Club G40 Forum

Club G40 => Photos and videos => Ongoing Projects => Topic started by: Matty! on August 14, 2013, 10:46:55 am

Title: Matty's Polo G40
Post by: Matty! on August 14, 2013, 10:46:55 am
So...

I've been looking left right and centre for an old school VW of some sort, after boring my mates and my brother for around a year of a different car every week I thought I would just hold on out untill something crops up.

And it did!

So after battling crashes, road closures and potty stops it had endured a mammoth 6.5 hour trek home from Kent in the middle of the night. We arrived home without a hitch in my Supercharger Pocket rocket!


A 110k 1992 Genuine Polo G40

Spec is as followed:

Spec:

14" BBS RA's with 4 brand with Yokahoma A539's
GAZ dampening and height adjustable coilovers on the rear
Koni Springs and shocks on the front
258mm front disk conversion
Master cylinder


R1 Spec charger (rebuilt 4,000 miles ago)
Jabbasport induction kit
Alloy catch tank
Boost return mod (hence open hose)
De-cat
Stainless system from manifold back
Hidden polished stainless silencer
G60 Injectors
And I think its Cammed as its lumpy as hell on Idle.

161bhp - 800kg's


:D

This car goes! Its so good fun, when you plant the throttle it just takes off, and all that way you are laughing so hard because its only a little 1.3 8v! Makes the TT feel like a boat, but a stable boat atleast.

The car has to have had a full respray in its life, as there in not an ounce of rust on the thing and its immaculate inside & out.

I absolutely adore it, and hopefully will be keeping it for a long long while.


(http://farm6.staticflickr.com/5342/9278296982_409d251500_z.jpg)

(http://farm4.staticflickr.com/3736/9278304740_c086860a16_z.jpg)


(http://farm3.staticflickr.com/2847/9275523119_b1a7623585_z.jpg)

(http://farm6.staticflickr.com/5519/9278312470_a3ab6b5220_z.jpg)

(http://farm6.staticflickr.com/5541/9278318834_a6677613b3_z.jpg)

(http://farm6.staticflickr.com/5540/9278324212_508900c1a3_z.jpg)

(http://farm6.staticflickr.com/5463/9278325882_627f6a3f09_z.jpg)

(http://farm3.staticflickr.com/2854/9275547857_aec3c738a1_z.jpg)

(http://farm4.staticflickr.com/3736/9278304740_c086860a16_z.jpg)

(http://farm3.staticflickr.com/2852/9278306318_53df0187dc_z.jpg)


Picture of it with the TT
(http://farm4.staticflickr.com/3722/9447796480_7fc56be41f_z.jpg) (http://"http://www.flickr.com/photos/kurt_blythman/9447796480/")
Audi TT (http://"http://www.flickr.com/photos/kurt_blythman/9447796480/") by Kurt Blythman (http://"http://www.flickr.com/people/kurt_blythman/"), on Flickr



Since having this...

I've Been doing abit of research as I wanted to know if my car has an upgraded 51mm Throttle Body and GT inlet manifold, after inspection it does not have the GT inlet manifold so I booked the car into John at Bigfishtuning for a Dyno run just to see if the power its outputting was accurate before I start fiddling for maybe no reason.

the results:
(http://i5.photobucket.com/albums/y154/mattys_trains/20130813_133211_zps1f5c5fda.jpg) (http://"http://s5.photobucket.com/user/mattys_trains/media/20130813_133211_zps1f5c5fda.jpg.html")

(http://i5.photobucket.com/albums/y154/mattys_trains/20130813_140205_zps8210ab70.jpg) (http://"http://s5.photobucket.com/user/mattys_trains/media/20130813_140205_zps8210ab70.jpg.html")





So, I think I need to whip the inlet manifold off when my GT one arrives and see if this little bugger has said bits as this proves its running the power!

The car hunts for revs occasionally on Idle, could this be signs of the 51mm TB or Cams? Or neither as it has had an idle problem from day one according to all the service history.

Secondly I adjusted the dampening on the rear coilovers and now the car actually turns! Happy days, going to look into running GAZ coilovers on the front so atleast I have a matching set.

Cleaned under the arches yesterday to find no horror stories at all too! Its always a good feeling when you buy a car and realise there is no hidden secrets.

Anywho bought a few boring stuff to just neaten it up but over time this car will have the full treatment bringing it back to a full on immaculate G40.

Few pics with Scott-O's MK2

(http://farm4.staticflickr.com/3797/9477177929_9243f3027b_z.jpg) (http://"http://www.flickr.com/photos/221matty/9477177929/")
mk2 g401. (http://"http://www.flickr.com/photos/221matty/9477177929/") by Matty! (http://"http://www.flickr.com/people/221matty/"), on Flickr

(http://farm3.staticflickr.com/2829/9501990672_77f3febf01_z.jpg) (http://"http://www.flickr.com/photos/221matty/9501990672/")
MK2 Golf / Polo G40 (http://"http://www.flickr.com/photos/221matty/9501990672/") by Matty! (http://"http://www.flickr.com/people/221matty/"), on Flickr

(http://farm4.staticflickr.com/3779/9499190063_3254ab597c_z.jpg) (http://"http://www.flickr.com/photos/221matty/9499190063/")
mk2 Golf / Polo G40 (http://"http://www.flickr.com/photos/221matty/9499190063/") by Matty! (http://"http://www.flickr.com/people/221matty/"), on Flickr


Future plans:
Change front to coilovers - lower 5-10mm
Beg AAS to make a full manifold/exhaust for it
Check the cam and possibly buy a Schrick for it.
If it hasnt already Port the Inlet manifold and Head
Just generally neaten everything up untill its 100% immaculate.

Can anybody in the know look at my spec and look at my power output and possibly tell me what this car may have that the previous owner didn't list in the advert?


Thanks
Matty
Title: Re: Matty's Polo G40
Post by: Matty! on January 06, 2014, 09:48:51 pm
Sooo, its all been happening, I thought I would post up a mid-build report :) Some of this is copied off vagcars so bare with me!

So after a lovley drive out:

(http://i5.photobucket.com/albums/y154/mattys_trains/20130921_113500_zps0d9e57cd.jpg) (http://s5.photobucket.com/user/mattys_trains/media/20130921_113500_zps0d9e57cd.jpg.html)

This had to happen....


It... Was only a matter of time.

(http://i5.photobucket.com/albums/y154/mattys_trains/20130925_213359_zps61d9f217.jpg) (http://s5.photobucket.com/user/mattys_trains/media/20130925_213359_zps61d9f217.jpg.html)

The charger was knocking its t*ts off on idle, but it would clear up as soon as you revved it, which to me sounded like something was rather amiss!

After some research I was heading in the direction of that the timing belt on the charger was delaminating, which is fairly common if it hasnt had the 11mm Belt upgrade, so got the charger off, opened it up and its fine and upgraded. b*llocks!

Looking at how to guides ect It looked easy enough to rebuild, so I looked for a rebuild kit  £190, then Scott-o alerted me to OnlyChargedDubs in manchester, few messages later the charger is now in his hands, for £300 and it comes back painted and fresh I wasnt going to groan!

And then he phones me... to tell me the charger is fine, what has actually gone is a bearing that isnt even in the rebuild kit because its so rare it fails in the top assembly, so now somewhere between Germany and here is my bearing for it! typical, yet im glad I didnt rebuild it now as I wouldnt have even had the contacts or the sense to look at that bearing.

Anyways it was a good excuse to buy these:
(http://i5.photobucket.com/albums/y154/mattys_trains/20131005_101908_zps6fb8582e.jpg) (http://s5.photobucket.com/user/mattys_trains/media/20131005_101908_zps6fb8582e.jpg.html)
Bartek toothed belts, which may I add I bought on Sunday night and arrived here Wednesday morning at 10:00am with a text asking me if thats okay! unbelievable service especially when they are from germany.

Also bought some uprated engine polybush mounts as the ones on mine are rather squidgy:
(http://i5.photobucket.com/albums/y154/mattys_trains/20131004_071839_zps5fe80b3c.jpg) (http://s5.photobucket.com/user/mattys_trains/media/20131004_071839_zps5fe80b3c.jpg.html)


Half way through fitting these, as every part that comes off this car either gets fully cleaned or sandblasted and painted, so things take twice as long when you do that.

Supercharger Mount:
Before
(http://i5.photobucket.com/albums/y154/mattys_trains/20131001_130140_zpscc7873f8.jpg) (http://s5.photobucket.com/user/mattys_trains/media/20131001_130140_zpscc7873f8.jpg.html)

After
(http://i5.photobucket.com/albums/y154/mattys_trains/20131005_101937_zps934d481e.jpg) (http://s5.photobucket.com/user/mattys_trains/media/20131005_101937_zps934d481e.jpg.html)


The grand plan this winter is to get the chassis fully up to top notch and dress the bay up.

Got hold of these beauties!
Adjustable top mounts:
(http://i5.photobucket.com/albums/y154/mattys_trains/20131004_071631_zps3c242b8f.jpg) (http://s5.photobucket.com/user/mattys_trains/media/20131004_071631_zps3c242b8f.jpg.html)

I asked the guy I bought them from (breadman)  can he give me just a quick sketch of how they go together, expecting a daft little sketch and I got this!

(http://i5.photobucket.com/albums/y154/mattys_trains/601e2194-510b-447a-afc4-39a23d3e5b58_zps23bacd06.jpg) (http://s5.photobucket.com/user/mattys_trains/media/601e2194-510b-447a-afc4-39a23d3e5b58_zps23bacd06.jpg.html)

Awesome sketch I must say.


So I've settled on my Chassis headache of which subframe to go for, Im going to go for the one that keeps the anti roll bars and went with the top mounts instead of rose jointed bottom arms, which are all pornographic yes, but good for a car that might go on track twice a year? probably not. So opted for the less hardcore version but in turn it should drive better on the roads it will be getting used on.


So anyways, got FAR too many things I need to save and order for this over winter, lets hope it can be done for March next year, but hopefully this car should be a huge step above what it is now by next year, Im just going to keep working on it when I can peel myself away from the Pub, GTA, work, dog, bike, GF, ect! Plus I have just got the use of a Milling machine, so watch this space!


Next update:
Quick picture of the wheels :)
(http://i5.photobucket.com/albums/y154/mattys_trains/IMG_20131210_165850_zps7de20707.jpg)

I had these refurbed along with a few other components by Grover at RS Alloys in hartlepool! Top job I must say, the colour is audi hyper silver.

However 2 days after I put the deposit down on some EXTREMLEY special wheels! But watch this space, I wont post pics untill I have them in my hands!

The car is still on axle stands awaiting a handful of tastey suspension/misc parts. 






Title: Re: Matty's Polo G40
Post by: Matty! on January 06, 2014, 09:50:23 pm
Soooooo, Been busy beavering away when I can, mainly when the weather has been god awful!

Not really anything flash as an update but bits and bobs that all help.

Started off with a standard G40 Rocker, now my car has had the return bypassed so the horrible inlet/outlet aint needed anymore, so I thought I would give it a bash at getting it blanked.

Start
(http://i5.photobucket.com/albums/y154/mattys_trains/Polo%20G40/G40Rocker_zps1da5e6b5.jpg) (http://s5.photobucket.com/user/mattys_trains/media/Polo%20G40/G40Rocker_zps1da5e6b5.jpg.html)

After it being milled
(http://farm4.staticflickr.com/3799/11644943353_9cc8cc981b_z.jpg) (http://www.flickr.com/photos/221matty/11644943353/)
polo g40 build (http://www.flickr.com/photos/221matty/11644943353/) by Matty! (http://www.flickr.com/people/221matty/), on Flickr

The alu welded
(http://farm3.staticflickr.com/2829/11645060274_d3a48793c0_z.jpg) (http://www.flickr.com/photos/221matty/11645060274/)
polo g40 build (http://www.flickr.com/photos/221matty/11645060274/) by Matty! (http://www.flickr.com/people/221matty/), on Flickr


After a quick whip over with a flapper wheel
(http://farm6.staticflickr.com/5498/11644665355_94b12fac06_z.jpg) (http://www.flickr.com/photos/221matty/11644665355/)
polo g40 build (http://www.flickr.com/photos/221matty/11644665355/) by Matty! (http://www.flickr.com/people/221matty/), on Flickr

Then after a hour or so of flapperwheeling!

(http://farm3.staticflickr.com/2887/11645434566_4fec9dab5b_z.jpg) (http://www.flickr.com/photos/221matty/11645434566/)
polo g40 build (http://www.flickr.com/photos/221matty/11645434566/) by Matty! (http://www.flickr.com/people/221matty/), on Flickr

(http://farm4.staticflickr.com/3679/11644658695_f6d18fa72c_z.jpg) (http://www.flickr.com/photos/221matty/11644658695/)
polo g40 build (http://www.flickr.com/photos/221matty/11644658695/) by Matty! (http://www.flickr.com/people/221matty/), on Flickr


So then I primered it and painted it Plastikote satin red...
(http://farm8.staticflickr.com/7322/11645031704_102f1ba5a5_z.jpg) (http://www.flickr.com/photos/221matty/11645031704/)
polo g40 build (http://www.flickr.com/photos/221matty/11645031704/) by Matty! (http://www.flickr.com/people/221matty/), on Flickr

When when dried looked more a lovley shade of Pink!!

So, I decided on VHT Crackle Red... which we on great, let it dry annddddd, it looks garbage, I put far too much paint on the top and not along the sides, the sides look awesome, the top is wrinklier than a 100 year old aborigines ball sack!

So I've sanded it back and painted again, fingers crossed it looks okay this time, havn't checked yet. 


I've painted and polybushed the TCA's and brake shields...
(http://farm6.staticflickr.com/5497/11644927423_383c3fbe15_z.jpg) (http://www.flickr.com/photos/221matty/11644927423/)
polo g40 build (http://www.flickr.com/photos/221matty/11644927423/) by Matty! (http://www.flickr.com/people/221matty/), on Flickr

(http://farm4.staticflickr.com/3833/11645018854_1466553de2_z.jpg) (http://www.flickr.com/photos/221matty/11645018854/)
polo g40 build (http://www.flickr.com/photos/221matty/11645018854/) by Matty! (http://www.flickr.com/people/221matty/), on Flickr

For any that are in the know I found out these actually arnt G40 items, these are normal TCA's however after abit of research if you polybush the TCA's its exactly the same as the G40 Rose jointed items which are £200!!!

Mounted up the Weichers Strut brace
(http://farm3.staticflickr.com/2824/11644649595_1c4012fe8d_z.jpg) (http://www.flickr.com/photos/221matty/11644649595/)
polo g40 build (http://www.flickr.com/photos/221matty/11644649595/) by Matty! (http://www.flickr.com/people/221matty/), on Flickr

I've had Grover Powder coat me ARB, Performance Subframe and soon to be strut brace as the finish on the strut brace I am not happy with so for £10 its a no brainer!



I have bought some extremely rare BBS wheels for this, but I wont post pictures ECT untill I have them here with me, as at the moment me and the previous owner dont want to risk loosing them at the courier in this busy time, but I will post them up when I get them.

Anywho, Im on with undersealing the arches and painting the calipers at the moment, got to send my struts off to KW for my coilovers which I am going to send off when the bank hols ect have ended.


So yeah, the list keeps getting bigger and bigger, but with the pressure of having to get it out the garage for my dads car it means im having to really pull my finger out!



So after having to do this for the second time!!
(http://i5.photobucket.com/albums/y154/mattys_trains/Polo%20G40/20140102_101803_zpsz1yyomdk.jpg) (http://s5.photobucket.com/user/mattys_trains/media/Polo%20G40/20140102_101803_zpsz1yyomdk.jpg.html)

I finally got a result with the wrinkle finish!
(http://i5.photobucket.com/albums/y154/mattys_trains/Polo%20G40/20140102_155724_zpsezsj4voa.jpg) (http://s5.photobucket.com/user/mattys_trains/media/Polo%20G40/20140102_155724_zpsezsj4voa.jpg.html)

Title: Re: Matty's Polo G40
Post by: Matty! on January 06, 2014, 09:50:36 pm
So me and my Dad got cracked on with the PPP Subframe/Gearbox mount.

It came in black so I sent it to RS Alloys in Hartlepool for Powdercoating along with my ARB.

(http://farm8.staticflickr.com/7357/11805922325_2e8179f2b3_z.jpg) (http://www.flickr.com/photos/221matty/11805922325/)
polo g40 subframe (http://www.flickr.com/photos/221matty/11805922325/) by Matty! (http://www.flickr.com/people/221matty/), on Flickr

Fitting consisted of dropping the exhaust downpipe, removing the gear linkage and removing the arb, which all came off according to plan, for a 20 year old car it is in fine condition underneath!

Got the subframe hooked over and mounted the gearbox mount, this stops the pivoting movement on the gearbox by attaching to some of the existing bolt holes in the side of the gearbox, this along with the polybush mounts should make it feel very direct.

So on with the subframe, we got the rear mounted up in place, attached the gearlinkage to find... it wouldnt select 2 or 4th this was diagnosed to the ball on the gear linkage fouling the subframe, so we had to skim that down... should affect the gear change at all as all touching surfaces weren't needed to be touched.

Placed the arb in place, aligned, and bolted up! Sounds simple and easy, it isnt, its awkward and the tolerances are super close.

Anywho Ill let the pics do the talking:

Note: Still yet to finish off painting calipers



(http://farm4.staticflickr.com/3689/11805916925_f544bf5b0d_z.jpg) (http://www.flickr.com/photos/221matty/11805916925/)
polo g40 subframe (http://www.flickr.com/photos/221matty/11805916925/) by Matty! (http://www.flickr.com/people/221matty/), on Flickr

(http://farm4.staticflickr.com/3709/11806153843_a50f67d5e8_z.jpg) (http://www.flickr.com/photos/221matty/11806153843/)
polo g40 subframe (http://www.flickr.com/photos/221matty/11806153843/) by Matty! (http://www.flickr.com/people/221matty/), on Flickr

Gearbox mount/subframe:
(http://farm6.staticflickr.com/5501/11806640316_a28188ff59_z.jpg) (http://www.flickr.com/photos/221matty/11806640316/)
polo g40 subframe (http://www.flickr.com/photos/221matty/11806640316/) by Matty! (http://www.flickr.com/people/221matty/), on Flickr

(http://farm6.staticflickr.com/5539/11806635926_4ee15e97c3_z.jpg) (http://www.flickr.com/photos/221matty/11806635926/)
polo g40 subframe (http://www.flickr.com/photos/221matty/11806635926/) by Matty! (http://www.flickr.com/people/221matty/), on Flickr

This along with the AAS exhaust is gonna make the underside of the car look better than above!
Title: Re: Matty's Polo G40
Post by: breadman on January 06, 2014, 10:19:40 pm
Hey Matty, that's coming along very nicely. I do like to see a job being done properly not just thrown together.
Can you remember to send me the suspension top hats that we spoke about? Would really help me out.
Cheers mate,
Richard.
Title: Re: Matty's Polo G40
Post by: Matty! on January 06, 2014, 10:34:47 pm
Yeah man! I PM'd you like 5 mins ago :D
Title: Re: Matty's Polo G40
Post by: breadman on January 06, 2014, 11:21:53 pm
Yeah man! I PM'd you like 5 mins ago :D


I didn't get a pm mate, maybe try again?
Title: Re: Matty's Polo G40
Post by: physicsfool on January 07, 2014, 01:46:15 pm
Really nice work
Title: Re: Matty's Polo G40
Post by: Matty! on January 07, 2014, 06:48:48 pm
Cheers :)

Anywho my wheels arrived today!
RS240 Which are 14" BBS RS's these are Uber uber rare, I've never seen a set in the flesh untill now.


(http://farm8.staticflickr.com/7381/11822201856_56b33ccc9f_z.jpg) (http://www.flickr.com/photos/221matty/11822201856/)
BBS RS 240 (http://www.flickr.com/photos/221matty/11822201856/) by Matty! (http://www.flickr.com/people/221matty/), on Flickr

(http://farm3.staticflickr.com/2872/11821853004_d1c7373260_z.jpg) (http://www.flickr.com/photos/221matty/11821853004/)
BBS RS 240 (http://www.flickr.com/photos/221matty/11821853004/) by Matty! (http://www.flickr.com/people/221matty/), on Flickr

(http://farm8.staticflickr.com/7384/11821860924_f3497e9e24_z.jpg) (http://www.flickr.com/photos/221matty/11821860924/)
BBS RS 240 (http://www.flickr.com/photos/221matty/11821860924/) by Matty! (http://www.flickr.com/people/221matty/), on Flickr
Title: Re: Matty's Polo G40
Post by: Jester on January 07, 2014, 10:00:20 pm
where did you manage to find a set of them  :o
Title: Re: Matty's Polo G40
Post by: JoeH on January 08, 2014, 11:32:36 pm
NICE work
Have you poly bushed the outer end of the TCA, its just I would defo Nylon bush it, PPP sell them, much harder and won' tear...

You gonna LSD/Quaife it, with that much power?
Title: Re: Matty's Polo G40
Post by: JoeH on January 08, 2014, 11:34:58 pm
Also, will you fit the little ARB block ring clamps? looks like you got the ARB that won't let your fit one on next to each block...
be interested to hear a solution
Title: Re: Matty's Polo G40
Post by: Lionheart on January 10, 2014, 11:52:50 pm
Hi Matty, is that a stage two sub frame? And why did you need to drop the down pipe? Great project and thank you for putting the thread up.
Title: Re: Matty's Polo G40
Post by: Matty! on January 12, 2014, 07:28:58 pm
Hey guys

I polybushed the inners, and the outers were already polybushed, I feel nylon would be abit of a rough ride for a road car especially coupled with the salzmann top mounts as ive heard they compromise on ride, I want it abit of a happy medium as im fortunate to have to epic roads on my doorstep, same as to why I went for stage 2 over 3, I dont think the benefits would benefit qhat I will be predominantly using the car for.

Thats not to say it will definitely be doing some track days this year!

I will eventually LSD it, but just one step at a time, dont want to do everything at once or I will have nothing to look forward too haha! Its probably on the limit at the moment but adds to the challenge of driving it, hopefully all this stiffening/ new setup should bring a little more confidence in the car, but depending on my situation next year I may look into a G60 or G45 setup but its not proirity, half cage is pencilled in for next winter! :D

I just hadn't fitted the clamps there, there on now, in satin black, look lovley!

Lion - had to drop the exhaust to get the rear of the frame over it :) if your planning on fitting one it will make sense when you come to it.

Bolted the rear strut brace in today too, probably the easiest mod I've ever done!

Title: Re: Matty's Polo G40
Post by: Matty! on April 07, 2014, 09:16:12 pm
UPDATE:


Been cracking on with this as and when.

First up, Front Bumper:

When I bought the car it had some mesh where the foglights were meant to go, and I always intended to get some foglights for the car, untill I realised how rare and expensive they are... I nearly spat my drink out when I saw how much they go for!

So I was browsing PVW bored as you do at work and found a MK3 golf that had brake vents installed, so I thought yeah Ill do that instead but make it a cold air feed.

Bit of measuring and headaches later I had some thing that would work, but when I placed them up to the car they were fouling the chassis... so had to rethink the ducts and eventually got them to fit nicely, happy days!

Also retro-fitted a new 6n front splitter to make the car look a tad more aggressive.

(http://farm8.staticflickr.com/7432/12951548053_0cdbc1f640_z.jpg) (http://www.flickr.com/photos/221matty/12951548053/)
Polo G40 KW (http://www.flickr.com/photos/221matty/12951548053/) by Matty! (http://www.flickr.com/people/221matty/), on Flickr

(http://farm4.staticflickr.com/3676/12951411075_79b889e5fe_z.jpg) (http://www.flickr.com/photos/221matty/12951411075/)
Polo G40 KW (http://www.flickr.com/photos/221matty/12951411075/) by Matty! (http://www.flickr.com/people/221matty/), on Flickr

(http://farm3.staticflickr.com/2854/12951818224_e51ba53770_z.jpg) (http://www.flickr.com/photos/221matty/12951818224/)
Polo G40 KW (http://www.flickr.com/photos/221matty/12951818224/) by Matty! (http://www.flickr.com/people/221matty/), on Flickr

(http://farm8.staticflickr.com/7419/12951399625_88be3fe7a2_z.jpg) (http://www.flickr.com/photos/221matty/12951399625/)
Polo G40 KW (http://www.flickr.com/photos/221matty/12951399625/) by Matty! (http://www.flickr.com/people/221matty/), on Flickr

(http://farm8.staticflickr.com/7295/12951530303_dd01de43a7_z.jpg) (http://www.flickr.com/photos/221matty/12951530303/)
Polo G40 KW (http://www.flickr.com/photos/221matty/12951530303/) by Matty! (http://www.flickr.com/people/221matty/), on Flickr



These arrived from KW this week... After the palava of loosing one strut 'during transit' and having to buy a second set...

(http://farm4.staticflickr.com/3799/12951380505_729a49be8a_z.jpg) (http://www.flickr.com/photos/221matty/12951380505/)
Polo G40 KW (http://www.flickr.com/photos/221matty/12951380505/) by Matty! (http://www.flickr.com/people/221matty/), on Flickr

(http://farm4.staticflickr.com/3766/12951798494_97f6c4c80e_z.jpg) (http://www.flickr.com/photos/221matty/12951798494/)
Polo G40 KW (http://www.flickr.com/photos/221matty/12951798494/) by Matty! (http://www.flickr.com/people/221matty/), on Flickr

Together will all the chassis components - Adjustable top mounts, Strut braces and V1's

I had the strut braces re powdercoated at RS-Alloys as the finish from wiechers was so weak it was chipping just looking at it.

(http://farm8.staticflickr.com/7340/12951794334_d1f6786e92_z.jpg) (http://www.flickr.com/photos/221matty/12951794334/)
Polo G40 KW (http://www.flickr.com/photos/221matty/12951794334/) by Matty! (http://www.flickr.com/people/221matty/), on Flickr

Should be a beauty with all these chassis mods on!

Also got a Ferrari wheel 502bb wheel!

(http://farm8.staticflickr.com/7371/12951415415_65ab902686_z.jpg) (http://www.flickr.com/photos/221matty/12951415415/)
Polo G40 KW (http://www.flickr.com/photos/221matty/12951415415/) by Matty! (http://www.flickr.com/people/221matty/), on Flickr

In which I have leather restored to freshen the 30 years worth of grubby mits to bring the old girl back up.


Got it all back together, the car had been stood for 6 months, and boom first flick of the key and it started! to a horrific noise... took me and my dad about 6 hours to work out what the hell was knocking we knew it was around the alternator but not sure what was after driving it it turned out to be the alternator pulley clipping the chassis due to the chassis being so stiff when the engine moved the toothed belt pulley was clipping it!

anywho modified the pulley and got the alternator refurbished whilst it was off and were all good! handles epically now!

Heres some pictorsss

Ferrari wheel on
(https://farm8.staticflickr.com/7261/13604305365_dd80755a9e.jpg) (https://flic.kr/p/mJaC24)

Carpetted the rear turrets
(https://farm4.staticflickr.com/3795/13604318575_589dce057d.jpg) (https://flic.kr/p/mJaFWP)

(https://farm8.staticflickr.com/7381/13604327163_008ced6782.jpg) (https://flic.kr/p/mJaJuT)

Rear KW's on
(https://farm4.staticflickr.com/3745/13604343323_0d788f1a63.jpg) (https://flic.kr/p/mJaPiv)

Fronts
(https://farm8.staticflickr.com/7233/13604252885_a8d07488ff.jpg) (https://flic.kr/p/mJamqe)

(https://farm3.staticflickr.com/2838/13604260113_f7fef2f113.jpg) (https://flic.kr/p/mJaoyR)

D-day
(https://farm8.staticflickr.com/7226/13604230235_1181752271.jpg) (https://flic.kr/p/mJaeFH)

Its probably slightly lower now but heres what it looked like straight off the jacks
(https://farm8.staticflickr.com/7134/13604307393_50d36f36c4.jpg) (https://flic.kr/p/mJaCC2)

(https://farm3.staticflickr.com/2845/13604061633_649724ffb3.jpg) (https://flic.kr/p/mJ9nyM)


(https://farm4.staticflickr.com/3694/13604259535_2ef52d3c33.jpg) (https://flic.kr/p/mJaooT)

(https://farm8.staticflickr.com/7085/13604708443_c2a6f28ce0.jpg) (https://flic.kr/p/mJcFQF)

(https://farm8.staticflickr.com/7028/13604694673_e88328c12d.jpg) (https://flic.kr/p/mJcBKg)

After a nice hoon over the moors:
(https://farm4.staticflickr.com/3766/13647674705_21fecd0212_c.jpg) (https://flic.kr/p/mMZUdi)

(https://farm3.staticflickr.com/2861/13647676723_2a4e1fd9ec_c.jpg) (https://flic.kr/p/mMZUP6)

(https://farm4.staticflickr.com/3804/13666737063_564d5af69f_c.jpg) (https://flic.kr/p/mPFAMD)





Verdict:

The car drives completely differently now, before I had to really manipulate the steering to get it to hold a corner at pace, since all the chassis mods I've found I am still learning the car especially with the limit becoming several levels beyond what it was before, I find I hardly have to move the steering now its so direct and flicky, looking forward to a few more sunny mornings/evenings!



This week the car is booked at AAS for a fully custom race exhaust, I consider these one of the best exhaust builders in the country so it should be interesting and definitely sound epic!

Heres what my lupo sounded like after there work...

https://www.youtube.com/watch?v=y-eiW5rxjjs
Title: Re: Matty's Polo G40
Post by: dan182 on April 08, 2014, 09:01:00 pm
Nice car was it a6n2 splitter
Title: Re: Matty's Polo G40
Post by: Matty! on April 11, 2014, 12:25:00 pm
Yes a 6n one off say a 1996 polo, pretty direct fit just cut a few nicks to help it bend round the shape of the MK3 bumper.
Title: Re: Matty's Polo G40
Post by: Matty! on June 04, 2014, 12:29:41 pm
UPDATE:

Ill start from the beginning, I took the car to AAS in Newcastle and dropped it off to get a 4-2-1 race system for the car, happy days, until they call me in the morning saying the jobs going to take too long so they have back healed the job... Awesome, especially after the 6 month waiting list. They said no one will take this on.

So I went around 10 minutes round the corner to a bloke who did do it! Took longer than expected but I wasn't in no rush but here we have it, a fully custom 4-2-1 Manifold - Decat with an outward rolled tip which is exactly what I wanted.



Ill let the pictures do the talking...


(https://farm3.staticflickr.com/2923/14127130307_409015a6f7_c.jpg) (https://flic.kr/p/nwneEc)Untitled (https://flic.kr/p/nwneEc) by Matty! (https://www.flickr.com/people/61752190@N03/), on Flickr

(https://farm4.staticflickr.com/3757/14313089144_b87cdcc49f_c.jpg) (https://flic.kr/p/nNNjK3)Untitled (https://flic.kr/p/nNNjK3) by Matty! (https://www.flickr.com/people/61752190@N03/), on Flickr

(https://farm6.staticflickr.com/5482/14313086364_bca7d8584d_c.jpg) (https://flic.kr/p/nNNiV7)Untitled (https://flic.kr/p/nNNiV7) by Matty! (https://www.flickr.com/people/61752190@N03/), on Flickr


Manifold
(https://farm4.staticflickr.com/3732/14127025318_ba6bdddaf1_c.jpg) (https://flic.kr/p/nwmGs3)Untitled (https://flic.kr/p/nwmGs3) by Matty! (https://www.flickr.com/people/61752190@N03/), on Flickr

(https://farm4.staticflickr.com/3786/14313081544_e02fb91872_c.jpg) (https://flic.kr/p/nNNhu1)Untitled (https://flic.kr/p/nNNhu1) by Matty! (https://www.flickr.com/people/61752190@N03/), on Flickr

(https://farm6.staticflickr.com/5314/14127144177_cfbb64e15c_c.jpg) (https://flic.kr/p/nwniMk)Untitled (https://flic.kr/p/nwniMk) by Matty! (https://www.flickr.com/people/61752190@N03/), on Flickr

(https://farm4.staticflickr.com/3705/14333858093_abdb2c08f8_c.jpg) (https://flic.kr/p/nQCLCn)Untitled (https://flic.kr/p/nQCLCn) by Matty! (https://www.flickr.com/people/61752190@N03/), on Flickr



So I'm really happy with it, Ill get a vid up soon.



Had the geometry setup for the Vagcars trackday @ Teesside Autodrome


(https://farm3.staticflickr.com/2921/14153839627_70b1f3b7aa_c.jpg) (https://flic.kr/p/nyJ8pH)VW Polo G40 (https://flic.kr/p/nyJ8pH) by Kurt Blythman (https://www.flickr.com/people//), on Flickr

Playing with the lift off oversteer :laugh:
(https://farm6.staticflickr.com/5074/14153671399_fee8093d2f_c.jpg) (https://flic.kr/p/nyHgpe)VW Polo G40 (https://flic.kr/p/nyHgpe) by Kurt Blythman (https://www.flickr.com/people//), on Flickr

(https://farm4.staticflickr.com/3835/14338696262_6a8102f616_c.jpg) (https://flic.kr/p/nR4yR5)VW Polo G40 (https://flic.kr/p/nR4yR5) by Kurt Blythman (https://www.flickr.com/people//), on Flickr

Was really good fun on track, comparing it to the Audi it was so much more 'flicky' could do what you want it in and you could do it fairly predictable.

On one session I was literally loving the lift off oversteer it could achieve so was having a right good laugh!

Thats what this car is all about, having a laugh and a play! So chuffed with the KW's/Subframe/Exhaust mods!


Currently saving and amounting parts for a handful of reliability mods such as Oil Cooler and Alloy Radiator, Silicone Hoses ect, so thats next.
Title: Re: Matty's Polo G40
Post by: Tav on June 04, 2014, 02:26:46 pm
Love how people are using these on track  ;D
Title: Re: Matty's Polo G40
Post by: JoeH on June 05, 2014, 01:10:07 pm
Do you know what the spec of this beast is now? reading the start of the thread you were unsure.

Looks really cool, like how clean it looks, think the black body and wheels works well.
Title: Re: Matty's Polo G40
Post by: Jester on June 05, 2014, 06:48:10 pm
Looking good man, sorry I didn't attend that track day monies tight at the moment sadly. Looks like I missed out.

When you getting them RS's sorted? :D
Title: Re: Matty's Polo G40
Post by: Snave on June 16, 2014, 11:56:15 am
Really nice ride and set up man ! ::)
Title: Re: Matty's Polo G40
Post by: Ben.lopo on June 16, 2014, 01:33:57 pm
Looking sweet man where's the vid of the track day ;-)
Title: Re: Matty's Polo G40
Post by: Matty! on June 23, 2014, 10:13:29 am
Got a video! Just my pap laptop keeps crashing when I upload... Ill get my mate to do it at some point :)

Also, not too sure on the spec TBH, once winter comes I am going to see if its ported which I am assuming so...


Ported the charger outlet myself too, and also cleaned out that strainer at the bottom which looked to have not been cleaned out for a very long while, raised the boost by .15 bar too so shows how much it can hold the car back.

(http://i5.photobucket.com/albums/y154/mattys_trains/Mobile%20Uploads/20140613_114429_zps7kssojoa.jpg) (http://s5.photobucket.com/user/mattys_trains/media/Mobile%20Uploads/20140613_114429_zps7kssojoa.jpg.html)

(http://i5.photobucket.com/albums/y154/mattys_trains/Mobile%20Uploads/20140613_114445_zpsckzib7dr.jpg) (http://s5.photobucket.com/user/mattys_trains/media/Mobile%20Uploads/20140613_114445_zpsckzib7dr.jpg.html)


Anywho got the show wheels on for a few up and coming shows then Ill revert back to the RA's as im off to the ring early October!

14" BBS RS's :D

(https://farm4.staticflickr.com/3893/14473808255_4d8a6d3f70_c.jpg) (https://flic.kr/p/o413Wc)Polo G40 (https://flic.kr/p/o413Wc) by Matty! (https://www.flickr.com/people//), on Flickr
Title: Re: Matty's Polo G40
Post by: Matty! on October 14, 2014, 06:07:35 pm
Bit of progress has happened on this...

I originally bought an Oil Cooler to start with, but after booking a Nurburgring trip it was time for the snowball effect to occur, so I set about focusing on reliability mods for the car.

Its temperature has always fluctuated in traffic from 90*- a nail biting 110* so I set about finiding solutions... 

I first started with an APS Oil Cooler, Mocal Thermostatic Sandwhich Plate and braided lines, but then I couldnt resist a set of SFS Coolant hoses to neaten up the bay, then I found it really hard to resist an aluminium race rad.


During this time the clutch decided to start slipping like a b*stard so that was abit of unplanned splashing out but whilst it was in the pipeline its worth doing right I suppose.

Ill start with the radiator:
Here is the sexy rad...
(https://farm4.staticflickr.com/3925/15400738141_96281c1698_c.jpg) (https://flic.kr/p/psUNTX)Untitled (https://flic.kr/p/psUNTX) by Matty! (https://www.flickr.com/people/61752190@N03/), on Flickr

Made some braces for the slimline cooling fan:
(https://farm3.staticflickr.com/2941/15205835780_7c4e6effd4_c.jpg) (https://flic.kr/p/paFTdq)Untitled (https://flic.kr/p/paFTdq) by Matty! (https://www.flickr.com/people/61752190@N03/), on Flickr

Then I went to the easy task of fitting this brass fan switch...
(https://farm6.staticflickr.com/5577/15109862559_41405ac6f1_c.jpg) (https://flic.kr/p/p2cZHH)Untitled (https://flic.kr/p/p2cZHH) by Matty! (https://www.flickr.com/people/61752190@N03/), on Flickr

Turns out the Einstein who made the Radiator put a M20 X1.5 thread in, when the polo's is M22X1.5. As this radiator is used in the kit car world I thought I would nip to the motorfactors and se what they had, turns out no manufacturer makes an M20 X1.5 switch... so why the hell they did that I dont know. Anywho I called in a favour at Billingham Machines company which machined my fan switch to fit perfectly.

This was also wired up onto a manual override switch.



all fitted :)
(https://farm3.staticflickr.com/2947/15392507155_bca70fbb8f_c.jpg) (https://flic.kr/p/psbC7p)Untitled (https://flic.kr/p/psbC7p) by Matty! (https://www.flickr.com/people/61752190@N03/), on Flickr

Next up is the oil cooler, mounted in the passenge side of the bumper it fits so neatly and compact, plus the ducting that I fitted to the bumper months ago now aims straight at it and with a purpose!

(https://farm4.staticflickr.com/3879/15392185862_a22421fe88_c.jpg) (https://flic.kr/p/ps9YAS)Untitled (https://flic.kr/p/ps9YAS) by Matty! (https://www.flickr.com/people/61752190@N03/), on Flickr

Next was I may aswell get the flywheel lightened! so I searched all over the internet with no luck, I ended up asking Carl (S1MK179) if he had any bits... in which he totally had one!

(https://farm3.staticflickr.com/2950/15217425227_592ccb62ca_c.jpg) (https://flic.kr/p/pbHhmt)Untitled (https://flic.kr/p/pbHhmt) by Matty! (https://www.flickr.com/people/61752190@N03/), on Flickr

And after a week at AMAC engineering...
(https://farm3.staticflickr.com/2945/15369466396_14d84b8cd8_c.jpg) (https://flic.kr/p/pq9wTW)Untitled (https://flic.kr/p/pq9wTW) by Matty! (https://www.flickr.com/people/61752190@N03/), on Flickr

Its now 4.1kg's! he managed to skim 1kg off the fly.

The standard clutch isn't much kop for the power the polo is running so a helix was the only option, I opted for the fast road as paddles are that hard to press they actually break the pedal box! plus it can handle about the same power anyways so win.

(https://farm3.staticflickr.com/2941/15205750799_873b6d0bbd_c.jpg) (https://flic.kr/p/paFrXe)Untitled (https://flic.kr/p/paFrXe) by Matty! (https://www.flickr.com/people/61752190@N03/), on Flickr

(https://farm3.staticflickr.com/2943/15205746409_808d4b7b59_c.jpg) (https://flic.kr/p/paFqDx)Untitled (https://flic.kr/p/paFqDx) by Matty! (https://www.flickr.com/people/61752190@N03/), on Flickr

Andy at Northeast Auto Tech fitted this for one hell of an epic price!!


So the list of things done are:
Aluminium Rad
Slimline fan with manual overide
SFS Coolant hoses
Brand new Coolant Bottle
Thermostat
Blue Temp Sender
APS Oil Cooler
Mocal Thermostatic Sandwhich plate
Braided Lines
1/2" BSP Fittings
Lightened Flywheel
Helix Fast road clutch
Pressure Plate
Release bearing
Oil Change
Spark Plug change
Coolant Change
Filter clean
Back on the BBS RA's


Had a few teething problems too like a disturbed Oring caused th heater matrix to leak, and the fact I forgot to put the CO Pot in properly which resulted in it firing it out under boost along with its orings and clips!

But apart from that, I have spent a **** load of money and effort of me, craig, Josh Chris and Higgins for something no one will see in essence.

However it does run 7 degrees less on a run and doesn't over heat either! wooooo so looking forward to the Nurburgring on Thursday!

(https://farm4.staticflickr.com/3838/15392485115_10de407563_c.jpg) (https://flic.kr/p/psbvyp)Untitled (https://flic.kr/p/psbvyp) by Matty! (https://www.flickr.com/people/61752190@N03/), on Flickr

(https://farm4.staticflickr.com/3872/15392160032_a78bc6d6d5_c.jpg) (https://flic.kr/p/ps9QVw)Untitled (https://flic.kr/p/ps9QVw) by Matty! (https://www.flickr.com/people/61752190@N03/), on Flickr

(https://farm3.staticflickr.com/2943/15403527242_031447724a_c.jpg) (https://flic.kr/p/pta6ZU)Polo G40 14" BBS RS (https://flic.kr/p/pta6ZU) by Matty! (https://www.flickr.com/people/61752190@N03/), on Flickr

Lets hope the 'ring is successful, if so, alot of mod's are coming this cars way!



.
.
.
.
Well the Nurburgring was a success for all of us! Apart from Bens V12 BMW coming back a straight 6 but we will brush over that...


Car was flawless through its 1070mile eurotrip including several tunnel runs, some epic mountain road bashing, 4 laps of the Nurburgring and a 20 minute soaking wet session on the GP Circuit.

So pleased with how the car performed, and in the end with some instructing from Craig the little polo was setting some good strong pace round the Green hell, even surprising a few people

Heres some pictures anywho:

(https://farm4.staticflickr.com/3928/15532816731_b38683fd06_c.jpg) (https://flic.kr/p/pEzKg2)G40 Nurburgring (https://flic.kr/p/pEzKg2) by Matty! (https://www.flickr.com/people/61752190@N03/), on Flickr

(https://farm4.staticflickr.com/3954/15349496197_7869f8feef_c.jpg) (https://flic.kr/p/poobsa)G40 Nurburgring (https://flic.kr/p/poobsa) by Matty! (https://www.flickr.com/people/61752190@N03/), on Flickr

(https://farm4.staticflickr.com/3949/15511806606_a20137a700_c.jpg) (https://flic.kr/p/pCJ4Fu)G40 Nurburgring (https://flic.kr/p/pCJ4Fu) by Matty! (https://www.flickr.com/people/61752190@N03/), on Flickr

(https://farm4.staticflickr.com/3934/15511802846_2eac13c36b_c.jpg) (https://flic.kr/p/pCJ3yE)G40 Nurburgring (https://flic.kr/p/pCJ3yE) by Matty! (https://www.flickr.com/people/61752190@N03/), on Flickr

(https://farm4.staticflickr.com/3939/15349334638_3df651c180_c.jpg) (https://flic.kr/p/ponmqE)G40 Nurburgring (https://flic.kr/p/ponmqE) by Matty! (https://www.flickr.com/people/61752190@N03/), on Flickr

(https://farm4.staticflickr.com/3944/14915070084_1ae71f193d_c.jpg) (https://flic.kr/p/oHZCGL)Generic Ring Photo (https://flic.kr/p/oHZCGL) by Matty! (https://www.flickr.com/people/61752190@N03/), on Flickr

(https://farm4.staticflickr.com/3946/15536653212_4c17112c47_c.jpg) (https://flic.kr/p/pEVpHf)Cocem (https://flic.kr/p/pEVpHf) by Matty! (https://www.flickr.com/people/61752190@N03/), on Flickr

(https://farm4.staticflickr.com/3954/15350185500_25ab1da833_c.jpg) (https://flic.kr/p/porHmG)Nurburgring 2014 (https://flic.kr/p/porHmG) by Matty! (https://www.flickr.com/people/61752190@N03/), on Flickr

Now I am in debate whether to Bucket and Cage it or let it sit pretty as is and work towards getting a devoted track car of the BMW variety.
Title: Re: Matty's Polo G40
Post by: Yoof on October 15, 2014, 11:41:49 am
Bucket & Cage... obviously! Get something lardy and comfortable to tow it around with  ;D
Title: Re: Matty's Polo G40
Post by: JoeH on October 16, 2014, 01:22:04 pm
Would a quaife or LSD bring better gains compared to cage, bucket seats, with your sort of power?
Title: Re: Matty's Polo G40
Post by: Matty! on October 19, 2014, 07:39:49 am
Im looking at more of a safety point of view mainly, have you seen the crash test of one of these at like 30mph?  Its rather eye opening!

Haven't felt I've needed a diff really, I would like one eventually to see what its like but not yet.
Title: Re: Matty's Polo G40
Post by: Matty! on April 19, 2015, 09:22:22 pm
So as some of you may or may not know I've been busy on this car this winter (not all of it me)

Fitted a 51mm Ported Throttle Body and GT inlet manifold...
(https://farm8.staticflickr.com/7586/16580859914_61019d13dc_z.jpg) (https://flic.kr/p/rgceZ5)20141229_170640 (https://flic.kr/p/rgceZ5) by Matty! (https://www.flickr.com/people/61752190@N03/), on Flickr

Left - GT Manifold Right - G40 you can see the GT is larger. this was powder coated silver by mr Grover at RS Alloys
(https://farm9.staticflickr.com/8647/15914990735_56da9b0dfe_z.jpg) (https://flic.kr/p/qfmugZ)20141130_164941 (https://flic.kr/p/qfmugZ) by Matty! (https://www.flickr.com/people/61752190@N03/), on Flickr

I also fitted Corbeau sprint bucket seats...
(https://farm9.staticflickr.com/8620/16198545376_f7967db82f_z.jpg) (https://flic.kr/p/qFpMc7)20150106_181209 (https://flic.kr/p/qFpMc7) by Matty! (https://www.flickr.com/people/61752190@N03/), on Flickr

The we get to the really juicy bit.

I had the car booked in at Performance & Proctection in Skipton for a full 6 point roll cage, through dash jobby.
So the car was there a while as I said I wasnt in a rush...

And here are the results:
(https://farm9.staticflickr.com/8796/16572333313_a767dd8819_z.jpg) (https://flic.kr/p/rfrxjH)20150417_200023 (https://flic.kr/p/rfrxjH) by Matty! (https://www.flickr.com/people/61752190@N03/), on Flickr

(https://farm6.staticflickr.com/5465/16985098587_dcfa446410_z.jpg) (https://flic.kr/p/rSV54n)20150417_195956 (https://flic.kr/p/rSV54n) by Matty! (https://www.flickr.com/people/61752190@N03/), on Flickr

(https://farm8.staticflickr.com/7640/16572333193_bbe03011f5_z.jpg) (https://flic.kr/p/rfrxhD)20150417_200013 (https://flic.kr/p/rfrxhD) by Matty! (https://www.flickr.com/people/61752190@N03/), on Flickr

(https://farm8.staticflickr.com/7604/17191944181_b7b6fd8e0f_z.jpg) (https://flic.kr/p/sccd3H)20150417_195748 (https://flic.kr/p/sccd3H) by Matty! (https://www.flickr.com/people/61752190@N03/), on Flickr

They have done a fantastic job, they make rollcages for all the big rally teams and manufacturers project cars so I knew I was in safe hands, the cage is not intrusive on getting in and out either, still allowing the sunroof to operate also.

It has really stiffened the car up also, feels fantastic to drive.

Still left to do:
Carpet it out with acoustic carpet to neaten it up.
Relocate the battery and use a Mitsubishi Evo 6 Battery behind passenger seat.
Relocate washer bottle with a washer bag somewhere.
Sun strip as the buckets are lower that standard seats.
get seatframes powder coated
Neaten everything up


More juicy bits:
I managed to get my hands on a Gripper LSD and ATV G40 gearbox
Wideband Guage
Oil Pressure Gauge
and polycarb windows which I am umming and arring about fitting at the moment.
VW Motorsport G40 bottoms arms with VWM Bushes
VW Motorsport Rear beam bushes

Got alot more still to go on the car, but I am glad to have it back so I can tinker!
Title: Re: Matty's Polo G40
Post by: Matty! on May 24, 2015, 06:59:58 pm
*Update*

So, been busy on this never ending project...

So far managed to pick up:
Gripper Diff LSD'd ATV Gearbox
Poly Carb windows
Oil Pressure Guage
Wideband
Oil Temp Guage
VW Motorsport Bottom Arms
FMIC - With Thermocouples
and a shed load of spares.

Anywho, been cracking on:

Fitted a FMIC which has thermocouples installed at either end of the intercooler to give a live readout of the inlet and outlet temperatures of the intercooler.

(https://c2.staticflickr.com/6/5342/17398716423_b9feea06b1_z.jpg) (https://flic.kr/p/svsYen)IMG_20150508_230344 (https://flic.kr/p/svsYen) by Matty Pollock (https://www.flickr.com/photos/221matty/), on Flickr

(https://c1.staticflickr.com/9/8814/17396655934_ca12f0c2be_z.jpg) (https://flic.kr/p/svhpHG)IMG_20150508_230422 (https://flic.kr/p/svhpHG) by Matty Pollock (https://www.flickr.com/photos/221matty/), on Flickr

(https://c4.staticflickr.com/8/7724/17398709183_267b1a8837_z.jpg) (https://flic.kr/p/svsW5x)IMG_20150510_160055 (https://flic.kr/p/svsW5x) by Matty Pollock (https://www.flickr.com/photos/221matty/), on Flickr

Also added a black tint film sunstrip, as once the buckets were in it really made the low sun a nightmare.

Here is the digital readout installed in the car:
(https://c1.staticflickr.com/9/8800/18020039411_e250d94112_z.jpg) (https://flic.kr/p/tsnpUF)IMG_20150523_185618 (https://flic.kr/p/tsnpUF) by Matty Pollock (https://www.flickr.com/photos/221matty/), on Flickr

Took it out for a good run yesterday with ChrisP to see what was what.

the ambient temperature was 20degrees, on average when driving normally around town ect at around 1700-2800 revs the inlet (Charger side) was around 31-33 degrees whilst the intercooler would keep a steady 21degrees.

Fast twisty road driving would raise the Inlet side to around 40-50 and the outlet holding around 25degrees.

On a really long mile straight stretch the max chager outlet temp I saw was 83degrees!! its amazing how fast it rockets up the temperatures whilst the outlet side was holding around 35 degrees! so as a whole it would cut the temperatures by half. Its a cool mod which proves that a front mount intercooler really does work, at some point I will experiment with water mist onto the cooler and see if that drops temps much more.

(https://c1.staticflickr.com/9/8818/18022501476_5eaee8ba0e_z.jpg) (https://flic.kr/p/tsA2N5)FB_IMG_1431429721115 (https://flic.kr/p/tsA2N5) by Matty Pollock (https://www.flickr.com/photos/221matty/), on Flickr
Pic of her at Teesside Autodrome
However upon inspection it looks like I have the dreaded pedal box crack :( so will have to get that sorted asap!
Title: Re: Matty's Polo G40
Post by: JoeH on May 24, 2015, 09:35:49 pm
Sweet mods, how do you know the pedal box is cracked?
What symptoms does it give?
Title: Re: Matty's Polo G40
Post by: Matty! on June 22, 2015, 04:47:01 pm
How do

When you put clutch down the brake pedal will move to the right. There's always a tiny bit of flex you you really can see it move.

Also a good visual inspection can tell also.
Title: Re: Matty's Polo G40
Post by: Matty! on November 09, 2015, 06:59:11 pm
Well this could do with an update:

I went to a wet croft on October 30th:

(https://farm1.staticflickr.com/742/22598243072_9776eb3891_c.jpg) (https://flic.kr/p/AqVUmy)Polo G40 Track Car Croft 4 (https://flic.kr/p/AqVUmy) by Matty Pollock (https://www.flickr.com/photos/221matty/), on Flickr

(https://farm6.staticflickr.com/5681/22585760816_e445dffbfc_c.jpg) (https://flic.kr/p/ApPVPf)Polo G40 Track Car Croft 6 (https://flic.kr/p/ApPVPf) by Matty Pollock (https://www.flickr.com/photos/221matty/), on Flickr

(https://farm6.staticflickr.com/5725/22622994901_24d66f5d67_c.jpg) (https://flic.kr/p/At7Lde)Polo G40 Track Car Croft 7 (https://flic.kr/p/At7Lde) by Matty Pollock (https://www.flickr.com/photos/221matty/), on Flickr

The car ran well, until mid morning the gearbox would intermittently select gears after around 20mins of use. I put this down to heat and the Gripper LSD together showing early signs of something.

But once it was home my dreads became a reality, the Diff either needs rebuilding or the gearbox does, as when I took it for another spin the gearbox gremlins reared there ugly head again... so it looks like a gearbox rebuild and diff rebuild is on the cards.

Anywho the more important part was that croft was Oct 30th and Cadwell was booked for November 6th! So Luckily I still had my old standard ATV gearbox, in which we had to fit on a night after work! Stressful times but we managed to get it running Wednesday Night  for the 2.5 Hour trip down to Louth after work Thursday.

Cadwell Park:
(https://farm6.staticflickr.com/5830/22913432691_83c7db0223_c.jpg) (https://flic.kr/p/AUMkfk)DSC_3473 (https://flic.kr/p/AUMkfk) by Matty Pollock (https://www.flickr.com/photos/221matty/), on Flickr

(https://farm1.staticflickr.com/663/22510132649_ca46bc5dfd_c.jpg) (https://flic.kr/p/Ai9jck)DSC_3618 (https://flic.kr/p/Ai9jck) by Matty Pollock (https://www.flickr.com/photos/221matty/), on Flickr

(https://farm6.staticflickr.com/5788/22876304316_57f6b2fc46_c.jpg) (https://flic.kr/p/ARv3gW)DSC_3571 (https://flic.kr/p/ARv3gW) by Matty Pollock (https://www.flickr.com/photos/221matty/), on Flickr

(https://farm1.staticflickr.com/596/22913405221_a9d9dffaf4_c.jpg) (https://flic.kr/p/AUMc5H)DSC_3846 (https://flic.kr/p/AUMc5H) by Matty Pollock (https://www.flickr.com/photos/221matty/), on Flickr

(https://farm1.staticflickr.com/748/22913413561_f38ca53948_c.jpg) (https://flic.kr/p/AUMeyv)DSC_3607 (https://flic.kr/p/AUMeyv) by Matty Pollock (https://www.flickr.com/photos/221matty/), on Flickr

The car held up perfectly all day! I will upload a video later however they don't look spectacular due to the fact it rained pretty much all day at Cadwell also!


So

Plans this winter are:
Fix a broken Box
Put my TH Mono's on
Neaten up the boost pipes to the intercooler

So not a lot but the Gearbox Rebuild isn't exactly cheap!
Title: Re: Matty's Polo G40
Post by: Matty! on November 10, 2015, 07:13:19 am
Heres a video from Cadwell
https://www.youtube.com/watch?v=v6fcssjHoIM
Title: Re: Matty's Polo G40
Post by: SamG40 on November 10, 2015, 12:25:52 pm
I love Cadwell. I did it a few times in my old car. Brilliant circuit, I broke a gearbox there once.

Pictures look good.
Title: Re: Matty's Polo G40
Post by: Matty! on November 10, 2015, 05:21:57 pm
Its my favourite circuit, its like the nurburgring without the possibility if financially ruining yourself lol!