-4EFD-80D0-D13B5EEE1E62_zpsmr73nmda.jpg.html)

After a good wash and bucket of T cut and some bumper spray. looking pretty flash.
(http://i959.photobucket.com/albums/ae75/physicsfool/6D084307-B880-46DC-919A-0B760D6294C0_zpsj9rfkjf9.jpg) (http://s959.photobucket.com/user/physicsfool/media/6D084307-B880-46DC-919A-0B760D6294C0_zpsj9rfkjf9.jpg.html)

But clean engine bay and no apparent abuse to any part of the engine
(http://i959.photobucket.com/albums/ae75/physicsfool/E32D9555-0E52-42BD-8FDA-E6764CBD0CBB_zpsgalsqta8.jpg) (http://s959.photobucket.com/user/physicsfool/media/E32D9555-0E52-42BD-8FDA-E6764CBD0CBB_zpsgalsqta8.jpg.html)

Now, I am still young and hopelessly optimistic, but when i thought i could run this car cheaply, that was my first and greatest mistake. Especially as i am not a mechanic, my hands are soft and only good for writing reports on my ergonomic keyboard.

24th birthday i got a Haynes manual, single greatest tool...... And then it all kicked off
(http://i959.photobucket.com/albums/ae75/physicsfool/713FA6B1-40AA-4888-A40A-16AF23B8AB3F_zps5k951gdf.jpg) (http://s959.photobucket.com/user/physicsfool/media/713FA6B1-40AA-4888-A40A-16AF23B8AB3F_zps5k951gdf.jpg.html)

but it was summer so long days and warm weekends
(http://i959.photobucket.com/albums/ae75/physicsfool/F64FFF01-DE1B-4D2E-B056-46629C5CBAE2_zps4puaoewl.jpg) (http://s959.photobucket.com/user/physicsfool/media/F64FFF01-DE1B-4D2E-B056-46629C5CBAE2_zps4puaoewl.jpg.html)

the culprit
(http://i959.photobucket.com/albums/ae75/physicsfool/A8BDBC8D-6211-427C-9905-7DB82E5FC867_zpsozrg8oaj.jpg) (http://s959.photobucket.com/user/physicsfool/media/A8BDBC8D-6211-427C-9905-7DB82E5FC867_zpsozrg8oaj.jpg.html)

but i made a good friend in the process.... his head work skills (waaaaahhey) are top notch
(http://i959.photobucket.com/albums/ae75/physicsfool/17B70EBE-4318-4C94-8215-AEE486572D19_zps51b7cm08.jpg) (http://s959.photobucket.com/user/physicsfool/media/17B70EBE-4318-4C94-8215-AEE486572D19_zps51b7cm08.jpg.html)

Plus the charger was pissing oil, so one top Yorkshire bloke later (pete) i had a fresh set of seals and a refurbished charger.
(http://i959.photobucket.com/albums/ae75/physicsfool/B453159C-996B-4365-A525-30B34502EDA5_zpskbvzmqxl.jpg) (http://s959.photobucket.com/user/physicsfool/media/B453159C-996B-4365-A525-30B34502EDA5_zpskbvzmqxl.jpg.html)

Usual top scroll bearing issues.............Hammer time
(http://i959.photobucket.com/albums/ae75/physicsfool/1F75168D-4EAD-43F3-B8AE-ECC9E0236BB5_zps1zq3kfnp.jpg) (http://s959.photobucket.com/user/physicsfool/media/1F75168D-4EAD-43F3-B8AE-ECC9E0236BB5_zps1zq3kfnp.jpg.html)

New belt and water pump....... never paying a mechanic to do one of these again is a good feeling
(http://i959.photobucket.com/albums/ae75/physicsfool/964C8EA5-8B5F-4DE6-B64B-631CB25FD825_zpsczamssm2.jpg) (http://s959.photobucket.com/user/physicsfool/media/964C8EA5-8B5F-4DE6-B64B-631CB25FD825_zpsczamssm2.jpg.html)

rebuild was a success and after a few timing issues she roared into life
(http://i959.photobucket.com/albums/ae75/physicsfool/C249038E-2C03-4B15-AC33-B78F5A7C6BC6_zps1g48rgi9.jpg) (http://s959.photobucket.com/user/physicsfool/media/C249038E-2C03-4B15-AC33-B78F5A7C6BC6_zps1g48rgi9.jpg.html)

Bought a £50 ATV with a smashed set of planetary gears
(http://i959.photobucket.com/albums/ae75/physicsfool/14669CD4-6AC9-4761-9B19-FFA366794F6C_zpsdunp9eml.jpg) (http://s959.photobucket.com/user/physicsfool/media/14669CD4-6AC9-4761-9B19-FFA366794F6C_zpsdunp9eml.jpg.html)

After a refurb and oil popped it on, runs mint but the release bearing has gone. Should havent swapped it out and not been a pikey about it
(http://i959.photobucket.com/albums/ae75/physicsfool/70ADEC0F-AF3C-4E9C-9776-82D3C1C75F9C_zpsaaxjrxw5.jpg) (http://s959.photobucket.com/user/physicsfool/media/70ADEC0F-AF3C-4E9C-9776-82D3C1C75F9C_zpsaaxjrxw5.jpg.html)

feel good small jobs..
(http://i959.photobucket.com/albums/ae75/physicsfool/C8E1C738-F7FD-467E-8291-6F7D44E292D4_zpsnbkv3u2z.jpg) (http://s959.photobucket.com/user/physicsfool/media/C8E1C738-F7FD-467E-8291-6F7D44E292D4_zpsnbkv3u2z.jpg.html)

..nice results
(http://i959.photobucket.com/albums/ae75/physicsfool/38A519BC-7644-4B4A-B831-42447E558F1E_zps1xop7spn.jpg) (http://s959.photobucket.com/user/physicsfool/media/38A519BC-7644-4B4A-B831-42447E558F1E_zps1xop7spn.jpg.html)

So here i am now, stripped the plastic arches to reveal bad wings. Popped some solid red doors on, not the best look though
(http://i959.photobucket.com/albums/ae75/physicsfool/3EA0CC55-47B2-4786-A294-1C493ABD6A59_zps3sgpvdal.jpg) (http://s959.photobucket.com/user/physicsfool/media/3EA0CC55-47B2-4786-A294-1C493ABD6A59_zps3sgpvdal.jpg.html)
(http://i959.photobucket.com/albums/ae75/physicsfool/59193811-8CBA-42D5-96E6-1734F1D17575_zps1lphf1hu.jpg) (http://s959.photobucket.com/user/physicsfool/media/59193811-8CBA-42D5-96E6-1734F1D17575_zps1lphf1hu.jpg.html)

Rust is pretty prevalent
(http://i959.photobucket.com/albums/ae75/physicsfool/639DB140-EF2D-4222-B4A4-18FC73C4C3BC_zpswjpk2kgo.jpg) (http://s959.photobucket.com/user/physicsfool/media/639DB140-EF2D-4222-B4A4-18FC73C4C3BC_zpswjpk2kgo.jpg.html)

So an window out spray is in order
(http://i959.photobucket.com/albums/ae75/physicsfool/15CB41BB-101E-46A7-967B-337A7E260415_zps4ijwve4n.jpg) (http://s959.photobucket.com/user/physicsfool/media/15CB41BB-101E-46A7-967B-337A7E260415_zps4ijwve4n.jpg.html)

frustratingly quite a bit of water still seems to be getting into the driver side foot well, i think the battery tray weld needs a touch up
(http://i959.photobucket.com/albums/ae75/physicsfool/51B59BA8-0178-40B5-92ED-090E93891717_zpsm3dwwhaw.jpg) (http://s959.photobucket.com/user/physicsfool/media/51B59BA8-0178-40B5-92ED-090E93891717_zpsm3dwwhaw.jpg.html)

The lake of water
(http://i959.photobucket.com/albums/ae75/physicsfool/0E88D37D-BF35-4B80-BF49-DDA32C90636C_zpsjxskfs5w.jpg) (http://s959.photobucket.com/user/physicsfool/media/0E88D37D-BF35-4B80-BF49-DDA32C90636C_zpsjxskfs5w.jpg.html)

So that's the plan, strip it down and paint it up.

Looks like a good project you have there!

Ay, getting it RR'd soon so i have a good starting point. I dont want to do anything too destructive.. but....

To do:

• Lighten the flywheel
• Chap that did the head work also ports, so fancy having a proper look into that
• Do all the bottom end seals

But this is mainly to repaint and freshen up

Nice! I like it, keeps us updated :)

Good man for getting your hands dirty and finding out what life's about. Nice one chap.

Got the rolling road on Saturday so in preparation I tightened the v-belts
(http://i959.photobucket.com/albums/ae75/physicsfool/2FD8E563-2026-48B7-8E29-90C4333C77F1_zps98jn3qwr.jpg) (http://s959.photobucket.com/user/physicsfool/media/2FD8E563-2026-48B7-8E29-90C4333C77F1_zps98jn3qwr.jpg.html)

And swapped the intercooler for one without a small stone chip hole on the front (left-stone chip)
(http://i959.photobucket.com/albums/ae75/physicsfool/316422B8-62EE-4A6E-8F49-B2D89341D1B1_zpseckwxwfj.jpg) (http://s959.photobucket.com/user/physicsfool/media/316422B8-62EE-4A6E-8F49-B2D89341D1B1_zpseckwxwfj.jpg.html)

Rolling road on Saturday. This is how it's done in the north.
(http://i959.photobucket.com/albums/ae75/physicsfool/D0889463-FAB2-4963-8A6D-1C6C00571D8E_zps6vljdau1.jpg) (http://s959.photobucket.com/user/physicsfool/media/D0889463-FAB2-4963-8A6D-1C6C00571D8E_zps6vljdau1.jpg.html)

Generic rolling road photo
(http://i959.photobucket.com/albums/ae75/physicsfool/BB9B3BE4-0CA5-433E-95C9-4D0A25071EFB_zpswqandgvi.jpg) (http://s959.photobucket.com/user/physicsfool/media/BB9B3BE4-0CA5-433E-95C9-4D0A25071EFB_zpswqandgvi.jpg.html)

Results were good 106 at the wheel. Reckoned around 130 at the flywheel. Torque was good and peaked at 127.
(http://i959.photobucket.com/albums/ae75/physicsfool/C5DE8D27-A8A3-4376-BEC6-19EE601B8CB6_zpscy6szrda.jpg) (http://s959.photobucket.com/user/physicsfool/media/C5DE8D27-A8A3-4376-BEC6-19EE601B8CB6_zpscy6szrda.jpg.html)

Sooo time to rebuild the engine as I need a project. Daily is a 1.9tdi A4.
(http://i959.photobucket.com/albums/ae75/physicsfool/BC7F20A9-E765-46E2-8264-79DE3C74DBAC_zpsilbgdnoy.jpg) (http://s959.photobucket.com/user/physicsfool/media/BC7F20A9-E765-46E2-8264-79DE3C74DBAC_zpsilbgdnoy.jpg.html)

Been tagging the wiring loom so I don't forget where each belongs. Plus plastic bags to hold the bundles. There is a bit of damage to various wires. So thinking I may replace some sections
(http://i959.photobucket.com/albums/ae75/physicsfool/3230A247-25F8-4603-BF5A-BA8C8C27CC8F_zpsuexqz1le.jpg) (http://s959.photobucket.com/user/physicsfool/media/3230A247-25F8-4603-BF5A-BA8C8C27CC8F_zpsuexqz1le.jpg.html)

Got hold of an engine hoist so thought I would get it all done in one weekend
(http://i959.photobucket.com/albums/ae75/physicsfool/40E334D7-7B00-4A4E-A242-0F7FDAEF135C_zpsit7xmpc3.jpg) (http://s959.photobucket.com/user/physicsfool/media/40E334D7-7B00-4A4E-A242-0F7FDAEF135C_zpsit7xmpc3.jpg.html)

Then once free, got to stripping it down. Much easier second time round
(http://i959.photobucket.com/albums/ae75/physicsfool/072945AD-E769-429F-85E7-E23B4EFB7ABC_zps09e1g8gj.jpg) (http://s959.photobucket.com/user/physicsfool/media/072945AD-E769-429F-85E7-E23B4EFB7ABC_zps09e1g8gj.jpg.html)

Finally 24 hours after the rolling road...
(http://i959.photobucket.com/albums/ae75/physicsfool/C9DD68A2-FCEB-4636-B95D-7E725691BAB3_zpsf3lgtlxh.jpg) (http://s959.photobucket.com/user/physicsfool/media/C9DD68A2-FCEB-4636-B95D-7E725691BAB3_zpsf3lgtlxh.jpg.html)

So been a cracking polo related weekend. Got a cylinder head off here. Hoping to get a bit of porting and flow figures.
(http://i959.photobucket.com/albums/ae75/physicsfool/C56621D4-F99A-4B33-8CA6-C6988F01A3E1_zps568rxmou.jpg) (http://s959.photobucket.com/user/physicsfool/media/C56621D4-F99A-4B33-8CA6-C6988F01A3E1_zps568rxmou.jpg.html)

And just wondering if this is a standard exhaust?
(http://i959.photobucket.com/albums/ae75/physicsfool/B27E9821-FE5B-40DC-8DD2-266D31B121F8_zpshonqlp4i.jpg) (http://s959.photobucket.com/user/physicsfool/media/B27E9821-FE5B-40DC-8DD2-266D31B121F8_zpshonqlp4i.jpg.html)

Cheeky 2 hour session this morning before uni, the bonus of studentom. Got hold of this weapon. With a fully charged battery it made quick work of the bottom crank bolt and flywheel bolts as well as the drive-shaft bolts. I have a feeling a lot more energy would have been expended otherwise. Plus i picked up a engine stand which i will attach the engine to later this evening.

(http://i959.photobucket.com/albums/ae75/physicsfool/A7425A3D-96C0-4B4F-84B4-57AF4DFAEC9E_zpsosg6ue06.jpg) (http://s959.photobucket.com/user/physicsfool/media/A7425A3D-96C0-4B4F-84B4-57AF4DFAEC9E_zpsosg6ue06.jpg.html)

I apologies for the photo quality, turns out apple are pikey's that develop incompatible software

Glad you tightened those belts Martin has your battery light gone off now?? Didn't realise you were breaking her down again after the rolling road haha! That looks like a standard exhaust to me fella, gimmie a shout if you want that modified one of mine it's yours for mega cheap  ;) will just need a decent backbox chucking on. Also gimmie a shout if youve got any q's when building the girl back up (seals n that)

Looks like yr doing a decent job.

If u need any parts let me know! !!

Battery light is still there, will be trying the new alternator.
Yeah count me in for the exhaust lad. When do I need to pick it up by?

Pete, list of parts from your horde is growing, just need my funding to kick in and I will be paying a visit!

So I have whipped the entirety of the engine bay loom out. And spent the week measuring cutting and determining current capacities. Just need to order some up and cut to size and hopefully I will have a spanking new loom.
This is how it all started:
(http://i959.photobucket.com/albums/ae75/physicsfool/C898198E-ED06-4CE6-B539-EA59F387D6CB_zpsxxm77tig.jpg) (http://s959.photobucket.com/user/physicsfool/media/C898198E-ED06-4CE6-B539-EA59F387D6CB_zpsxxm77tig.jpg.html)

Now I have spent the day breaking the cylinder head off, valves and plugs are pretty black. Over fuelling is my guess!?
(http://i959.photobucket.com/albums/ae75/physicsfool/A61A136E-970D-4D5F-BE44-7B9AD1C2F0FA_zpsh9ohjcmv.jpg) (http://s959.photobucket.com/user/physicsfool/media/A61A136E-970D-4D5F-BE44-7B9AD1C2F0FA_zpsh9ohjcmv.jpg.html)

And finally p*ssing around trying to be arty!
(http://i959.photobucket.com/albums/ae75/physicsfool/8B5DA454-45CF-4B8E-80BF-B424BC177BE8_zpsslmi3icv.jpg) (http://s959.photobucket.com/user/physicsfool/media/8B5DA454-45CF-4B8E-80BF-B424BC177BE8_zpsslmi3icv.jpg.html)

awesome!!
im getting a workshop with a booth in the sumer (going halves with a mate :))
if you havnt sorted the paint out by then we could work something out if you want me to spray it? only problem is its in stevenage. but could do a pro job for like half what a bodyshop would charge! :D
Taylor

I'll be tempted after the show season Taylor! Great work with the loom Martin, you keeping all the old connectors then? Valves look like they are overfuelling as much as mine , factor in a wideband dude when your putting it all together  ;D

Yeah Taylor, reckon I will hold out for your booth. May even learn something at the same time. Let me when when it's up and running and I will sort out a trailer.

Yeah I will get one sorted for the rebuild Tom, to save money I am cleaning the plastic connectors. But replacing wire and pins.

Sent off the flywheel and got it back looking shiny and thinner, looks to be about 1kg knocked off which is spot on
(http://i959.photobucket.com/albums/ae75/physicsfool/504E92AD-E7D6-4DD5-A6F1-6CF16F97B175_zpsths8liod.jpg) (http://s959.photobucket.com/user/physicsfool/media/504E92AD-E7D6-4DD5-A6F1-6CF16F97B175_zpsths8liod.jpg.html)

This kick started the motivation and I stripped the front wings and struts off
(http://i959.photobucket.com/albums/ae75/physicsfool/93CB607B-3E33-44D2-9E62-50B7C6CFF96B_zpszv8ixpy1.jpg) (http://s959.photobucket.com/user/physicsfool/media/93CB607B-3E33-44D2-9E62-50B7C6CFF96B_zpszv8ixpy1.jpg.html)

plenty of seized bolts means I am going to have to get hold of an impact driver again, but that shouldn't be a problem and then I can drop the struts and brake carriers in deox-c and get them painted.
(http://i959.photobucket.com/albums/ae75/physicsfool/22883333-2D73-47A9-BE9F-3D0753A02D66_zpsl7oji1zj.jpg) (http://s959.photobucket.com/user/physicsfool/media/22883333-2D73-47A9-BE9F-3D0753A02D66_zpsl7oji1zj.jpg.html)

Next step will be to clean up the arches, check for cracks and get the bulkhead strengthened.

It looks like this workshop/booth is getting built sooner than later
My mate is digging the foundations already, concrete should be layed this month
Started buying equipment, bought an £850 compressor...
When you looking to get it sprayed mate?

Ah excellent news, probably take me 3 months to prep/weld engine bay and struts/rear axle as its a time/money project. So any time after April/May time will probably be realistic.
Are you able to cut holes for the repeaters in the new wings?

Leave the repeaters out man looks loads better!

Quote from: Etches on February 11, 2014, 04:28:48 PM
Leave the repeaters out man looks loads better!

Ah tom, need to keep the car standard looking.

yeah sure man! between me and my mate there really isnt anything we cant do!
hes a panel beater and restored his golf, replaced floor pans did loads of metal fabrication :D
your car would be in good hands :)

Found this recess tonight while fettling...... Any ideas? Or just a good stashing place

(http://i959.photobucket.com/albums/ae75/physicsfool/4126F7E5-54C0-4E01-BC77-7F467EFF3E6F_zpsupnjiwqi.jpg) (http://s959.photobucket.com/user/physicsfool/media/4126F7E5-54C0-4E01-BC77-7F467EFF3E6F_zpsupnjiwqi.jpg.html)

That's one of the factory holes when they build then, for either lifting the car on the production line or for when squinting waxoyle in, either way that sticky thing you pulled off needs to be stuck back on and re sealed :) don't want water in the chassis leg

We welded and sealed Ryans ones up as it's a bit of a week point on the leg

Recent activity has included stripping fuel and brake lines, now the bay is looking bare and ready to be sanded and welded.
(http://i959.photobucket.com/albums/ae75/physicsfool/4109589C-0058-4863-88B2-4B5228B2BFD9_zpswbsoot35.jpg) (http://s959.photobucket.com/user/physicsfool/media/4109589C-0058-4863-88B2-4B5228B2BFD9_zpswbsoot35.jpg.html)

The struts have been causing me all sorts of problems due to seized and snapped bolts. Had to get my mate and his torch on the carrier bolts. Happy to say they are now stripped and ready for a deox-c bath.
Added pressure of my parents wanting to move in the very near future means i need to get the old girl on all 4 tires again.
(http://i959.photobucket.com/albums/ae75/physicsfool/9B3596A1-E733-4420-B33D-C3DC805662BC_zpsfibbcy2t.jpg) (http://s959.photobucket.com/user/physicsfool/media/9B3596A1-E733-4420-B33D-C3DC805662BC_zpsfibbcy2t.jpg.html)

What condition was fuel tank in?
as I know they corrode on filler neck, yet also know a few mk3's all running the original tank still.

Nice work

About 3 months ago I had to swap my old tank for this one from a mk3 polo van! It had a hole around the filler neck! And was pissing fuel, reason for a sudden drop in mpg!

Por15 the hell out of the tank pictured and still looks good!

Lol, that rusty fuel pump bracket is such a pile of poo, they rot out so bad and then those little rubber doobries always snap and end up being cable tied up haha

Haha had to cut 2 cable ties!!

Mines cable tied on too haha

Haha :P
I found a website that sells near identical rubber things for cheap
I'll post it up later

Taylor pointed me in the direction Bigg Red a brake refurbishment company! So decided the brakes needed stripping and prepping as they have a lot of surface rust!

http://(http://i959.photobucket.com/albums/ae75/physicsfool/24865CE0-6846-4DE5-8C51-54ED5D6BECF5_zpsdxjsphxd.jpg) (http://s959.photobucket.com/user/physicsfool/media/24865CE0-6846-4DE5-8C51-54ED5D6BECF5_zpsdxjsphxd.jpg.html)

Talk to me.... ive got some calipers fresh refurbished but one has an issue... at very least they can be used for new pistons,  piston seals, nipples etc!

Nipped ha
Martin stripping his calipers down at 1 in the morning :P

Gotta squeeze every hour out of the day! Especially when the missus isn't round!

Righto, been about a month since my last update... So here is my process so far, this is the slower slightly less revolutionary stuff, but a big ol' learning curve never the less.

here are the areas of greatest concern.. drivers side sill
(http://i959.photobucket.com/albums/ae75/physicsfool/2E587872-D1C3-4FB2-8A88-93315011BB32_zpsarjyf62p.jpg) (http://s959.photobucket.com/user/physicsfool/media/2E587872-D1C3-4FB2-8A88-93315011BB32_zpsarjyf62p.jpg.html)

coil pack area
(http://i959.photobucket.com/albums/ae75/physicsfool/8A070EDD-8FC0-4546-AF5E-EB1544DB8DDA_zpsj65cy3uw.jpg) (http://s959.photobucket.com/user/physicsfool/media/8A070EDD-8FC0-4546-AF5E-EB1544DB8DDA_zpsj65cy3uw.jpg.html)

and bottom of the passenger side front wheel arch corner
(http://i959.photobucket.com/albums/ae75/physicsfool/0D056F41-5083-4AC8-947C-E64279BB2681_zpsatxaa1dd.jpg) (http://s959.photobucket.com/user/physicsfool/media/0D056F41-5083-4AC8-947C-E64279BB2681_zpsatxaa1dd.jpg.html)

First bit of fabrication
(http://i959.photobucket.com/albums/ae75/physicsfool/9BD599CA-43AD-48C8-B88A-8FA29C1689EE_zpsmr3odqxt.jpg) (http://s959.photobucket.com/user/physicsfool/media/9BD599CA-43AD-48C8-B88A-8FA29C1689EE_zpsmr3odqxt.jpg.html)

And the rear wheel arches are in decent condition, nothing a quick sand and primer won't sort
(http://i959.photobucket.com/albums/ae75/physicsfool/123B5488-9829-4FB0-B0AC-601A6EE7E526_zpsdlemipvs.jpg) (http://s959.photobucket.com/user/physicsfool/media/123B5488-9829-4FB0-B0AC-601A6EE7E526_zpsdlemipvs.jpg.html)

Arches are fully stripped and welded up, welds are still looking urrrrgggeeellly but doing the trick
(http://i959.photobucket.com/albums/ae75/physicsfool/901F3B15-AE48-4C5B-BBDA-824E2E963AAD_zpsvqv2vsww.jpg) (http://s959.photobucket.com/user/physicsfool/media/901F3B15-AE48-4C5B-BBDA-824E2E963AAD_zpsvqv2vsww.jpg.html)

Annd the drivers side with the rust patches brushed out and etch primered up
(http://i959.photobucket.com/albums/ae75/physicsfool/F0AB4DFF-B70F-420A-826C-67E9E647235B_zpsrvmz6cvj.jpg) (http://s959.photobucket.com/user/physicsfool/media/F0AB4DFF-B70F-420A-826C-67E9E647235B_zpsrvmz6cvj.jpg.html)

Empty bay with small weld job by the coil pack area
(http://i959.photobucket.com/albums/ae75/physicsfool/7A67A24C-F4DA-45C8-B940-7DA8A5A65E36_zps1noqujna.jpg) (http://s959.photobucket.com/user/physicsfool/media/7A67A24C-F4DA-45C8-B940-7DA8A5A65E36_zps1noqujna.jpg.html)

brakes and steering arms are close to being refurbed so not long till she is rolling once again....

Ahh! Yes!! She is bare indeed! Love it dude! She is going to look epic once painted ;)

So update, most of this was on a thread but trying to keep it sequential

Found the drivers side chassis leg is cracked and slightly off, so i need to get hold of a stage 2 subframe from PPP and get it welded up, not ideal but it will be worth it when its finished.

(http://i959.photobucket.com/albums/ae75/physicsfool/BA508251-1C08-42FA-9577-981ACB8F0C14_zpsslnl6dfg.jpg) (http://s959.photobucket.com/user/physicsfool/media/BA508251-1C08-42FA-9577-981ACB8F0C14_zpsslnl6dfg.jpg.html)

from the underside, its cracked the underseal which isnt ideal
(http://i959.photobucket.com/albums/ae75/physicsfool/7728D02A-A411-4CC5-B8BD-4FCC1E6E6F9C_zpsj1vphcrf.jpg) (http://s959.photobucket.com/user/physicsfool/media/7728D02A-A411-4CC5-B8BD-4FCC1E6E6F9C_zpsj1vphcrf.jpg.html)

and separated slightly
(http://i959.photobucket.com/albums/ae75/physicsfool/639CF469-2001-4816-9C4B-9CEFFD98DD28_zpsyujrew7m.jpg) (http://s959.photobucket.com/user/physicsfool/media/639CF469-2001-4816-9C4B-9CEFFD98DD28_zpsyujrew7m.jpg.html)

this also looks fairly lairy but i was calmed by the other G40 chaps and with it due a respray in the next month its going to look quality when all put back together
(http://i959.photobucket.com/albums/ae75/physicsfool/15ED1A28-9C40-47DD-BDD6-928506D686FA_zpshrrn4s2j.jpg) (http://s959.photobucket.com/user/physicsfool/media/15ED1A28-9C40-47DD-BDD6-928506D686FA_zpshrrn4s2j.jpg.html)

I have also sent the rear axle off for sandblasting as its looks pretty rusty.
(http://i959.photobucket.com/albums/ae75/physicsfool/7D345F9E-6554-4906-AF0A-229CD6FD1C2D_zpscudymnla.jpg) (http://s959.photobucket.com/user/physicsfool/media/7D345F9E-6554-4906-AF0A-229CD6FD1C2D_zpscudymnla.jpg.html)

Picking up the painted front struts with fresh skf bearings thanks to Taylor and all parts to refurb the rear drums inc cables and bearings (PeteG40).

Will be at Stanford hall this weekend so good motivation to get the polo finished

Here are some photos of the front struts being painted and other bits and bobs

Here is how the strut started out
(http://i959.photobucket.com/albums/ae75/physicsfool/22883333-2D73-47A9-BE9F-3D0753A02D66_zpsl7oji1zj.jpg) (http://s959.photobucket.com/user/physicsfool/media/22883333-2D73-47A9-BE9F-3D0753A02D66_zpsl7oji1zj.jpg.html)

Once sandblasted and painted (z3i or Taylor)
(http://i959.photobucket.com/albums/ae75/physicsfool/43611AC2-BB52-4AE2-B396-3688D19DBCB6_zpsq4rx15rj.jpg) (http://s959.photobucket.com/user/physicsfool/media/43611AC2-BB52-4AE2-B396-3688D19DBCB6_zpsq4rx15rj.jpg.html)

Painted disc protectors, fairly pitted but Taylor has done a cracking job
(http://i959.photobucket.com/albums/ae75/physicsfool/22554E90-9F32-4BC5-8678-EBF1E6EEFA36_zps2kwjolel.jpg) (http://s959.photobucket.com/user/physicsfool/media/22554E90-9F32-4BC5-8678-EBF1E6EEFA36_zps2kwjolel.jpg.html)

bearings pressed in and looking goood. Thanks again Taylor top lad
(http://i959.photobucket.com/albums/ae75/physicsfool/FCCB85D0-7BA7-43CC-A58B-2EC87D658921_zps0uqujk1q.jpg) (http://s959.photobucket.com/user/physicsfool/media/FCCB85D0-7BA7-43CC-A58B-2EC87D658921_zps0uqujk1q.jpg.html)

Steering arms also needed a refresh
(http://i959.photobucket.com/albums/ae75/physicsfool/5AB4A434-0D51-43B5-889B-0C483A9B9AE0_zpsp1kbl9ax.jpg) (http://s959.photobucket.com/user/physicsfool/media/5AB4A434-0D51-43B5-889B-0C483A9B9AE0_zpsp1kbl9ax.jpg.html)

and paint
(http://i959.photobucket.com/albums/ae75/physicsfool/AF2E41F9-C334-45C8-9F4A-2D46AB5673A2_zpsjqwxhg1s.jpg) (http://s959.photobucket.com/user/physicsfool/media/AF2E41F9-C334-45C8-9F4A-2D46AB5673A2_zpsjqwxhg1s.jpg.html)

I have painted them black since, just don't have a photo of it
(http://i959.photobucket.com/albums/ae75/physicsfool/74E02E51-AF57-466E-8EA9-5044E9B422D3_zpspvpufyog.jpg) (http://s959.photobucket.com/user/physicsfool/media/74E02E51-AF57-466E-8EA9-5044E9B422D3_zpspvpufyog.jpg.html)

any way I think that's pretty much it so far..

Some top work going on here!

Keep it up!

Quote from: z3i on February 20, 2014, 10:14:26 AM
Haha :P
I found a website that sells near identical rubber things for cheap
I'll post it up later

GSF list the Fuel pump bracket rubbers for fairly cheap under "injection parts" iirc.

Afternoon all, mid week boredom has kicked in so updating this with last weekends work!

First things first (rear axle bushes going in) questionable choice in footwear i agree and the track suit trousers shouldnt really be worn in public but fashion isnt a priority anymore, getting this car finished is.
(http://i959.photobucket.com/albums/ae75/physicsfool/F24DFE3A-DDA7-42A0-AF35-61A158A698EB_zpskkbswhtu.jpg) (http://s959.photobucket.com/user/physicsfool/media/F24DFE3A-DDA7-42A0-AF35-61A158A698EB_zpskkbswhtu.jpg.html)

This is where the weekend started, no wheels and no engine
(http://i959.photobucket.com/albums/ae75/physicsfool/EEF9398B-AEA3-41B7-A2FC-7D0A8CB10756_zpsuitlhwib.jpg) (http://s959.photobucket.com/user/physicsfool/media/EEF9398B-AEA3-41B7-A2FC-7D0A8CB10756_zpsuitlhwib.jpg.html)

Coming together with the GAZ rear coilovers i purchsed off Matty! cheers lad
(http://i959.photobucket.com/albums/ae75/physicsfool/CD72FA68-06D7-4A24-901A-829E12F1BEA7_zps3lny2dta.jpg) (http://s959.photobucket.com/user/physicsfool/media/CD72FA68-06D7-4A24-901A-829E12F1BEA7_zps3lny2dta.jpg.html)

All in place ready for the wheel
(http://i959.photobucket.com/albums/ae75/physicsfool/070C1AC4-7959-44B0-A600-8917AB279E3F_zpsvdkaxkhz.jpg) (http://s959.photobucket.com/user/physicsfool/media/070C1AC4-7959-44B0-A600-8917AB279E3F_zpsvdkaxkhz.jpg.html)

And finally she is rolling again (sort of)
(http://i959.photobucket.com/albums/ae75/physicsfool/1A7E872D-6901-42E2-B5F1-E165DB7AEF10_zpsnshbvufx.jpg) (http://s959.photobucket.com/user/physicsfool/media/1A7E872D-6901-42E2-B5F1-E165DB7AEF10_zpsnshbvufx.jpg.html)

Fitted an uprated radiator brace in prep for the PPP stage 2 subframe and welding that will happen soon
(http://i959.photobucket.com/albums/ae75/physicsfool/FC36D6CA-A50B-48B4-A58A-5C8F911AFE80_zpsu1ogu9ow.jpg) (http://s959.photobucket.com/user/physicsfool/media/FC36D6CA-A50B-48B4-A58A-5C8F911AFE80_zpsu1ogu9ow.jpg.html)

Sun is shining all is coming along well so i decide to take another look at the drivers side sill which isnt looking too great
(http://i959.photobucket.com/albums/ae75/physicsfool/C99130ED-2B09-43B4-982C-8942747E11AC_zpsjcgeap2r.jpg) (http://s959.photobucket.com/user/physicsfool/media/C99130ED-2B09-43B4-982C-8942747E11AC_zpsjcgeap2r.jpg.html)

Its fairly rotten all the way along, so currently assessing my options.

You make that brace yourself? Nice idea!!
Rear axle looks so clean man! Nice work!!

Love it ;D

Got the uprated rad brace off vee_dub90, mild steel and zinc coated! quite the weapon. twinned with a stage 2 she will be a handling monster

And modified chassis! And Gaz coilies! Oh and weight saving from all those rust holes :P
You decided on front shocks yet?

Dan Knight made up a bunch of those Taylor, I've had one in the shed for 2 years haha! Looking good Martin, I'd be patching those holes mate forget replacing the whole thing. Still mega jealous of the Gaz rears  :P . Keep cracking on pal! Ps I'm going back to uni now haha

Talking to my fabricator chum tomorrow and seeing what I can do! Yes lad, university of Cumbria?

The stage 2 arrived today, so I thought I would paint it with por15
(http://i959.photobucket.com/albums/ae75/physicsfool/23471713-100D-4857-AD10-36CC121EDE8A_zpsvwhoge4q.jpg) (http://s959.photobucket.com/user/physicsfool/media/23471713-100D-4857-AD10-36CC121EDE8A_zpsvwhoge4q.jpg.html)

And now it's nice and shiny
(http://i959.photobucket.com/albums/ae75/physicsfool/B34F1E92-AC5C-4A33-A509-C5A86BD24F32_zpsbxofrlgw.jpg) (http://s959.photobucket.com/user/physicsfool/media/B34F1E92-AC5C-4A33-A509-C5A86BD24F32_zpsbxofrlgw.jpg.html)

Looks nice  :)

Make sure the paint isn't too thick on the TCA mounts, otherwise you'll have to open them up (or remove paint) so it slides on.

Cheers

Pete

P.S- Did you prep with metal ready from POR-15 too?

Quote from: Yoof on May 20, 2014, 10:29:51 AM

P.S- Did you prep with metal ready from POR-15 too?

Aha did warn you martin :P

Haha, it looked pretty good this morning, sadly no metal prep. But brushed the TCA mountings pretty finely so hopefully wont be too much bother.

Hmm, see how you get on, but in my experience it will flake off  :(

Yeah, it's pretty particular, doesn't like going over paint either and has to be heavily scotched

Ah if it does martin I'll just prep and paint it when I do the car :) no sweat

Quote from: z3i on May 20, 2014, 01:03:13 PM
Yeah, it's pretty particular, doesn't like going over paint either and has to be heavily scotched

Ah if it does martin I'll just prep and paint it when I do the car :) no sweat

Rule of thumb I should just leave the painting to you :)

When is Taylor spraying it for you? Top restoration going on here. I'd love a full respray.....hopefully next year.

June I think, keen to get mine back together. While its with Taylor will give me a good 6 weeks to concentrate on the engine

That's quite soon :D

What are your plans for the engine?

Bit of porting in the head but apart from that just a bearing refresh and re-bore for fresh piston rings. Trying to keep the car close to standard.

Quote from: physicsfool on May 23, 2014, 03:43:34 PM
Bit of porting in the head but apart from that just a bearing refresh and re-bore for fresh piston rings. Trying to keep the car close to standard.

If you are going to the trouble of getting it sleeved/bored, would you not consider fitting larger pistons? Saves you doing it later if you wanted more power. Its a little expensive for the pistons but you might save a little in re-boring it to fit larger pistons than getting it sleeved/bored for the standard ones? I'm pretty sure that's more expensive than re-boring for larger pistons. Just an idea haha.

i think he means honed not rebored!

Quote from: PeteG40 on May 23, 2014, 05:09:21 PM
i think he means honed not rebored!

What Pete said, plus they will source all the bearings for me! 1272 is plenty enough for me! Plus if i spend any more on the car I may have to declare bankruptcy

Fair enough. Rebuilt engine and full respray. Sounds awesome :) - cant wait to see the respray!

So been getting the motor rolling again to my parents amazement, think they may be sick of loooking at a shell

Firstly rebuilding the front legs with all new/resprayed parts (apart from some pikey apex springs)
(http://i959.photobucket.com/albums/ae75/physicsfool/CC8AC79C-8A6D-4C5E-BD55-D0AF4500B537_zpssvkssequ.jpg) (http://s959.photobucket.com/user/physicsfool/media/CC8AC79C-8A6D-4C5E-BD55-D0AF4500B537_zpssvkssequ.jpg.html)

and the car as she stood at the beginning of the weekend
(http://i959.photobucket.com/albums/ae75/physicsfool/BE078908-2C68-465B-91D7-DD7BF336D4F5_zpstvrlwrwu.jpg) (http://s959.photobucket.com/user/physicsfool/media/BE078908-2C68-465B-91D7-DD7BF336D4F5_zpstvrlwrwu.jpg.html)

One PPP stage 2 fitted, not an easy job but worth it. one of the chassis legs was slightly twisted
(http://i959.photobucket.com/albums/ae75/physicsfool/89005FA0-55DA-4844-9D12-2576BD15C0A0_zpsctcp6ylo.jpg) (http://s959.photobucket.com/user/physicsfool/media/89005FA0-55DA-4844-9D12-2576BD15C0A0_zpsctcp6ylo.jpg.html)

(http://i959.photobucket.com/albums/ae75/physicsfool/2014-05/A9C141F9-9233-490D-BB28-936E831D50E6_zpsfyqk5vvh.jpg) (http://s959.photobucket.com/user/physicsfool/media/2014-05/A9C141F9-9233-490D-BB28-936E831D50E6_zpsfyqk5vvh.jpg.html)

And voilllla
(http://i959.photobucket.com/albums/ae75/physicsfool/2014-05/95FCCCFF-6181-480A-A31D-C0AF343F44E8_zps8ct3xycn.jpg) (http://s959.photobucket.com/user/physicsfool/media/2014-05/95FCCCFF-6181-480A-A31D-C0AF343F44E8_zps8ct3xycn.jpg.html)

So with it rolling i took it to my mates for the sills to be welded and engine bay where it had cracked.
one pallet and a forklift later:
(http://i959.photobucket.com/albums/ae75/physicsfool/2014-06/5495347F-62B5-4BA7-903A-59DEA1C34FB8_zpsernzqlrn.jpg) (http://s959.photobucket.com/user/physicsfool/media/2014-06/5495347F-62B5-4BA7-903A-59DEA1C34FB8_zpsernzqlrn.jpg.html)

Pretty jealous of the workshop he has on his farm.
(http://i959.photobucket.com/albums/ae75/physicsfool/D9F32AF0-2753-4F88-91EF-6ADC6C19E8D8_zpsrmhg2xpz.jpg) (http://s959.photobucket.com/user/physicsfool/media/D9F32AF0-2753-4F88-91EF-6ADC6C19E8D8_zpsrmhg2xpz.jpg.html)

Poor photo but the work is good.
(http://i959.photobucket.com/albums/ae75/physicsfool/E2A90CBB-D5E7-4E51-BB49-1D6D38277996_zpsvaczkegu.jpg) (http://s959.photobucket.com/user/physicsfool/media/E2A90CBB-D5E7-4E51-BB49-1D6D38277996_zpsvaczkegu.jpg.html)

Going to be one very nice g40 mate :)

Looks great Martin! Sills look much nicer than mine :)

Come a long way since you came up to sheff in it!

So the time has come, its off for a paint job, i have sourced new wings and drivers door, passenger door was courtesy of Steve lea and its a beaut. Plus when i picked it up i got to have a good perv at his L reg G which has focused me on getting mine finished and back on the road.

(http://i959.photobucket.com/albums/ae75/physicsfool/BF8D4476-84B8-4891-B926-A3C77E0502EE_zps3wyg4sjf.jpg) (http://s959.photobucket.com/user/physicsfool/media/BF8D4476-84B8-4891-B926-A3C77E0502EE_zps3wyg4sjf.jpg.html)

Pikey number plate
(http://i959.photobucket.com/albums/ae75/physicsfool/7E6AC67F-2A38-429A-B393-E759D83ED6FD_zpshui2qnhf.jpg) (http://s959.photobucket.com/user/physicsfool/media/7E6AC67F-2A38-429A-B393-E759D83ED6FD_zpshui2qnhf.jpg.html)


of course the sun was shining and so with cardboard in my windows i set off for stevenage

(http://i959.photobucket.com/albums/ae75/physicsfool/2D8E60EA-F1ED-4E2F-AD33-06F8E919D4E1_zpszgnsp752.jpg) (http://s959.photobucket.com/user/physicsfool/media/2D8E60EA-F1ED-4E2F-AD33-06F8E919D4E1_zpszgnsp752.jpg.html)

Most of the engine rebuild parts are on order now, so July is the month of the engine rebuild

So today is a dark day in the world of G40's, however this spot had some monstrous cranes, car weighed in at 240kg with all panels minus the wings
(http://i959.photobucket.com/albums/ae75/physicsfool/1EF45D23-B6E8-40B0-A921-3259C109CB31_zpsdfkhfb6b.jpg) (http://s959.photobucket.com/user/physicsfool/media/1EF45D23-B6E8-40B0-A921-3259C109CB31_zpsdfkhfb6b.jpg.html)
(http://i959.photobucket.com/albums/ae75/physicsfool/2DE93EC5-9DD5-4B74-9222-D2B6426A4FA5_zpsgnosebgx.jpg) (http://s959.photobucket.com/user/physicsfool/media/2DE93EC5-9DD5-4B74-9222-D2B6426A4FA5_zpsgnosebgx.jpg.html)
(http://i959.photobucket.com/albums/ae75/physicsfool/14B4E390-8B13-4C32-87A0-E635F01D60AF_zpspa1i1xol.jpg) (http://s959.photobucket.com/user/physicsfool/media/14B4E390-8B13-4C32-87A0-E635F01D60AF_zpspa1i1xol.jpg.html)

The engine lives on, but sadly we are down one more tornado red G40.

Dang, horrible pictures laddo :(

A sad end to a G40  :(

That's sucks, not a nice sight to see  :'(

It burns my eyes!!! Take it down!!

is that a normal part of the painting process at Taylor's workshop?

Quote from: PeteG40 on July 07, 2014, 09:56:35 PM
is that a normal part of the painting process at Taylor's workshop?

Hahaha!! Yeah standard rust removal procedure :P

I can remember scrapping my old shell, was a sorry sight made even worse by the £30 I got scrap value for it

Yeah 240kg got me £24

Should have filled the cavitys up with concrete... Saying that, would have fallen straight out the rust holes at the bottom :P

So time to get over my moping and start this up again. I have decided to keep the engine after plenty of changes of heart but i want to finish and the distant memory of how it drove also makes that decision a tad easier.

As usual any rebuild starts with a message to Mr Mirfin and a box load of febi parts later i am well on my way
(http://i959.photobucket.com/albums/ae75/physicsfool/357AB124-2B89-441F-B0EC-CC0607F53323_zpsauomupv4.jpg) (http://s959.photobucket.com/user/physicsfool/media/357AB124-2B89-441F-B0EC-CC0607F53323_zpsauomupv4.jpg.html)

I have managed to aquire a space in my mates garage as my engine building experience is non-existent and he is a professional engine builder, so first stage is to dismantle and clean:
(http://i959.photobucket.com/albums/ae75/physicsfool/F5729889-146E-47C0-8E21-E7E4E6946EA8_zpste6owriq.jpg) (http://s959.photobucket.com/user/physicsfool/media/F5729889-146E-47C0-8E21-E7E4E6946EA8_zpste6owriq.jpg.html)

and now to pop into the tank of gunk remover
(http://i959.photobucket.com/albums/ae75/physicsfool/874D249B-E280-4D3D-B671-0FB8F1342B09_zps3oxtnvtf.jpg) (http://s959.photobucket.com/user/physicsfool/media/874D249B-E280-4D3D-B671-0FB8F1342B09_zps3oxtnvtf.jpg.html)

It smelt sweet like almonds which scared me all the more.

But the final product was good, and everything was smelling clean when i finished
(http://i959.photobucket.com/albums/ae75/physicsfool/A1DAB48A-4C1F-42AA-AC9B-5F1B377F2B6A_zpsjgsjpmgt.jpg) (http://s959.photobucket.com/user/physicsfool/media/A1DAB48A-4C1F-42AA-AC9B-5F1B377F2B6A_zpsjgsjpmgt.jpg.html)

Then stripped the head, as i want it flow testing and a bit of porting.
(http://i959.photobucket.com/albums/ae75/physicsfool/ECD4BE55-0F0C-4B22-A35D-489C9998E202_zpsadbbokew.jpg) (http://s959.photobucket.com/user/physicsfool/media/ECD4BE55-0F0C-4B22-A35D-489C9998E202_zpsadbbokew.jpg.html)

Took the block to the local engineering spot who are decking it and looking at the tolerences of the bore, unfortunately the top rings of the pistons have worn the top of the bore so i need a rebore to sort that.

As there isnt much price difference between cast and forged pistons i will be going for 77 mm forged wossners, against the advice of my mates as he reckons 76 mm to allow for a rebore down the line, but i think i have aquired a set up to suit the slightly larger pistons so that is my preference at the moment. Wossner currently have a 3-4 week back order so its a time game at the moment.

Should be picking up a few new parts over the coming weeks but mainly just waiting on the pistons 

Good stuff! Do you have something to put it all in yet?

No shell yet! Keeping my eye on a few. But main priority at this stage is the engine and sent the loom off for a full refurb

Yes martin!!!! Such a lad!! Major man points for not selling up and buying a honda..... Wait a minute...

Quote from: z3i on September 11, 2014, 07:33:56 PM
Yes martin!!!! Such a lad!! Major man points for not selling up and buying a honda..... Wait a minute...

You're doing it wrong, I'm selling a Honda and bought another Polo...

Well in lad, defo the most fun when building a car is building the engine up!

Yeah engine work interests me, bodywork doesn't as much! Think if I need owt doing I will just drop it off at Taylor's

Got my refurbed loom back, it looks really good and didnt cause any stress. I priced up the cable and bits separately and there wasnt a big difference.

(http://i959.photobucket.com/albums/ae75/physicsfool/B133B40A-8858-4BED-81AE-FBEB2B17BA8E_zpspshsnlsb.jpg) (http://s959.photobucket.com/user/physicsfool/media/B133B40A-8858-4BED-81AE-FBEB2B17BA8E_zpspshsnlsb.jpg.html)

He even re-wrote the tags, what a boss
(http://i959.photobucket.com/albums/ae75/physicsfool/7F7B973D-7EDF-47F2-B17B-2DEE16B9B0E0_zpsu3zqnogy.jpg) (http://s959.photobucket.com/user/physicsfool/media/7F7B973D-7EDF-47F2-B17B-2DEE16B9B0E0_zpsu3zqnogy.jpg.html)

Now i just need some pistons and a shell

Who did the loom? What did they do exactly?

Quote from: SamG40 on September 18, 2014, 12:43:21 PM
Who did the loom? What did they do exactly?

Rayne Automotive, check company feedback section for details. Replaced the whole lot with tri-rated thinwall cable and added the uprated headlight module, but re-used the connectors as they were all in decent condition.

I reckon a fresh loom with a freshly rebuilt engine should make a big difference

That looks the Bollucks!!!! Nice one dude!!!

Looks banging that dude, might be tempted to use em myself! Got those G60 injectors ready for when you need em.

Quote from: Etches on September 18, 2014, 01:40:34 PM
Looks banging that dude, might be tempted to use em myself! Got those G60 injectors ready for when you need em.

Cheers lad, get paid on the 26th, those pistons have cleared my bank account for the time being.

Thats really cool. Twenty odd year old wires that will have been subjected to thousands of heat cycles could probably do with replacement by now. Probably money well spent to avoid any future issues.

And finally the pistons arrived yesterday, and one went straight to the engineering workshop

(http://i959.photobucket.com/albums/ae75/physicsfool/D1A1E5D0-2A06-4E3B-BA1C-7AADC6633611_zpspiztnqfp.jpg) (http://s959.photobucket.com/user/physicsfool/media/D1A1E5D0-2A06-4E3B-BA1C-7AADC6633611_zpspiztnqfp.jpg.html)

So i am hoping to work on the engine a bit this weekend, but at the same time painting the new house. As per its all happened at once

What the garage like at the new house? Posted those injectors and relays this morning dude!

Quote from: Etches on October 03, 2014, 03:40:19 PM
What the garage like at the new house? Posted those injectors and relays this morning dude!

Non-existent, going to have to persuade my mate he needs a polo in his garage!

Could just store it at mine.... For when I paint it?....

May I ask how much it cost you to get the loom remade?

Quote from: C0UP3 on October 05, 2014, 02:59:50 PM
May I ask how much it cost you to get the loom remade?

£200 with up rated headlight module. Impressive work

Before you stick that loom in I'd push some of those wire seals fully home, doesn't look like they're all seated properly. Still, at £200 for a complete remade loom the guy can't be making much if doing it properly!

Quote from: Andy on October 05, 2014, 08:32:07 PM
Before you stick that loom in I'd push some of those wire seals fully home, doesn't look like they're all seated properly. Still, at £200 for a complete remade loom the guy can't be making much if doing it properly!

Yeah I will make sure all are tight and seated well. I priced up the wire separately and that was pricey

Got the rebored block and polished crank back
(http://i959.photobucket.com/albums/ae75/physicsfool/A9D570D9-B754-477B-9CAA-E72056AED088_zpsqew96y3j.jpg) (http://s959.photobucket.com/user/physicsfool/media/A9D570D9-B754-477B-9CAA-E72056AED088_zpsqew96y3j.jpg.html)
(http://i959.photobucket.com/albums/ae75/physicsfool/DC6D5771-38A3-4C37-A77C-0658EFCB47B7_zpsavlj7tgx.jpg) (http://s959.photobucket.com/user/physicsfool/media/DC6D5771-38A3-4C37-A77C-0658EFCB47B7_zpsavlj7tgx.jpg.html)

And finally it begins
(http://i959.photobucket.com/albums/ae75/physicsfool/1A8AD2C6-03AB-4818-B924-3B9E51D477ED_zpsuhisaee7.jpg) (http://s959.photobucket.com/user/physicsfool/media/1A8AD2C6-03AB-4818-B924-3B9E51D477ED_zpsuhisaee7.jpg.html)

These pics are bringing back memories haha!

Made any progress yet?

Quote from: AdzCM on October 28, 2014, 09:44:41 PM
These pics are bringing back memories haha!

Made any progress yet?

Crank, flywheel and clutch are currently being balanced. Lightened the flywheel by a kilo so thought it best. So hopefully getting cracked on with it this weekend!

So my day has started very positively (considering it began at 6 am) I have bought a mk2 polo with a GT engine
(http://i959.photobucket.com/albums/ae75/physicsfool/AEA249F4-478E-44F4-9769-2C48E5CB62A5_zpsfax2wegi.jpg) (http://s959.photobucket.com/user/physicsfool/media/AEA249F4-478E-44F4-9769-2C48E5CB62A5_zpsfax2wegi.jpg.html)

and although the body work is a tad shonky it goes like stink. Conversion was done by a chap in south wales i believe and its done to a very good standard.
(http://i959.photobucket.com/albums/ae75/physicsfool/A9D057BD-E4D9-40E7-AF4C-4F0D73C8AA08_zpsprox0hsu.jpg) (http://s959.photobucket.com/user/physicsfool/media/A9D057BD-E4D9-40E7-AF4C-4F0D73C8AA08_zpsprox0hsu.jpg.html)

I didnt take this one but this is what the bay looks like
(http://i959.photobucket.com/albums/ae75/physicsfool/847EB8AE-6F15-409E-9D72-95C801866CEE_zpspvq0hz1g.jpg) (http://s959.photobucket.com/user/physicsfool/media/847EB8AE-6F15-409E-9D72-95C801866CEE_zpspvq0hz1g.jpg.html)

So its in for MOT today as it needs one and then i will be taking it for a spin around the Yorkshire wolds/dales.

I got the crank back today from being balanced so i can start putting the G back together in earnest now

Is that the new daily, or the shell for the G?

I think I may be inclined to keep it as is and keep looking for a shell for the G as I really like the way it drives!

Had an interesting evening fixing problems for the MOT, mostly electrical! Stuff like the rear number plate lights and washer bottle motor. Wired up really interestingly but not in the most productive way. And put a more handbrake lever on as the old one was bent out of place!

The most difficult problem has been sorting the dipped beam setting as at the moment I only have sides and full beam. Figured it out to be the indicator stalk which isn't switching the power to the cable that supplies the light switch so no dipped beam.

I reckon I will drive it as is for the foreseeable future, but first it needs an MOT

Any idea on the spec of the GT engine?
to be fair a highly modded GT engine in a lighter mk2 shell, probably isn't far away from a stock G...
Good luck with MOT

Port & polished cylinder head, Schrick 268 cam, custom PPP ecu chip
Pipex cone filter, S/S 4-2-1 manifold and Longlife S/S exhaust system
Vauxhall Calibra ATE front calipers with 256mm vented discs & yellow stuff pads
G-laderseite Poly ARB blocks and TCA bushes
GMax suspension
Polo GT rear axle with ARB
Sparco Sprint bucket seat and Sabelt 4-point harnesses
Polo GT clocks
Stripped-out interior
Ronal 14x6 multi-spoke wheels with road tyres

Awesome!!!! :D get that g40 engine in there!

Yea get that g40 in it!

mk2 shell + g40 = awesome

My iphone is slowly failing and dying. So i apologise for the poor quality images

Any hoo got the bog brush and contact cleaner out
(http://i959.photobucket.com/albums/ae75/physicsfool/90607031-7076-4CE2-A6F5-55835B9CA53C_zpsddcqkbuu.jpg) (http://s959.photobucket.com/user/physicsfool/media/90607031-7076-4CE2-A6F5-55835B9CA53C_zpsddcqkbuu.jpg.html)

As well as cleaning all the bearing and thrust washer
(http://i959.photobucket.com/albums/ae75/physicsfool/8AAEB2BE-487A-47D8-991C-6E91F925DF99_zpsd3avvyde.jpg) (http://s959.photobucket.com/user/physicsfool/media/8AAEB2BE-487A-47D8-991C-6E91F925DF99_zpsd3avvyde.jpg.html)

And then bolted and torqued the lot up.
(http://i959.photobucket.com/albums/ae75/physicsfool/FC2E659D-2867-440F-8022-17404374B0A7_zpshk0l7ign.jpg) (http://s959.photobucket.com/user/physicsfool/media/FC2E659D-2867-440F-8022-17404374B0A7_zpshk0l7ign.jpg.html)

Tonights job is popping the 3 pistons in (one is without an oil ring as i managed to snap it popping it on) Got a 7-10 day wait for a set.

The mk2 is off for its re-test today as the headlights appear to have confused the MOT centre. Lets hope todays tester is a touch more competant

And i reassembled the head with the new cam and dizzy. Gave it all a good clean first
(http://i959.photobucket.com/albums/ae75/physicsfool/8E7C8044-6C24-4E50-A67A-6B69D7CA0DB6_zpsoucdhdov.jpg) (http://s959.photobucket.com/user/physicsfool/media/8E7C8044-6C24-4E50-A67A-6B69D7CA0DB6_zpsoucdhdov.jpg.html)

Last night was spent putting 3 of the 4 pistons in the block. got a fair wait till the piston ring set turns up. but plenty of other jobs in the meantime
(http://i959.photobucket.com/albums/ae75/physicsfool/3218882D-43E1-42B0-8471-E7D8BCD79CA5_zps2acxbdpp.jpg) (http://s959.photobucket.com/user/physicsfool/media/3218882D-43E1-42B0-8471-E7D8BCD79CA5_zps2acxbdpp.jpg.html)

And this morning went for a spin in a freshly mot'd and taxed motor
(http://i959.photobucket.com/albums/ae75/physicsfool/14FAD626-8094-4B24-9B0C-64EC62060D81_zps5u26gqqs.jpg) (http://s959.photobucket.com/user/physicsfool/media/14FAD626-8094-4B24-9B0C-64EC62060D81_zps5u26gqqs.jpg.html)

So i bet my mate i would have this finished and drive it into uni by the end of the year, i may be losing a fiver.

But i have put some hours in this week after the piston ring fiasco
Oil pump and chain, poured some oil in to prime it
(http://i959.photobucket.com/albums/ae75/physicsfool/7ECF8352-8E52-4903-BCC6-BCC4519EFA7F_zpsas1qtdpg.jpg) (http://s959.photobucket.com/user/physicsfool/media/7ECF8352-8E52-4903-BCC6-BCC4519EFA7F_zpsas1qtdpg.jpg.html)

Had all the gaskets bar this one, so being northern i wasnt going to spend money on buying the whole set, cheeky bit of gasket paper instead
(http://i959.photobucket.com/albums/ae75/physicsfool/E80E5CAD-3737-4A2D-BC65-097719C04F59_zpsy0ogseod.jpg) (http://s959.photobucket.com/user/physicsfool/media/E80E5CAD-3737-4A2D-BC65-097719C04F59_zpsy0ogseod.jpg.html)

Oil started coming out of the filter hole so a mini oil filter is on for the time being, thread doesn't feel quite right so will change when i pop the oil in
(http://i959.photobucket.com/albums/ae75/physicsfool/D899325A-7058-442E-BABA-30FFC4360341_zpsrgtbhkpk.jpg) (http://s959.photobucket.com/user/physicsfool/media/D899325A-7058-442E-BABA-30FFC4360341_zpsrgtbhkpk.jpg.html)

Mad painting skills, good job i put newspaper down, one messy pup
(http://i959.photobucket.com/albums/ae75/physicsfool/31EB2B6B-9FCC-4C92-8C92-0ACA9115D3E2_zpshaljdt9z.jpg) (http://s959.photobucket.com/user/physicsfool/media/31EB2B6B-9FCC-4C92-8C92-0ACA9115D3E2_zpshaljdt9z.jpg.html)

And a metal head-gasket and precision tightening later and i have a head attached
(http://i959.photobucket.com/albums/ae75/physicsfool/3BCEC11E-276F-462E-9723-DEE95B705094_zpspxvuflkq.jpg) (http://s959.photobucket.com/user/physicsfool/media/3BCEC11E-276F-462E-9723-DEE95B705094_zpspxvuflkq.jpg.html)

Hopefully i will get an hour or two in before the weekend and get the timing belt cover on and the engine timed up

Anymore updates on this Martin??

Hows the mk2 shell looking now?

I dropped my phone on Christmas Day, replacement screen should be with me tomorrow.

But the engine is in,

• exhaust is back together
• gear linkage is all set up
• charger is in place
• driveshafts all torqued up

Need to decide on an intercooler design and radiator position as it doesn't quite fit
And pop the wiring back in, so hopefully not too far off.

Pictures to follow shortly

So then i timed the motor up and popped the cam cover back on,
(http://i959.photobucket.com/albums/ae75/physicsfool/95CF65BB-3E8C-4CCB-9766-7075747C0650_zpsqnd8jzz1.jpg) (http://s959.photobucket.com/user/physicsfool/media/95CF65BB-3E8C-4CCB-9766-7075747C0650_zpsqnd8jzz1.jpg.html)

And slowly its starting to look like an engine again.
(http://i959.photobucket.com/albums/ae75/physicsfool/44DE11BC-FC7C-4F67-B1DF-CDF664EC0ECB_zpsvcub841v.jpg) (http://s959.photobucket.com/user/physicsfool/media/44DE11BC-FC7C-4F67-B1DF-CDF664EC0ECB_zpsvcub841v.jpg.html)

I stole various parts off the GT motor like the starter motor and its wiring harness as well as injector jackets
(http://i959.photobucket.com/albums/ae75/physicsfool/2A41B6F7-5C75-47E8-9F04-CE0CD4B3CAE3_zpsa9f6vhzk.jpg) (http://s959.photobucket.com/user/physicsfool/media/2A41B6F7-5C75-47E8-9F04-CE0CD4B3CAE3_zpsa9f6vhzk.jpg.html)

And a touch more..
(http://i959.photobucket.com/albums/ae75/physicsfool/2B063939-7EC5-40D3-872D-71AF9754F917_zpsjgo2gdmh.jpg) (http://s959.photobucket.com/user/physicsfool/media/2B063939-7EC5-40D3-872D-71AF9754F917_zpsjgo2gdmh.jpg.html)

And then the Christmas holiday arrived, which meant whole days on the car, missus had an assignment deadline which worked well for me

So here is the GT engine which sadly i ended up breaking.
(http://i959.photobucket.com/albums/ae75/physicsfool/9D1F4231-C33A-42AB-B051-57810FEA9F74_zps34v19gl2.jpg) (http://s959.photobucket.com/user/physicsfool/media/9D1F4231-C33A-42AB-B051-57810FEA9F74_zps34v19gl2.jpg.html)

But it will make way for the G so i believe its a worthy cause
(http://i959.photobucket.com/albums/ae75/physicsfool/F274AAB8-F4D9-4917-910D-5D48B99943FB_zpskphlfrmo.jpg) (http://s959.photobucket.com/user/physicsfool/media/F274AAB8-F4D9-4917-910D-5D48B99943FB_zpskphlfrmo.jpg.html)

Dragged it into the workshop to take the engine out, G watching from afar.....
(http://i959.photobucket.com/albums/ae75/physicsfool/35B4656C-A927-4319-9E55-CC85E058AB1E_zpsj5mjyjtl.jpg) (http://s959.photobucket.com/user/physicsfool/media/35B4656C-A927-4319-9E55-CC85E058AB1E_zpsj5mjyjtl.jpg.html)


After a morning of sweating and dealing with driveshaft bolts
(http://i959.photobucket.com/albums/ae75/physicsfool/E7F13E1D-5D27-4446-A275-72574AE41462_zpszknbib2i.jpg) (http://s959.photobucket.com/user/physicsfool/media/E7F13E1D-5D27-4446-A275-72574AE41462_zpszknbib2i.jpg.html)

Both engines out and so i set about breaking the GT for parts
(http://i959.photobucket.com/albums/ae75/physicsfool/935D178F-F71C-42B2-8864-29B566BDE320_zpsuycpdtrb.jpg) (http://s959.photobucket.com/user/physicsfool/media/935D178F-F71C-42B2-8864-29B566BDE320_zpsuycpdtrb.jpg.html)


......And then on christmas day i dropped my phone. which buggered it proper. Being the holidays i had to wait a week for the next screen... However i couldnt stop working so voila....Engine in car now
(http://i959.photobucket.com/albums/ae75/physicsfool/B7C9E0BF-6468-405F-B0F9-79DE65E9E77A_zpsso2cwmnb.jpg) (http://s959.photobucket.com/user/physicsfool/media/B7C9E0BF-6468-405F-B0F9-79DE65E9E77A_zpsso2cwmnb.jpg.html)

With most of the engine loom in.... I chopped the central bonnet catch support out to make way for the intercooler which fits rather well, but had to make slight adjustments to the radiator so that it now sits in fresh holes.
(http://i959.photobucket.com/albums/ae75/physicsfool/CCDC5039-3C93-417B-8E79-466A5244C828_zpsvjylouee.jpg) (http://s959.photobucket.com/user/physicsfool/media/CCDC5039-3C93-417B-8E79-466A5244C828_zpsvjylouee.jpg.html)

With the rad fitted
(http://i959.photobucket.com/albums/ae75/physicsfool/605C64B6-0026-46CA-B684-8466579745D6_zps48mrcxa9.jpg) (http://s959.photobucket.com/user/physicsfool/media/605C64B6-0026-46CA-B684-8466579745D6_zps48mrcxa9.jpg.html)

And the cowling, I chose to use this one as it still fits and should have better draw as well as shielding the radiator from the exhaust manifold

(http://i959.photobucket.com/albums/ae75/physicsfool/2A7DEACB-D65D-41DD-B5B6-A1FA6519A293_zpsxap7foj9.jpg) (http://s959.photobucket.com/user/physicsfool/media/2A7DEACB-D65D-41DD-B5B6-A1FA6519A293_zpsxap7foj9.jpg.html)


It all fits...just

Need to finish off the cooling system pipework, figure out where the last few clips on the engine loom go and mount the oil cooler as well as fitting the last part of the boost system...

This is going to be so sweet once done Martin, good job.

What sort of power you aiming for from this.

That intercooler setup looks very familiar......  Works spot on!

Is this a new loom? You need to push home all the rubber grommets, otherwise they're not sealed and moisture will get in.

Rest looks spot on though  ;D

No idea Matt, will get it on the same rolling road I used just before I took it all apart.

Yes it's a Freddy special. Yeah decent route and no real cutting to the shell!

Yeah Pete, he appears to have put to large ends in. So they won't push in any more! Will have to wait and see.

They compress down a fair bit. But I'd send it back if they really don't push home, it's not much use otherwise.

Cooling system is now in, plenty of cutting hoses due to the front end shortening.first

Will need to modify the fuel pump wiring as it's on a remote switch for track use, and the fuel pump is positioned in the footwell behind the drivers seat so it's loud. I have a bracket but still need fresh fuel lines

Will get it running first though

So progress has been good, putting in mornings and evenings to get her done as i am finally moving out of my parents house and into a flat.

Front end view with trial fit oil cooler. snug but not many options
(http://i959.photobucket.com/albums/ae75/physicsfool/6B0480C4-7858-4975-BD42-856E6CB611E6_zpsuu1svmrw.jpg) (http://s959.photobucket.com/user/physicsfool/media/6B0480C4-7858-4975-BD42-856E6CB611E6_zpsuu1svmrw.jpg.html)

And as i cut the bonnet latch support pillar out i have to pop some bonnet pins in, holes for bonnet rubbers looked to be cock on
(http://i959.photobucket.com/albums/ae75/physicsfool/BE1CFA01-C8AB-4E96-9C4E-9E040EA4E147_zpsmknyyo6i.jpg) (http://s959.photobucket.com/user/physicsfool/media/BE1CFA01-C8AB-4E96-9C4E-9E040EA4E147_zpsmknyyo6i.jpg.html)

As the bonnet is double layered i had to make a nick in one of the existing slits to drop the inner support plate through
(http://i959.photobucket.com/albums/ae75/physicsfool/18DB7BB7-9512-46D8-B045-DED4037F1284_zpsevahvcda.jpg) (http://s959.photobucket.com/user/physicsfool/media/18DB7BB7-9512-46D8-B045-DED4037F1284_zpsevahvcda.jpg.html)

All fits a treat
(http://i959.photobucket.com/albums/ae75/physicsfool/A5455685-8F9F-4BE6-8FB4-485B763C8A53_zps5vlqbnhq.jpg) (http://s959.photobucket.com/user/physicsfool/media/A5455685-8F9F-4BE6-8FB4-485B763C8A53_zps5vlqbnhq.jpg.html)

Now i came across some interesting soldering while checking the bumper indicators. My OCD went wild so had to re do it
(http://i959.photobucket.com/albums/ae75/physicsfool/FFEE78B3-1623-43E3-9661-4E7D1D0AD526_zpshodtcnvn.jpg) (http://s959.photobucket.com/user/physicsfool/media/FFEE78B3-1623-43E3-9661-4E7D1D0AD526_zpshodtcnvn.jpg.html)

and ...
(http://i959.photobucket.com/albums/ae75/physicsfool/4999D472-6793-449A-BC15-A1DCDB3629D0_zpsamegnfis.jpg) (http://s959.photobucket.com/user/physicsfool/media/4999D472-6793-449A-BC15-A1DCDB3629D0_zpsamegnfis.jpg.html)

with a cheeky bit of heat shrink for good measure.

Just before i got the proper oil cooler position, but clears the charger nicely and a bit of slack in the pipes to accommodate engine movement
(http://i959.photobucket.com/albums/ae75/physicsfool/49871224-0EF5-4270-88CC-716223A7BCAD_zpslvffso5i.jpg) (http://s959.photobucket.com/user/physicsfool/media/49871224-0EF5-4270-88CC-716223A7BCAD_zpslvffso5i.jpg.html)

Grille back on
(http://i959.photobucket.com/albums/ae75/physicsfool/AF261E75-5E66-4178-9A3C-E2FB7935A38E_zpsabouoimx.jpg) (http://s959.photobucket.com/user/physicsfool/media/AF261E75-5E66-4178-9A3C-E2FB7935A38E_zpsabouoimx.jpg.html)

and my freshly soldered indicators in the bumper and reattached
(http://i959.photobucket.com/albums/ae75/physicsfool/7FF3525C-8432-486E-8CE5-3AA2B6983379_zpssewj6j73.jpg) (http://s959.photobucket.com/user/physicsfool/media/7FF3525C-8432-486E-8CE5-3AA2B6983379_zpssewj6j73.jpg.html)

With the engine and loom looking so clean i couldn't let the washers hoses let it down
(http://i959.photobucket.com/albums/ae75/physicsfool/2498AD27-E8F5-4F47-B953-A4842FEC292C_zpshtgnfa7a.jpg) (http://s959.photobucket.com/user/physicsfool/media/2498AD27-E8F5-4F47-B953-A4842FEC292C_zpshtgnfa7a.jpg.html)

So knocked up a new set in black (stealth)
(http://i959.photobucket.com/albums/ae75/physicsfool/B3834971-FB60-4F42-A46F-9F726AE0397D_zps0guxohcv.jpg) (http://s959.photobucket.com/user/physicsfool/media/B3834971-FB60-4F42-A46F-9F726AE0397D_zps0guxohcv.jpg.html)

And after a final engine check tomorrow i will be starting it up. With the freshly charged battery

Will drop the plugs out and disconnect the hall sender so that i can build some oil pressure up and then get it all timed up wth the blue temp unplugged.

Lets hope its a good start to the weekend

Looks amazing dude! Can't wait to hear about your first drive in a G for agesss!

Lovely work, can't beat the look of a G40 lump in a Mk2 engine bay  :)

Well, did you get it started :)

Hope it went well. Looks awesome, well done. The oil cooler and intercooler position is spot on. Jealous of the mk 2 shell :(

Hmmmmmmm.... not quite yet, had a loom related issue
(http://i959.photobucket.com/albums/ae75/physicsfool/6B705922-8230-472A-A939-A46701A52BB9_zps8ur91o1b.jpg) (http://s959.photobucket.com/user/physicsfool/media/6B705922-8230-472A-A939-A46701A52BB9_zps8ur91o1b.jpg.html)

and ....
(http://i959.photobucket.com/albums/ae75/physicsfool/BCD98761-2C9F-4479-B7F2-6128FDA4FD9D_zpsbjzztfhr.jpg) (http://s959.photobucket.com/user/physicsfool/media/BCD98761-2C9F-4479-B7F2-6128FDA4FD9D_zpsbjzztfhr.jpg.html)

and i reckon this is the connector that caused the issue
(http://i959.photobucket.com/albums/ae75/physicsfool/8CDB3594-F20B-420C-90C0-9FD19F4C75AC_zpsyluemucc.jpg) (http://s959.photobucket.com/user/physicsfool/media/8CDB3594-F20B-420C-90C0-9FD19F4C75AC_zpsyluemucc.jpg.html)

Chap has been really good about taking it back and replacing it, bad news is that its taken the coil and some of the internal loom with it
(http://i959.photobucket.com/albums/ae75/physicsfool/DC534330-9EE4-4BDD-BC1A-7BC9698DE331_zpssowvmhkg.jpg) (http://s959.photobucket.com/user/physicsfool/media/DC534330-9EE4-4BDD-BC1A-7BC9698DE331_zpssowvmhkg.jpg.html)

But he has refunded the dolla to replace all of the parts.

So tomorrow night i am going to start replacing the interior loom and putting the new coil on

WOW, that is unfortunate :( How quickly did that happen?

That's decent of the chap.

I have had problem after problem after problem. From the moment I started stripping the engine back in November 2013, to now, where I still don't have it on the road. Hopefully, it will be on the road this week...

Hope you have better luck than me :) couldn't be hard lol.

Yeah it happened immediately, this will give me the opportunity to relocate the fuel pump back to its original place. But replacing the whole interior loom is going to be a pain.

Haha i agree its a bloody nuisance, how far are you off now? i thought you had it running?

It was running. Ran it in, took it to get it mapped but the guy didn't have an EPROM emulator and so tried to get it running on the larger injectors/larger map sensor which he somehow did, but it ran badly. So popped the standard injectors back in and he gave me a rough map to get me back home. I'm waiting on a chip from Andy which should arrive soon to suit the larger map sensor and injectors, then take it back to get mapped.

Getting it mapped is my only issue :(

Best of luck with yours. Really unfortunate that happened. Its probably killing you to know if it will run ok etc. haha.

So, here goes sorting my electrical issues.

Firstly i wanted to replace the interior loom as it got damaged. and sort the fuel pump wiring out at the same time.

(http://i959.photobucket.com/albums/ae75/physicsfool/5E73AB5F-2ECA-4CAA-9312-84D24A2BC162_zpshbiklv4z.jpg) (http://s959.photobucket.com/user/physicsfool/media/5E73AB5F-2ECA-4CAA-9312-84D24A2BC162_zpshbiklv4z.jpg.html)

And as i used a mk2f loom i realised i was going to have a few rear light and indicator/ignition plug issues. So got cracked on and changed the ignition barrels over and casings as you can see the bottom screw hole is a few mm over so wouldnt fit the mk2f indicator stalk. Also the door locks are on their way out so this gave me a chance to replace all the locks and use only one key. Plus this loom is wired up to an immobiliser.
(http://i959.photobucket.com/albums/ae75/physicsfool/FCABBB84-C7B0-4DD1-A87D-1DE7E64B5BBA_zps6ux3sevk.jpg) (http://s959.photobucket.com/user/physicsfool/media/FCABBB84-C7B0-4DD1-A87D-1DE7E64B5BBA_zps6ux3sevk.jpg.html)

And after a bit of tweeking it all fits a treat
(http://i959.photobucket.com/albums/ae75/physicsfool/E4FCEC8A-8CB0-4789-BA83-9F9AE6B05864_zps0sw73fza.jpg) (http://s959.photobucket.com/user/physicsfool/media/E4FCEC8A-8CB0-4789-BA83-9F9AE6B05864_zps0sw73fza.jpg.html)

But had to replace the handbrake sensor and little bits like that as the mk2f loom has different connectors to the previous mk2 interior loom, this has also allowed me to use my G clocks
(http://i959.photobucket.com/albums/ae75/physicsfool/36D5C389-87E6-4FCE-B51D-77012682DB84_zpstrmh6ham.jpg) (http://s959.photobucket.com/user/physicsfool/media/36D5C389-87E6-4FCE-B51D-77012682DB84_zpstrmh6ham.jpg.html)

and by the fuse box
(http://i959.photobucket.com/albums/ae75/physicsfool/D7D517F6-8763-4DBB-AF6C-DA148B6E250A_zpsanz0i6se.jpg) (http://s959.photobucket.com/user/physicsfool/media/D7D517F6-8763-4DBB-AF6C-DA148B6E250A_zpsanz0i6se.jpg.html)

So i just need to sort the rear lights but i have all the relevant bits of loom so shouldnt be too difficult.

Now this is where the frustration started, received the refurb loom that caused the electrical issue last time. But wasnt happy with the finish
Missing grommets
(http://i959.photobucket.com/albums/ae75/physicsfool/6BB3E5A2-F23D-4DB5-AF98-E88EB87353DF_zpsmasoffno.jpg) (http://s959.photobucket.com/user/physicsfool/media/6BB3E5A2-F23D-4DB5-AF98-E88EB87353DF_zpsmasoffno.jpg.html)

He didnt replace the heat damaged wire on this loom
(http://i959.photobucket.com/albums/ae75/physicsfool/06E4EA77-D98B-48DD-B8EC-CB6975B95461_zpsw1gz13cc.jpg) (http://s959.photobucket.com/user/physicsfool/media/06E4EA77-D98B-48DD-B8EC-CB6975B95461_zpsw1gz13cc.jpg.html)

and forgot the protective outer here
(http://i959.photobucket.com/albums/ae75/physicsfool/22665842-A83C-422D-BDB4-AED7EA6E452E_zpsez0wedog.jpg) (http://s959.photobucket.com/user/physicsfool/media/22665842-A83C-422D-BDB4-AED7EA6E452E_zpsez0wedog.jpg.html)

So i have decided to ask for a refund and stick with a 20 year old factory jobbie. Another delay but i am getting used to them 

So having replaced the internal loom, i got hold of markG40T after he mentioned he has fuel lines off a clean mk2f.

so swapped him some seats and racing seatbelts and got the fuel lines and genesis interior
(http://i959.photobucket.com/albums/ae75/physicsfool/DD789507-168B-40CF-8168-E5472D736516_zpshqdfjlqk.jpg) (http://s959.photobucket.com/user/physicsfool/media/DD789507-168B-40CF-8168-E5472D736516_zpshqdfjlqk.jpg.html)

(http://i959.photobucket.com/albums/ae75/physicsfool/C4A64159-A0C2-42A5-900C-E33C14508857_zpseb1v7u5m.jpg) (http://s959.photobucket.com/user/physicsfool/media/C4A64159-A0C2-42A5-900C-E33C14508857_zpseb1v7u5m.jpg.html)

Seats
(http://i959.photobucket.com/albums/ae75/physicsfool/F8FADA8A-1CE8-44B6-A85F-EC826E5DD293_zps68zrxhhp.jpg) (http://s959.photobucket.com/user/physicsfool/media/F8FADA8A-1CE8-44B6-A85F-EC826E5DD293_zps68zrxhhp.jpg.html)

rears, and even door cards and seatbelts
(http://i959.photobucket.com/albums/ae75/physicsfool/386196AD-D097-45D0-BC3B-A968A5B0D0B6_zpsx9vxwnkt.jpg) (http://s959.photobucket.com/user/physicsfool/media/386196AD-D097-45D0-BC3B-A968A5B0D0B6_zpsx9vxwnkt.jpg.html)

Dash back in with the Clocks thats go with this engine
(http://i959.photobucket.com/albums/ae75/physicsfool/C585DB08-99AB-4277-A09F-B51EFDAB22EA_zpse6cj7pcn.jpg) (http://s959.photobucket.com/user/physicsfool/media/C585DB08-99AB-4277-A09F-B51EFDAB22EA_zpse6cj7pcn.jpg.html)

and wheel
(http://i959.photobucket.com/albums/ae75/physicsfool/17A3054E-58EE-493F-B803-F45801948977_zpssxs9nply.jpg) (http://s959.photobucket.com/user/physicsfool/media/17A3054E-58EE-493F-B803-F45801948977_zpssxs9nply.jpg.html)

Light was starting to go
(http://i959.photobucket.com/albums/ae75/physicsfool/1B030B5A-86AB-47ED-9850-3B60FB46DD41_zpssbyhfhfm.jpg) (http://s959.photobucket.com/user/physicsfool/media/1B030B5A-86AB-47ED-9850-3B60FB46DD41_zpssbyhfhfm.jpg.html)

and the buttons dont look quite right, but will do for now
(http://i959.photobucket.com/albums/ae75/physicsfool/99891989-2057-4621-82D4-6978775F6E53_zpsl7ibxuid.jpg) (http://s959.photobucket.com/user/physicsfool/media/99891989-2057-4621-82D4-6978775F6E53_zpsl7ibxuid.jpg.html)

Finally sorting the loom and rewrapping. Soooooo much insulation tape
(http://i959.photobucket.com/albums/ae75/physicsfool/60D513BA-3952-42E9-9529-D0DBDD9230BB_zpsppoo8vdz.jpg) (http://s959.photobucket.com/user/physicsfool/media/60D513BA-3952-42E9-9529-D0DBDD9230BB_zpsppoo8vdz.jpg.html)

and i cleaned up the fuel lines... all falling into place for this weekend
(http://i959.photobucket.com/albums/ae75/physicsfool/7B836784-41A7-4262-91EC-0F41D25E181A_zpscki0fb27.jpg) (http://s959.photobucket.com/user/physicsfool/media/7B836784-41A7-4262-91EC-0F41D25E181A_zpscki0fb27.jpg.html)

All looking good, Glad to be of service with the bits. Hopefully you will be turning the key soon.

Day finally came to install the fuel lines, i was going to live with the current set up but decided last minute to appease the ocd and sort the fuel lines out.

The old girl showing us what she is made of, i popped some axle stands in before doing work. Safety first
(http://i959.photobucket.com/albums/ae75/physicsfool/6E4B11ED-1BAF-4749-B9EE-43AAF761101F_zpsetchbg8r.jpg) (http://s959.photobucket.com/user/physicsfool/media/6E4B11ED-1BAF-4749-B9EE-43AAF761101F_zpsetchbg8r.jpg.html)

Fresh filter and some zip ties
(http://i959.photobucket.com/albums/ae75/physicsfool/6E45237C-A6ED-44D8-A47D-EF596D23FBF0_zpsjooxytzr.jpg) (http://s959.photobucket.com/user/physicsfool/media/6E45237C-A6ED-44D8-A47D-EF596D23FBF0_zpsjooxytzr.jpg.html)

Then i measured up the fuel pump bracket to the back chassis and popped some rivet nuts in
(http://i959.photobucket.com/albums/ae75/physicsfool/ED13FE0A-DC08-48FD-8751-38F0F2543334_zpsprzqnmhq.jpg) (http://s959.photobucket.com/user/physicsfool/media/ED13FE0A-DC08-48FD-8751-38F0F2543334_zpsprzqnmhq.jpg.html)

After drilling a hole in the boot for the fuel pump wire and routing the breather and fuel lines over the tank i screwed it all into place
(http://i959.photobucket.com/albums/ae75/physicsfool/C8FD1F34-7F5D-43E7-A4DD-B6CF4F77E816_zps0ba0dpyy.jpg) (http://s959.photobucket.com/user/physicsfool/media/C8FD1F34-7F5D-43E7-A4DD-B6CF4F77E816_zps0ba0dpyy.jpg.html)

Now to fit the final piece of loom and get her started. But the next 2 weekends will be spent drinking continental larger and reducing my coefficient of friction. So will put that on hold for a little while longer, also hoping to hear back from York city council about a garage soon, which will make storage and tinkering a lot easier

Looking good Martin! You've put some right graft into this , enjoy having a few weekends off pal!

Poor effort on my part. Well it runs and lives. Still a few niggling issues.... Like it tends to stall when changing down gears from about 2k. But apart from that I am chuffed.

Sold the Ronals to make way for some questionable gold painted steelies
(http://i959.photobucket.com/albums/ae75/physicsfool/3189636A-6BDE-48BE-93B9-506DF5E8A3F7_zpsjgdzz1sn.jpg) (http://s959.photobucket.com/user/physicsfool/media/3189636A-6BDE-48BE-93B9-506DF5E8A3F7_zpsjgdzz1sn.jpg.html)

And I finally moved out of my parents house again. But the first floor one bed flat doesn't have a garden or garage to speak of... So work takes place on the road
(http://i959.photobucket.com/albums/ae75/physicsfool/17B69826-6EDB-4E54-8375-5816F1E2AA79_zpsisq2nclu.jpg) (http://s959.photobucket.com/user/physicsfool/media/17B69826-6EDB-4E54-8375-5816F1E2AA79_zpsisq2nclu.jpg.html)

Swapped by Vauxhall set up for Etches VW11 one. Only needed fresh bleed nipples and throwing on the car
(http://i959.photobucket.com/albums/ae75/physicsfool/1F3BE525-7883-4807-919F-46E613E2E45A_zpszqugkhp4.jpg) (http://s959.photobucket.com/user/physicsfool/media/1F3BE525-7883-4807-919F-46E613E2E45A_zpszqugkhp4.jpg.html)

While I was at it I rebled the brakes with an easy bleed kit donated by my neighbour.... He must get the skint student vibe

While I was at it I had a quick peer at the suspension, looks to be a cheapo set up which isn't very forgiving. So I have invested in a bilstein/eibach combo
(http://i959.photobucket.com/albums/ae75/physicsfool/7D8000B0-163D-45A7-9F8C-6091AF0B6BDF_zpsfajtwev1.jpg) (http://s959.photobucket.com/user/physicsfool/media/7D8000B0-163D-45A7-9F8C-6091AF0B6BDF_zpsfajtwev1.jpg.html)

I like my mk2 shell, it doesn't owe me a penny, however it's full of holes, leaks from all the doors and sunroof and is 50 shades of red. So I am giving to give it to my mate as a project and hopefully re shelling into a 2f G shell in the near future. First the club polo track day though which has prompted me to ditch the skinny steelies and suit up some 13" Ra's with fresh rubber

Quick update:
Club polo track day was a success, really good fun hooning around, quickly learning how far i could push the little polo. Ended up being my driving ability that topped out. But what a day
(http://i959.photobucket.com/albums/ae75/physicsfool/Mobile%20Uploads/IMG_3979_zpse7atf8je.jpg) (http://s959.photobucket.com/user/physicsfool/media/Mobile%20Uploads/IMG_3979_zpse7atf8je.jpg.html)

Action shot, courtesy of Mark Croxford
(http://i959.photobucket.com/albums/ae75/physicsfool/Mobile%20Uploads/IMG_3976_zpslva1jodf.jpg) (http://s959.photobucket.com/user/physicsfool/media/Mobile%20Uploads/IMG_3976_zpslva1jodf.jpg.html)

Good mix of non polos too
(http://i959.photobucket.com/albums/ae75/physicsfool/Mobile%20Uploads/IMG_3978_zpslaymrdko.jpg) (http://s959.photobucket.com/user/physicsfool/media/Mobile%20Uploads/IMG_3978_zpslaymrdko.jpg.html)

But good track and management, Thanks again for sorting it
(http://i959.photobucket.com/albums/ae75/physicsfool/Mobile%20Uploads/IMG_3981_zpsgtgnle8w.jpg) (http://s959.photobucket.com/user/physicsfool/media/Mobile%20Uploads/IMG_3981_zpsgtgnle8w.jpg.html)

I have also purchased a few more bits:
(http://i959.photobucket.com/albums/ae75/physicsfool/Mobile%20Uploads/received_10156077961210593_zps2iyqzlie.jpeg) (http://s959.photobucket.com/user/physicsfool/media/Mobile%20Uploads/received_10156077961210593_zps2iyqzlie.jpeg.html)

To bling it up a bit
(http://i959.photobucket.com/albums/ae75/physicsfool/Mobile%20Uploads/1443174308687_zpsm9tw10ul.jpg) (http://s959.photobucket.com/user/physicsfool/media/Mobile%20Uploads/1443174308687_zpsm9tw10ul.jpg.html)

But finally after 8 months on a waiting list I have managed to get a council garage
(http://i959.photobucket.com/albums/ae75/physicsfool/Mobile%20Uploads/20150920_131635_zpsowg0fmtm.jpg) (http://s959.photobucket.com/user/physicsfool/media/Mobile%20Uploads/20150920_131635_zpsowg0fmtm.jpg.html)

And this meant i could pick my new shell up, courtesy of Mark. A rust free G shell. Who knew they even existed
(http://i959.photobucket.com/albums/ae75/physicsfool/Mobile%20Uploads/20151017_134152_zpscw7442sv.jpg) (http://s959.photobucket.com/user/physicsfool/media/Mobile%20Uploads/20151017_134152_zpscw7442sv.jpg.html)


So this means i can start stripping the mk2 to pop the engine back in its rightful place
(http://i959.photobucket.com/albums/ae75/physicsfool/Mobile%20Uploads/20151003_155602_zpsx0x5cqhc.jpg) (http://s959.photobucket.com/user/physicsfool/media/Mobile%20Uploads/20151003_155602_zpsx0x5cqhc.jpg.html)

Also look to overhaul the oil seals on the charger while its all apart
(http://i959.photobucket.com/albums/ae75/physicsfool/Mobile%20Uploads/20151003_175137_zps6ywcbl3u.jpg) (http://s959.photobucket.com/user/physicsfool/media/Mobile%20Uploads/20151003_175137_zps6ywcbl3u.jpg.html)

So its going to be a busy winter.

looks good in its new home. hopefully will do you well.

Good luck with the new shell Martin, sounds like you've got a good one. I'm excited to see it all come together.

How far from home is your garage?

Now then Rich, on a good run its 13 mins from my flat. On a busy day its more like 30. way over on the west side of York.

Had a late night session yesterday, got the front up on axle stands and stripped the existing suspension and ARB.

(http://i959.photobucket.com/albums/ae75/physicsfool/Mobile%20Uploads/received_10156227997140593_zpsi7om5bb5.jpeg) (http://s959.photobucket.com/user/physicsfool/media/Mobile%20Uploads/received_10156227997140593_zpsi7om5bb5.jpeg.html)

Just in the process of Painting the subframe and stripping the front legs off the mk2 ready for the new springs and shocks to go on. Then simply drop the engine and get the old girl moving again....... In theory

Also well impressed with my Aldi LED tube lighting, mega bright and rechargeable with magnetic ends and rotatable. All that German quality for £25

Progress has been slow lately, work getting in the way and the location of the garage relative to me isn't great so i find late evenings are when I tend to nip over.

But I have sorted and re-wrapped all the wiring and popped it back in the car. I have also re-attached the master cylinder back on.
(http://i959.photobucket.com/albums/ae75/physicsfool/20151116_221851_zpsxslprvnq.jpg) (http://s959.photobucket.com/user/physicsfool/media/20151116_221851_zpsxslprvnq.jpg.html)

Only part of the rear beam that needed refreshing was the bushes. drums have been done relatively recently
(http://i959.photobucket.com/albums/ae75/physicsfool/20151116_211514_zpszk92nmt3.jpg) (http://s959.photobucket.com/user/physicsfool/media/20151116_211514_zpszk92nmt3.jpg.html)

I have also run the fuel lines under the car and in the process of refitting the fuel tank.

Now just to fit the front brakes, suspension as well as the subframe, just need to finish painting the subframe

Would love to see how it fits on your new suspension how much were shocks and springs?

So the subframe is on and master cylinder. Luckily the brake lines were still in place

(http://i959.photobucket.com/albums/ae75/physicsfool/1450439827837_zpszd9mgsmb.jpg) (http://s959.photobucket.com/user/physicsfool/media/1450439827837_zpszd9mgsmb.jpg.html)

New FAG bearings in the front struts
(http://i959.photobucket.com/albums/ae75/physicsfool/20151218_100359_zpsgadwpdnv.jpg) (http://s959.photobucket.com/user/physicsfool/media/20151218_100359_zpsgadwpdnv.jpg.html)

I borrowed some spring compressors and put the front suspension together
(http://i959.photobucket.com/albums/ae75/physicsfool/20151221_123016_zpsmdt3ki0l.jpg) (http://s959.photobucket.com/user/physicsfool/media/20151221_123016_zpsmdt3ki0l.jpg.html)

Now its just a case of throwing the rears back on and getting the shell rolling again.

Hi Dan i bought the kit of someone who had it sitting around from new, i think i paid around 350. Looks like a quality piece of kit but who knows until I have it back on the car and its all settled

In a dark and damp garage somewhere in the north, 3 grown men wrestled with a petrol tank and won.....eventually
(http://i959.photobucket.com/albums/ae75/physicsfool/received_10156421367150593_zpsky1awju1.jpeg) (http://s959.photobucket.com/user/physicsfool/media/received_10156421367150593_zpsky1awju1.jpeg.html)

I was joined by 2 skilled G40 mechanics, both Matt and Rich made this particular grim Yorkshire Saturday a whole lot more fun.
(http://i959.photobucket.com/albums/ae75/physicsfool/20160102_144222_zps6ium6fmw.jpg) (http://s959.photobucket.com/user/physicsfool/media/20160102_144222_zps6ium6fmw.jpg.html)

Plan was to drop the engine back in a wrestle a few of the bigger jobs
(http://i959.photobucket.com/albums/ae75/physicsfool/20160102_144229_zpsyobavesh.jpg) (http://s959.photobucket.com/user/physicsfool/media/20160102_144229_zpsyobavesh.jpg.html)

Bar my poor planning and missing a torque wrench it all went to plan
(http://i959.photobucket.com/albums/ae75/physicsfool/20160102_144249_zpseqpagnvr.jpg) (http://s959.photobucket.com/user/physicsfool/media/20160102_144249_zpseqpagnvr.jpg.html)

While storing the engine in my mates garage i must have damaged the TB plastic clip. So on the hunt for another
(http://i959.photobucket.com/albums/ae75/physicsfool/received_10156422760725593_zps6jnacjov.jpeg) (http://s959.photobucket.com/user/physicsfool/media/received_10156422760725593_zps6jnacjov.jpeg.html)

Last night i bled the brakes and dumped some fresh dot 4 in. As well as popping the new engine mount on. In the process of cleaning the kluber grease off the inside of the charger before re-assembly. As all the seals and bearings look in good nick (only serviced 2 years and 8K ago).

Attaching both fuel pumps and making sure all the internal wiring is sorted, got a quote off Greenlight for £350 with all mods declared. So will be going for that, hopefully that will motivate me a bit more

sweet update, keep motivated man it'll be worth it in the end!
...' 2 skilled G40 mechanics' LOL

Looks great dude! Glad to here you are still cracking on with this!

You got a genuine g40 shell!! :D and a straight one :P

I've missed a bit here.  The 1st g40 shell was on its way to the body shop and next thing I know it's being picked up by the scrappy's crane?


I thought the shell had been fixed and welded prior to the intended full respray?

What cropped up for it to be scrapped?

Ben

Haha so many things have happened in my 3 years of polo ownership.
But the welding on the sills ended up being sub par. The real problems started when the windows, windscreen and rear lights were stripped at the body shop. Was going to require a hell of a lot of welding then expected as the seals were hidings a lot of rust.
Economy and reality unfortunately kicked in and that shell was sent to the heavens. But the one i have acquired to replace it is solid. And i only need a few more days of sunshine and free time to get it running again

Quick update after a period of tinkering with my passat instead

Managed to sort the TB out, so many kind people lurking after the various forums
(http://i959.photobucket.com/albums/ae75/physicsfool/1455128043633_zpse7lgd0gb.jpg) (http://s959.photobucket.com/user/physicsfool/media/1455128043633_zpse7lgd0gb.jpg.html)

And to finish the engine part i need to sort the intercooler and oil cooler
(http://i959.photobucket.com/albums/ae75/physicsfool/20160222_100554_zpsouo04gff.jpg) (http://s959.photobucket.com/user/physicsfool/media/20160222_100554_zpsouo04gff.jpg.html)

Cannot decide whether to go for a thinner longer intercooler, will pop the charger in and see what fits best
(http://i959.photobucket.com/albums/ae75/physicsfool/20160222_100438_zpssdbufmu0.jpg) (http://s959.photobucket.com/user/physicsfool/media/20160222_100438_zpssdbufmu0.jpg.html)

Moved the polo into the garage of the flat i am currently renting, this will increase my motivation to finish it quicker
(http://i959.photobucket.com/albums/ae75/physicsfool/20160504_110939_zpsyj4ghlpd.jpg) (http://s959.photobucket.com/user/physicsfool/media/20160504_110939_zpsyj4ghlpd.jpg.html)

Plus it is a much bigger space
(http://i959.photobucket.com/albums/ae75/physicsfool/20160504_112240_zpsdwrghzf6.jpg) (http://s959.photobucket.com/user/physicsfool/media/20160504_112240_zpsdwrghzf6.jpg.html)

Hopefully i will have a much more infomative update soon now i can start tinkering again

Nice update martin, new flat looks very posh.. much better garage then your previous one.

I hope I'm still invited for it's first run? :)

New garage looks ace mate, what have you done to the passat?  ;D

Yeah its nice having a space I can work on the car when its wet outside. Nowt yet, just egr delete and cleaned up the boost pipes and inlet mani. Sorted a few niggles like the drivers door not opening on fob. More of a workhorse, so maintence costs but wont be lowering or putting 19"s on. But got a trip up to the isle of Skye in a few weeks

Also got my mate to put a fresh gearbox in, as the diff bearing had gone
(http://i959.photobucket.com/albums/ae75/physicsfool/received_10156600249840593_zpswbvqhttf.jpeg) (http://s959.photobucket.com/user/physicsfool/media/received_10156600249840593_zpswbvqhttf.jpeg.html)


And a cheeky clean this weekend
(http://i959.photobucket.com/albums/ae75/physicsfool/20160509_201838_zpsm8bensmm.jpg) (http://s959.photobucket.com/user/physicsfool/media/20160509_201838_zpsm8bensmm.jpg.html)

After a tip off from Pete Mirfman I went for a frontera intercooler. And popped the charger and rad back in

(http://i959.photobucket.com/albums/ae75/physicsfool/20160517_092152_zpsgaiw5ary.jpg) (http://s959.photobucket.com/user/physicsfool/media/20160517_092152_zpsgaiw5ary.jpg.html)

And just need to get a few mounting brackets for the intercooler and order a few reducer elbows as the inlets look to be 2"
(http://i959.photobucket.com/albums/ae75/physicsfool/20160517_092217_zpsfe6ozfq6.jpg) (http://s959.photobucket.com/user/physicsfool/media/20160517_092217_zpsfe6ozfq6.jpg.html)

But getting there slowly, hoping another few sessions and i should be able to test the engine.

Bit more progress

Managed to suss an oil cooler position with thanks to everyones suggestions, it sits really snugly and only requires a few zip ties to keep it in place. All trial an error at this stage
(http://i959.photobucket.com/albums/ae75/physicsfool/20160704_194254_zpswbb06ymo.jpg) (http://s959.photobucket.com/user/physicsfool/media/20160704_194254_zpswbb06ymo.jpg.html)

Modified the bumper bar to allow a bit more flow to the intercooler, (intercooler is off a frontera and fits a treat, heads up to Pete Mirfin for the suggestion)
(http://i959.photobucket.com/albums/ae75/physicsfool/20160705_183141_zpsv6x3z4oo.jpg) (http://s959.photobucket.com/user/physicsfool/media/20160705_183141_zpsv6x3z4oo.jpg.html)

And test fit with the grille, fits behind a treat
(http://i959.photobucket.com/albums/ae75/physicsfool/20160705_183243_zpsvsf5eerp.jpg) (http://s959.photobucket.com/user/physicsfool/media/20160705_183243_zpsvsf5eerp.jpg.html)

And finally the bumper test, which i am happy with, just need a bit of tidying up now
(http://i959.photobucket.com/albums/ae75/physicsfool/20160705_185045_zpskeh3sxqv.jpg) (http://s959.photobucket.com/user/physicsfool/media/20160705_185045_zpskeh3sxqv.jpg.html)

Just refilling the gearbox oil and coolant and i should have a car that moves under its own steam again. which is totes exciting

Word of warning - braided lines will (and do) rub through anything, so make sure you clip it securely up  ;)

Do like a red G  8)

Cheers, will keep an eye on them. They get pretty warm as well so will make sure nothing gets damaged

Chip turned up today, thanks again for sorting it

Hey man,
Did you have to get different hoses for the intercooler?
I'll definitely check out the frontera for a cooler!

Quote from: Sknight92 on July 06, 2016, 11:41:03 PM
Hey man,
Did you have to get different hoses for the intercooler?
I'll definitely check out the frontera for a cooler!

I needed a reducer 51 mm (Intercooler) to 57 mm (rest of the system), used 90 degree jobbies and a stainless 45 degree piece from the hard plastic (co pot) boost pipe down to the intercooler on the pass side. Was all straight forward, and as the outlets on the intercooler face backwards it saves using another 90 bend

Sweet, thanks man I'll check that out!
My G is causing me so much pain - currently getting forged by a friend who works at Mclarren (Yup, thee mcclaren, he's on the f1 now)
But still so much to do, praying I have it back before the summer ends. Yours is looking sweet man,
Definitely wish I had another colour other than grey!!
Keep up the good work!

Damn Martin this is turning out to be a bit of a beast.

Just a quick update: Had a cracking Sunday weather wise, thought the G needed a small nudge towards its MOT, sorted insurance now so just a matter of getting it mechanically sound.

Well I have finished most of the motor issues, just sorting seat belts and making sure the indicators work and the like. Oh and my windscreen washers are back to front so i need to swap the pipes over on the motor.
(http://i959.photobucket.com/albums/ae75/physicsfool/20160918_144730_zpso7fvagrx.jpg) (http://s959.photobucket.com/user/physicsfool/media/20160918_144730_zpso7fvagrx.jpg.html)

need to sort the outer trim, but thats way down the list
(http://i959.photobucket.com/albums/ae75/physicsfool/20160918_144739_zpsdnum1kyv.jpg) (http://s959.photobucket.com/user/physicsfool/media/20160918_144739_zpsdnum1kyv.jpg.html)

And before i take it for an MOT i will give it a good clean and make sure its looking its best
(http://i959.photobucket.com/albums/ae75/physicsfool/20160918_150743_zpszuapycel.jpg) (http://s959.photobucket.com/user/physicsfool/media/20160918_150743_zpszuapycel.jpg.html)

But I took it for a drive (down a private road) and brought the smiles right back, that has helped with motivation

I have also bought another project (missus still doesnt know about it). Will update on that when i start working on it

Or swap the 2 cables, that will work too!  ;D

So finally some exciting news, got it MOT'd which means it no longer needs to spend all its time in a garage. Had a few internal loom issues while prepping it, and maybe a touch of smoke. Also emissions were way out so finally diagnosed as a dead lambda. But gave it a quick Italian tune before its MOT and the old girl does drive really nicely, stage 3 sub frame means handling is spot on.

(http://i959.photobucket.com/albums/ae75/physicsfool/20170105_122019_zps167rzfje.jpg) (http://s959.photobucket.com/user/physicsfool/media/20170105_122019_zps167rzfje.jpg.html)

Want to do a bit of touching up and pop the rear seats back in as well as a good clean.

Emissions failure culprit
(http://i959.photobucket.com/albums/ae75/physicsfool/20170105_133939_zpsgasrplbu.jpg) (http://s959.photobucket.com/user/physicsfool/media/20170105_133939_zpsgasrplbu.jpg.html)

So with the better weather will hopefully come more regular updates. Winter is always tough for motivation. Plus I have a thesis to write and a grown up job to find

Yes Martin! congrats. Hope you had a good new year and it's nice to see you finished it.

We should arrange a meet up when the weather improves  8)

So since its MOT I have been for a few blasts and also washed it for the first time in a long while
(http://i959.photobucket.com/albums/ae75/physicsfool/20170108_134036_zpskmnzmike.jpg) (http://s959.photobucket.com/user/physicsfool/media/20170108_134036_zpskmnzmike.jpg.html)

Still have the CL badge on, needs swapping over
(http://i959.photobucket.com/albums/ae75/physicsfool/20170108_134020_zpsw0uykrt9.jpg) (http://s959.photobucket.com/user/physicsfool/media/20170108_134020_zpsw0uykrt9.jpg.html)

Even drove it to work one day
(http://i959.photobucket.com/albums/ae75/physicsfool/ae81be1b-2289-4934-b3cc-fd5a61222c1a_zpssdkm3voy.jpg) (http://s959.photobucket.com/user/physicsfool/media/ae81be1b-2289-4934-b3cc-fd5a61222c1a_zpssdkm3voy.jpg.html)

Also fitted the rear seats and belts so now it can carry multiple passengers again. Need to find my red tape for the bumpers. and finish the dash wiring

I got bored of looking at the spare engine, so plan is to build this one back up. Was told it is low mileage 77K and looks in good nick. But not taking any chances, so doing the oil pump and waterpump/belt
(http://i959.photobucket.com/albums/ae75/physicsfool/20170305_151944_zpsngonygpt.jpg) (http://s959.photobucket.com/user/physicsfool/media/20170305_151944_zpsngonygpt.jpg.html)


Plus I am going to need an engine for mk1 when i finally get the shell sorted.
(http://i959.photobucket.com/albums/ae75/physicsfool/20170305_151955_zpstqkda30a.jpg) (http://s959.photobucket.com/user/physicsfool/media/20170305_151955_zpstqkda30a.jpg.html)

looks good man, you keeping the mk1 now? I saw it on ebay a few weeks ago...

Rich, I saw sense and am keeping it. But popped it into a mates barn this week as a longer term storage option until i can afford to get started properly

(http://i959.photobucket.com/albums/ae75/physicsfool/20170409_133406_zpsv4b3v5o3.jpg) (http://s959.photobucket.com/user/physicsfool/media/20170409_133406_zpsv4b3v5o3.jpg.html)

But in other news I have finally got round to sorting some of the trim as it was such a nice weekend
(http://i959.photobucket.com/albums/ae75/physicsfool/20170408_105614_zpsksebnf7i.jpg) (http://s959.photobucket.com/user/physicsfool/media/20170408_105614_zpsksebnf7i.jpg.html)

Clean the door and rear quarter, got plenty of funny looks as I was wielding a hairdryer
(http://i959.photobucket.com/albums/ae75/physicsfool/20170408_114555_zpsjrq5s9ho.jpg) (http://s959.photobucket.com/user/physicsfool/media/20170408_114555_zpsjrq5s9ho.jpg.html)

But happy with how it has come out. Just need to sort the gutter trim and give it all a good clean and treat the plastic as its all shades of grey

What you treating your plastic with???? Mines is all shades too but cause mines is black looks so much worse.... still got lots of work to do but a marathon not a sprint

Got some autoglym bumper and trim gel as it was on offer. But there is a thread in the bodywork section that outlines a load of options

https://www.amazon.co.uk/d/Automotive/Forever-Black-Bumper-Trim-Cleaner-Reconditioner-Dye/B001MPY436

Unbelievable! wipe it on, done. No residue or faffing. Lasts a few years, truly is a "wonder" product. Only £15ish and a bottle will do a Polo a few times over, you can also use it on anything else black plastic I believe, possibly tyres too

yeh I use autoglym stuff these days but I don't know how well it will actually restore the trim that is already faded...it might be worth getting some boiled linseed oil to try and bring them back to black first or that stuff ereeiz has recommended if the autoglym doesnt work, depends how much you care (probably not that much knowing you haha)...

still looks a ton better already as it is, also loving the random bench...

keep us posted on the mk1 Martin if you ever get started on it.

I recently tried some stuff called Gtechniq C4 on my plastics and it is the best stuff I've ever used!

https://www.amazon.co.uk/C4-Permanent-Trim-Restorer-0-015/dp/B00IOMDUN0/ref=sr_1_1?s=automotive&ie=UTF8&qid=1492050788&sr=1-1&keywords=Gtechniq+C4

Unlike most trim 'restore' products that are nothing more than a dye which leave a finish which is just too shiny and comes off in the next wash, this C4 stuff actually seems to be absorbed by the plastic and the finish is a lot more natural looking.

Before:
(http://i224.photobucket.com/albums/dd245/Kwijibo_photos/20170408_175422_zpsebmihwhq.jpg) (http://s224.photobucket.com/user/Kwijibo_photos/media/20170408_175422_zpsebmihwhq.jpg.html)

After:
(http://i224.photobucket.com/albums/dd245/Kwijibo_photos/20170408_180848_zpsvytowck4.jpg) (http://s224.photobucket.com/user/Kwijibo_photos/media/20170408_180848_zpsvytowck4.jpg.html)

Well its been a busy few months and lots has happened...

Firstly I picked up some speedlines off Gaz and proceeded to get them painted in satin silver
(http://i959.photobucket.com/albums/ae75/physicsfool/20170605_101428_zps0cfkfqtj.jpg) (http://s959.photobucket.com/user/physicsfool/media/20170605_101428_zps0cfkfqtj.jpg.html)

Final product:
(http://i959.photobucket.com/albums/ae75/physicsfool/20170614_114011_zpsb6psfm2c.jpg) (http://s959.photobucket.com/user/physicsfool/media/20170614_114011_zpsb6psfm2c.jpg.html)

Which I am very happy with.

I also washed and polished the car for pretty much the first time. Treated the trim as well
(http://i959.photobucket.com/albums/ae75/physicsfool/20170423_165012_zpscnogk6lj.jpg) (http://s959.photobucket.com/user/physicsfool/media/20170423_165012_zpscnogk6lj.jpg.html)

Lots of time and pretty labour intensive. But like the results
(http://i959.photobucket.com/albums/ae75/physicsfool/20170423_164947_zpsxtakl42a.jpg) (http://s959.photobucket.com/user/physicsfool/media/20170423_164947_zpsxtakl42a.jpg.html)

(http://i959.photobucket.com/albums/ae75/physicsfool/20170423_160906_zpsybkb45rd.jpg) (http://s959.photobucket.com/user/physicsfool/media/20170423_160906_zpsybkb45rd.jpg.html)

(http://i959.photobucket.com/albums/ae75/physicsfool/20170423_160756_zpsmi8uzxqz.jpg) (http://s959.photobucket.com/user/physicsfool/media/20170423_160756_zpsmi8uzxqz.jpg.html)

I also bought one of the repo rear badges off eBay, pretty chuffed with how they look
(http://i959.photobucket.com/albums/ae75/physicsfool/20170622_135334_zpsb9m388gu.jpg) (http://s959.photobucket.com/user/physicsfool/media/20170622_135334_zpsb9m388gu.jpg.html)

and finishes the car off nicely
(http://i959.photobucket.com/albums/ae75/physicsfool/20170622_135338_zpsnspcgoj1.jpg) (http://s959.photobucket.com/user/physicsfool/media/20170622_135338_zpsnspcgoj1.jpg.html)

However no sooner had i cleaned and driven it, someone offered me money for it.... It took me a few days to come to a decision. But after 4 years of G40 ownership I decided I would focus on the mk1 i bought last year instead. My aim was always to rebuild an engine and hopefully get it to run. So time to do that all over again, this time with a different car. As I am no welder or painter, I will be getting someone else to do those parts. But the engine is once again my domain.....so time to decide whats going in it....

Bit of a shame Martin but well done on finishing it off, it looks really good in those last few pics,

good luck with the Mk1 mate, hope to see it running one day.