Club G40 Forum

Club G40 => Photos and videos => Ongoing Projects => Topic started by: Jezza-7 on January 27, 2010, 10:36:53 am

Title: My G40...... finally
Post by: Jezza-7 on January 27, 2010, 10:36:53 am
Now i have got a little money together i have started buying parts and bits.

So im gonna start putting pics up of what i am doing and what has been done. Hopefully this will be finished by the summer, fingers crossed.

So here we are from the start of when i bought her as some of you will remember the car ( with fantastic headlights  :-[)

(http://i443.photobucket.com/albums/qq157/jezza-3/DSC00871-1.jpg)

(http://i443.photobucket.com/albums/qq157/jezza-3/DSC00873-1.jpg)

After a good clean

(http://i443.photobucket.com/albums/qq157/jezza-3/DSC00876.jpg)

Then i got the original hella headlights and got some 14" bbs RA's

(http://i443.photobucket.com/albums/qq157/jezza-3/DSC01032.jpg)

Fitted a standard grille as i was having trouble getting hole of the original black badge one

(http://i443.photobucket.com/albums/qq157/jezza-3/DSC01034.jpg)

This is the latest pic with clear indicators and a G40 front grille badge

(http://i443.photobucket.com/albums/qq157/jezza-3/DSC01091-1.jpg)

Will get more pics up soon but my car is away having some work done to it and will be back friday.

Will keep this updated.



Title: Re: My G40 is beggining progress
Post by: Jezza-7 on February 02, 2010, 07:22:17 pm
Right after getting it back from garage i did a little work on it, put the original interior back in and put an induction kit on.

I have just got new rear wheel bearings replaced, rear wheel cyclinders, brake shoes and hubs, new fuel tank, stainless steel brake hoses, standard brembo disc's, red stuff pads, AP dot 5 brake fluid and im also doing my front wheel bearings this week.

Also put on the grille with black VW badge.

Here is the engine in standard conditon, with exception on GT inlet and de-wedge TB

(http://i443.photobucket.com/albums/qq157/jezza-3/DSC01142.jpg)

(http://i443.photobucket.com/albums/qq157/jezza-3/DSC01143.jpg)

Here is the interior

(http://i443.photobucket.com/albums/qq157/jezza-3/DSC01144.jpg)

(http://i443.photobucket.com/albums/qq157/jezza-3/DSC01145.jpg)

Steering wheel that came with the car

(http://i443.photobucket.com/albums/qq157/jezza-3/DSC01146.jpg)

Put an audi grille on but not sure

(http://i443.photobucket.com/albums/qq157/jezza-3/DSC01152.jpg)

induction kit

(http://i443.photobucket.com/albums/qq157/jezza-3/DSC01148.jpg)

New grille

(http://i443.photobucket.com/albums/qq157/jezza-3/DSC01153.jpg)

Engine bay currently (heat shield was put on after (pic above))

(http://i443.photobucket.com/albums/qq157/jezza-3/DSC01150.jpg)

After cleaning it and using mer polish and mer bumper & external vinyl cleaning gel it come up well and looked nice

(http://i443.photobucket.com/albums/qq157/jezza-3/DSC01154.jpg)


More to follow soon

 
Title: Re: My G40 is beggining progress
Post by: jez1272gt on February 03, 2010, 10:11:03 pm
Looking much better than the first pics .......... keep up the good work!
Title: Re: My G40 is beggining progress
Post by: Jezza-7 on February 06, 2010, 09:47:21 am
Cheers!
Title: Re: My G40 is beggining progress
Post by: Yoof on February 06, 2010, 10:47:35 am
Looks alot better now! I've PM'd you re: injectors.

I've got some toothies if you want a little extra charger whine and a few bhp?
Title: Re: My G40 is beggining progress
Post by: Jezza-7 on March 01, 2010, 08:06:20 pm
Standalone tank and custom made catch tank are now on. Just awaiting hosing for catch tank and breather filter.

(http://i443.photobucket.com/albums/qq157/jezza-3/DSC01167.jpg)

(http://i443.photobucket.com/albums/qq157/jezza-3/DSC01166.jpg)

(http://i443.photobucket.com/albums/qq157/jezza-3/DSC01165.jpg)
Title: Re: My G40 is beggining progress
Post by: Jezza-7 on March 13, 2010, 07:01:18 pm
Another update:

Here is my new custom made intercooler

(http://i443.photobucket.com/albums/qq157/jezza-3/DSC01209.jpg)

(http://i443.photobucket.com/albums/qq157/jezza-3/DSC01208.jpg)

Inside

(http://i443.photobucket.com/albums/qq157/jezza-3/DSC01210.jpg)

(http://i443.photobucket.com/albums/qq157/jezza-3/DSC01211.jpg)

Nice fit when it was installed today

(http://i443.photobucket.com/albums/qq157/jezza-3/DSC01217.jpg)

Oil cooler sandwich plate with thermostat built in

(http://i443.photobucket.com/albums/qq157/jezza-3/DSC01219.jpg)

Cooler itself behind grille ( mocal 13 row)

(http://i443.photobucket.com/albums/qq157/jezza-3/DSC01221.jpg)

Little problem with boost pipe

(http://i443.photobucket.com/albums/qq157/jezza-3/DSC01212.jpg)

Inside of dome on outlet for g-lader looking ok and not too dirty

(http://i443.photobucket.com/albums/qq157/jezza-3/DSC01214.jpg)

Had very little oil insdie the intercooler that came off and i was told there would be alot. Good im guessing.

More to follow.....

Title: Re: My G40 is beggining progress
Post by: Jezza-7 on March 27, 2010, 08:07:29 pm
Well after fitting new intercooler my boost pressure has increased and is now running 9/10 psi.

Little video here taken on my iphone.

(http://i443.photobucket.com/albums/qq157/jezza-3/th_011.jpg) (http://s443.photobucket.com/albums/qq157/jezza-3/?action=view&current=011.flv)
Title: Re: My G40 is beggining progress
Post by: dub-disaster on March 27, 2010, 10:30:21 pm
Nice catch tank mate looks like mine, glad to see those fittings went to a good home :D
Title: Re: My G40 is beggining progress
Post by: Jezza-7 on April 27, 2010, 04:03:17 pm
Another little update.

After spending lots of money a now have got the following and i think im at a stage where it can all go on:

Adjustable vernier pulley
PSD Toothed kit
PSD Full blend charger
SNS chip stage 5
G60 green injectors
Custom made manifold
Custom made 2.25 system

Not long till i will have it all on hopefully.

Looking to get it rolling roaded to see power now then do one after to see power increase, plus getting the car looked at for timing and a/r mix.

Think i will put standard air box back on as well for the 1st rr. Manifold made a 23bhp increase on last rr on a friends car.

Thinking about a cam to get next but not 100% sure.
Also on the list for the engine is forged pistons and aquamist.

Will get pics of stuff brought and as it goes on the car.
Title: Re: My G40 is beggining progress
Post by: Alex on April 27, 2010, 04:29:48 pm
Who made your intercooler? :D
Title: Re: My G40 is beggining progress
Post by: AdzCM on April 27, 2010, 05:19:50 pm
never actually seen this thread till there now, ur cars lookin mint lad, unreal.

would an exhaust manifold really make that much a difference?
Title: Re: My G40 is beggining progress
Post by: Jezza-7 on May 06, 2010, 05:29:30 pm
Who made your intercooler? :D

My intercooler, i bought from a good friend of mine who had it made from an excact copy of the standard intercooler. Will find out. Cost around £400 to be custom made though but my psi inccreased 3psi.

Title: Re: My G40 is beggining progress
Post by: Jezza-7 on May 06, 2010, 05:30:51 pm
never actually seen this thread till there now, ur cars lookin mint lad, unreal.

would an exhaust manifold really make that much a difference?

Thankyou very much. The manifold and system that i have now, soon to go on, gave a 23bhp increase.

It was rolling roaded before the manifold then after to see the gain.
Title: Re: My G40 is beggining progress
Post by: Daryl on May 09, 2010, 09:59:58 pm
Intercooler was made by radtec.
Title: Re: My G40 is beggining progress
Post by: Jezza-7 on May 10, 2010, 07:26:12 pm
Cheers daryl!
Title: Re: My G40 is beggining progress
Post by: Jezza-7 on June 02, 2010, 01:09:10 pm
More work has been carried out, and hopefully all will be done before BVF.

Past few weeks just gone had a few bits that were getting old and replaced.

So both fuel pumps were done, new dizzy and hall sender, water pump, alternator and cam belt.

Then some parts for more power, Vernier pulley, PSD pullies, G60 injectors and PSD chip to suit.

Couldnt put the ported charger on as there is a strange noise coming from it when turned so thats getting sent off to jabba this week.

Once thats back that will be going on as well as the manifold and system.

PPS Subframe was fitted and getting uprated driveshafts soon.

Also my ATS cups have been restored and should be back with me next week. Will post up pics of bits n bobs soon.
Title: Re: My G40 is beggining progress
Post by: Jezza-7 on June 02, 2010, 01:15:38 pm
Forgot to mention im running 14/15psi of boost.
Title: Re: My G40 is beggining progress
Post by: Jezza-7 on June 03, 2010, 09:12:34 pm
Gauges in car, up and running.

(http://i443.photobucket.com/albums/qq157/jezza-3/029-1.jpg)
Title: Re: My G40 is beggining progress
Post by: Varley on June 09, 2010, 12:26:43 pm
Gauges look awesome Jezza, where did you get em from and what sort of ££?
Title: Re: My G40 is beggining progress
Post by: Jezza-7 on June 09, 2010, 06:16:40 pm
Cheers. The most expensive one was the Air fuel which was £233

The boost and oil are mechanical and cost £50 and £40.

Awesome gauges.
Title: Re: My G40 is beggining progress
Post by: Jezza-7 on June 09, 2010, 06:26:00 pm
Manifold and Exhaust system is now on.

(http://i443.photobucket.com/albums/qq157/jezza-3/021.jpg)

(http://i443.photobucket.com/albums/qq157/jezza-3/022.jpg)

And im much preferring the exhaust style compared to the Twin tailpipe.

(http://i443.photobucket.com/albums/qq157/jezza-3/024.jpg)
Title: Re: My G40 is beggining progress
Post by: Jezza-7 on July 17, 2010, 10:47:59 am
Had my car rolling roaded today.

It put out 149hp and 134 ft-lb

Running a bit lean and leaned out on the 3rd run. Getting that sorted next week.

Almost finished with engine work now, as this is what i have done to get this power

Induction kit
Full blend charger
65mm psd tooth kit
custom intercooler
de-wedge tb
gt inlet
vernier pulley (5% advanced)
G60 injectors
SNS stage 5 chip
Stainless manifold
2.25 stanless exhaust system with de-cat


Still got boost return mod and cam to do.
possibly aquamist kit.

Then im on to suspesion and bodywork.

Here is most recent pic with cups on

(http://i443.photobucket.com/albums/qq157/jezza-3/058.jpg)

(http://i443.photobucket.com/albums/qq157/jezza-3/059.jpg)

And dyno printout (ignore a/f mix)

(http://i443.photobucket.com/albums/qq157/jezza-3/092.jpg)

(http://i443.photobucket.com/albums/qq157/jezza-3/093.jpg)
Title: Re: My G40 is beggining progress
Post by: MartinB on July 17, 2010, 12:06:27 pm
This cruised past us on the campsite at BVF the other week on the Saturday afternoon. Toothies sounded immense!
Title: Re: My G40 is beggining progress
Post by: Jezza-7 on September 18, 2010, 05:14:54 pm
After a long time i finally got some foggies and now there on.

(http://i443.photobucket.com/albums/qq157/jezza-3/037-3.jpg)

(http://i443.photobucket.com/albums/qq157/jezza-3/036-3.jpg)
Title: Re: My G40 is beggining progress
Post by: Alexiskayak_7 on September 19, 2010, 01:13:57 pm
I love your g, Jezza...
Oh, and lower it asap!!!
Title: Re: My G40 is beggining progress
Post by: Jezza-7 on September 19, 2010, 10:45:28 pm
Thanks mate.

KW suspension kit will be ordered next month and fitted so will put the pics up of doing the job as well as when its finished.

Not much engine work left to do now. Sorted out my ruff idle and got my schrick cam so just waiting to get that fitted and combine a remap with andy hopefully.

Then its on to suspension and mounts as well as engine mounts.
Then fitting new golf gti 22.5mm master cyclinder amd audi brakes with 256mm discs.
Then looking to dry store it over winter.

After winter looking into a full respray.
Title: Re: My G40 is beggining progress
Post by: dub-disaster on September 19, 2010, 11:02:12 pm
Let me know how the kw kit works out for you mate how much is it costing n wear from I'm thinking of going for somthing like this early next year do you know if there gas or oil shocks ?
Title: Re: My G40 is beggining progress
Post by: Jezza-7 on November 06, 2010, 07:49:45 pm
Attended a rolling road meet at TSR today. Got a little video and some intersting results  :o

http://www.youtube.com/watch?v=icorWoi-N5E

Here is the graph and the power figures

(http://i443.photobucket.com/albums/qq157/jezza-3/100.jpg)

(http://i443.photobucket.com/albums/qq157/jezza-3/099.jpg)

After the 1st run Rob said could he red line it, and i said you can hit 7k ok as the chip has a near 9k limit.
After the 2nd run he said that it just wanted to give more power but was loosing power from transmission and the 191 bhp was inaccurate due to clutch. He said something like the clutch was sticking or slipping? Cant remember now. But a new clutch is being looked into now, just need some money.

Title: Re: My G40 is beggining progress
Post by: Daryl on November 06, 2010, 08:09:46 pm
Looking and sounding great james keep up the good work.

Daryl
Title: Re: My G40 is beggining progress
Post by: Jezza-7 on November 07, 2010, 11:13:49 am
Cheers daryl
Title: Re: My G40 is beggining progress
Post by: JregGT on November 07, 2010, 06:04:00 pm
Gorgeous car fella, can't help but think a cheeky red stripe in the bumpers would be perfection!! And that intercooler is awesome, first time i've looked at your thread. Well impressed.

Rich
Title: Re: My G40 is beggining progress
Post by: GR40 on November 08, 2010, 09:07:36 am
I noticed that you have removed the exhaust side mount of the g-lader! Not a good Idea mate, it will put stress on the belt side and you will, overtime, have problems with it!
Title: Re: My G40 is beggining progress
Post by: Jezza-7 on November 08, 2010, 07:25:31 pm
Cheers rich, i like the red stripe in them but not sure if i like it the way mine is at the moment.
Trying to keep the car looking standard so i thought the intercooler was a good idea, maybe a red stripe....
Will ask around how is the best way to get a stripe.

GR40- I have already done one belt but i have seen a few people without it. I think after xmas i might look into a ppp manifold, thanks though  :)

Title: Re: My G40 is beggining progress
Post by: hardchargin40 on November 09, 2010, 11:33:32 am
I noticed that you have removed the exhaust side mount of the g-lader! Not a good Idea mate, it will put stress on the belt side and you will, overtime, have problems with it!

Nah, it'll be fine.
Title: Re: My G40 is beggining progress
Post by: JregGT on November 09, 2010, 05:12:01 pm
I did my bumpers with some (I think) 8mm red strip from halfords, drops in easily, and its easy to whip off if not to your taste. Either way, whole thing is gonna be awesome.
Big thumbs up fella  :)
Title: Re: My G40 is beggining progress
Post by: Justin14100 on November 09, 2010, 07:14:31 pm
I did my bumpers with some (I think) 8mm red strip from halfords, drops in easily, and its easy to whip off if not to your taste. Either way, whole thing is gonna be awesome.
Big thumbs up fella  :)
6mm tape ;)
Title: Re: My G40 is beggining progress
Post by: Jezza-7 on January 17, 2011, 07:02:46 pm
Well since the last rolling road i did, i haven't really done a lot. Bought a BVH that was done by jabba. Porting looks tip top. Also bought a R1 charger, 3k miles from brand new off shelf. Porting looks soo much better than the PSD one thats currently fitted. Will be nice to see if there is any boost pressure differences when thats fitted. So now i have 3 chargers.

Bought a new clutch kit recently, when the box comes off for its rebuild then that will be going on, along with the lightened flywheel. Going to give the quaife diff a miss. Once the box is on it will be getting an MOT. Then its head off, charger off and replace a few parts like a knock sensor as mines seen better days and ISV.

Once thats on then i will be getting the car either driven or trailered to andy for a remap. Should be ready for april/may.

So, what i have done is fitted my newschrick cam and tappets. All lubed up and was a fairly easy task.

Here's new tappets

(http://i443.photobucket.com/albums/qq157/jezza-3/IMG_0058.jpg)

(http://i443.photobucket.com/albums/qq157/jezza-3/IMG_0059.jpg)

Then the 2nd and 4th bearing caps on, stage 1 torque.

(http://i443.photobucket.com/albums/qq157/jezza-3/IMG_0061.jpg)

All caps on, stage 1 plus the 90 degree final torque stage and new rocker gasket. Pic awaiting.

And new oil seal crank pulley end.

(http://i443.photobucket.com/albums/qq157/jezza-3/IMG_0062.jpg)

Once the head goes on then its all seals and gaskets replaced as well as thermostat housing, sensors and senders (oil and water).

Not gonna do waterpump as it was only done 4 months ago. All from vag and cost alot in the end. Oh well, i think in the long run its pays to buy the vag gear.

Except head bolts, £60 is alot when GSF do them for something like £2 a bolt. 2mm shorter but would that make a difference?

When the gearbox is off i will get some pics of it coming off as well as the clutch and flywheel replacement.

Hopefully if there done in time i will get a 51mm tb from justin before the remap.
Title: Re: My G40 is beggining progress
Post by: Alexiskayak_7 on January 18, 2011, 09:32:40 am
Sweet Jezza, i love it!
Is that the G40 specific 252/276 camshaft?
Are you going to use a vernier pulley?
Title: Re: My G40 is beggining progress
Post by: Jezza-7 on January 19, 2011, 08:57:28 pm
Ooo good question, i forgot what cam it is. Will check.

Already running a vernier pulley set to 5 advanced.
Title: Re: My G40 is beggining progress
Post by: Jezza-7 on January 19, 2011, 08:59:08 pm
Yes it is Asym. Camshaft (252° / 276°) for the VW Polo G40.

You got one?
Title: Re: My G40 is beggining progress
Post by: Alexiskayak_7 on January 20, 2011, 09:42:14 pm
Yes, i have a 252/276 cam too,a 51mm throttle body, an extra g lader which is ported with 65mm pulley and chip match all the mods (i have to buy a vernier pulley at one point!), but i unfitted all these from my car, due to economic crisis and high fuel price... Lets wish we'll see better days!
Title: Re: My G40 is beggining progress
Post by: Jezza-7 on January 21, 2011, 12:14:27 pm
What power was you running and how did you find the cam? Im on 150 atm but should see 160-170 with cam and big valve head.


(http://i443.photobucket.com/albums/qq157/jezza-3/IMG_0064.jpg)

Title: Re: My G40 is beggining progress
Post by: Alexiskayak_7 on January 23, 2011, 09:50:45 pm
What power was you running and how did you find the cam? Im on 150 atm but should see 160-170 with cam and big valve head.

Well, i felt that it was a bit laggy after the cam installation to be honest... If i had a vernier pulley a gt inlet and a better mapped chip, propably the responce of the engine should be much better...

If i were you, i would opened my tb to 51mm (i remember that you have only de-wedged your tb). I paid 85euros and i haven't regret it at all...
As for the power figures you are right...

P.S: With the mods you have done can you beat a cammed 106 rallye? ;D
Title: Re: My G40 is beggining progress
Post by: Jezza-7 on January 24, 2011, 11:15:55 pm
Hopefully i will be getting one from justin soon. Where did you get that done?

Mines only de-wedge but i have got gt inlet and vernier. When its on im gonna get andy to remap it.

I could beat one of them by pushing my car lol.
Title: Re: My G40 is beggining progress
Post by: Alexiskayak_7 on January 25, 2011, 01:22:58 pm
Hopefully i will be getting one from justin soon. Where did you get that done?

Mines only de-wedge but i have got gt inlet and vernier. When its on im gonna get andy to remap it.

I could beat one of them by pushing my car lol.


I've done it in a local machine shop, he bored the tb and made a buttefly and i've ported/polished to match the upper part...
Title: Re: My G40 is beggining progress
Post by: Jezza-7 on February 07, 2011, 05:12:19 pm
Well, i forgot to take pictures but this weekend i put a new gearbox on and while it was off i put on a new lightened flywheel and new clutch. Still have a gearbox problem but hopefully that will be sorted out this week.
Title: Re: My G40 is beggining progress
Post by: Jezza-7 on April 01, 2011, 04:01:31 pm
Well gearbox has all been sorted since then and the new clutch has failed already.

So bought a helix clutch kit, cost a bit but its on and feels about 100% better than the other one from cg motorsport. The quality was soo much better and was better made as you would expect!

Now the transmission is all sorted!

So last weekend i replaced the charger with my new 3k (off the shelf) R1 spec charger. Forgot to take pictures of the porting as it was really well done by jabba sport!

Also the standalone oil supply kit i have had since..... last year has finally gone on.

So i have purchased a PPP subframe and will be getting that fitted by yoof soon.

As soon as thats done and the clutch has covered enough miles, i will be putting on the BVH i have. Its all ready to go on so cant wait to see the outcome of that.

Ah and i bought a devils own water injection kit for £100. Need to get the correct nozzle for the engine and im also thinking of getting a dual connection so i can run to nozzles. Was going to put one into the intercooler as its ally and the other either on the throttle body or the boost pipe (either in front or behing the co pot)

Once all is complete then plan is for andy to remap it in may if i have the time to do it all by then, might be off to lybia at the end of the month!

Here is the kit fitted.

(http://i443.photobucket.com/albums/qq157/jezza-3/IMG_0149.jpg)

(http://i443.photobucket.com/albums/qq157/jezza-3/IMG_0147.jpg)

(http://i443.photobucket.com/albums/qq157/jezza-3/IMG_0148.jpg)
Title: Re: My G40 is beggining progress
Post by: Jezza-7 on June 09, 2011, 07:20:44 pm
Right it has been a while since i have updated this.

Well since the last post i have moved house and been busy really and then about 3 weeks ago i got a stage 3 ppp subframe fitted to replace my pps one. So after having that installed i took it for a drive and the handling was improved again. Big smiles for me. So left yoof's unit and then i was about 40 miles from and there was a supra and it had race him all over. So i did and then regret it as i melted a piston.

(http://i443.photobucket.com/albums/qq157/jezza-3/IMG_0267.jpg)

Ooppss!! So as i was searching for one, as i wanted the car running for bvf this year, yoof had one that had been fully rebuilt. So went and picked it up from him a few days later.

During the evenings and weekends i spent most of the time getting it ready to go in. But without an engine crane it was a little harder than usual but i coped.

Gave the block a paint and swapped over everything from my old block to the new block then i put it in with my mate.

(http://i443.photobucket.com/albums/qq157/jezza-3/IMG_0269.jpg)

(http://i443.photobucket.com/albums/qq157/jezza-3/IMG_0270.jpg)

Then we started putting all the ancillaries back on and the really awkward timing cover.

(http://i443.photobucket.com/albums/qq157/jezza-3/IMG_0271.jpg)

Then the head was put on and torqued down,

(http://i443.photobucket.com/albums/qq157/jezza-3/IMG_0272.jpg)

Everything else was reconnected and fitted and was looking really good and clean, except tb as i was waiting for a 51mm.

(http://i443.photobucket.com/albums/qq157/jezza-3/IMG_0275.jpg)

(http://i443.photobucket.com/albums/qq157/jezza-3/IMG_0276.jpg)

(http://i443.photobucket.com/albums/qq157/jezza-3/IMG_0277.jpg)

So me and my mate worked from 11 till 9 on a saturday and it was all done. Forgot to take a final picture though. We also made a modification on the jabba heat shield. We drilled into the filter and used a bolt and two nuts to lock it and secure it in place and then we made a little bracket up to fit the oil catch tank. All worked well and apart from being bright shiny red it looked good.

Unfortunately the next day after towing the g40 up to andy for a remap we struck a problem and took the plugs out to see if there was any oil on them, as we thought it might of been a piston problem. It was very hard to undo and instantly thought this isn't right. So it came put after a lot of hard work and looked like this

(http://i443.photobucket.com/albums/qq157/jezza-3/IMG_0279.jpg)

Something definitely not right there. Lots of swarf and metal shards everywhere and i thought i hope this isn't a bad as last time. Well that was a misjudgement lol.

Day after this happened i just wanted to take the head off to see what was the damage. After about an hour and half the head was off and looking like this

(http://i443.photobucket.com/albums/qq157/jezza-3/IMG_0285.jpg)

I turned round to look at the block and saw this

(http://i443.photobucket.com/albums/qq157/jezza-3/IMG_0290.jpg)

(http://i443.photobucket.com/albums/qq157/jezza-3/IMG_0292.jpg)

Pretty sure that piston shouldn't look like that.

So after a long two weeks of really putting a new engine back in i left in the same situation as i was in when the piston got melted.
I was thinking of selling up but the amount of power i was making felt a lot more during the remap with 3 of us in the car compared to when it was just me in the car before the bvh went on.

Only option it leaves me with is to get one of my bottom ends re-bored and fit forged pistons and then send my head off to be a bvh. Cant get rid of this car. Love it to much.

Title: Re: My G40 is beggining progress
Post by: Yoof on June 12, 2011, 10:01:04 pm
100% Dedication- +1 Beer for you at BVF.
Title: Re: My G40 is beggining progress
Post by: Jezza-7 on August 03, 2011, 09:58:48 pm
Well my engine has been rebuilt and is now in the garage ready to go in. Put everything on the engine as i thought it might be easier to go in tomorrow.

So on my 3rd engine now since the 21st may. Rebuild cost £1510. All vag parts used incl oil pump. Head done by man in shed and looks sweet.

Hopefully this time my luck is better and i get no problems.

Will post up some pics of the rebuild and other bits.
Title: Re: My G40 is beggining progress
Post by: Jezza-7 on August 03, 2011, 10:28:35 pm
1st engine melted piston removed

(http://i443.photobucket.com/albums/qq157/jezza-3/IMG_0434.jpg)

(http://i443.photobucket.com/albums/qq157/jezza-3/S7001030.jpg)

(http://i443.photobucket.com/albums/qq157/jezza-3/S7001035.jpg)

One of my favourites pics!

(http://i443.photobucket.com/albums/qq157/jezza-3/S7001036.jpg)

(http://i443.photobucket.com/albums/qq157/jezza-3/S7001038.jpg)

(http://i443.photobucket.com/albums/qq157/jezza-3/S7001033-1.jpg)
Title: Re: My G40 is beggining progress
Post by: Jezza-7 on August 31, 2011, 08:31:04 pm
Well its been a while and now its probably my final update on my g40 as this is what i pretty much wanted to do and i have achieved this over the past 2 years. Suspension is only thing left but thats going to be sorted very soon.

So the new engine went in and he remap was done after it was run in. Put out some really nice power from the remap and i couldn't thank Andy enough for it. Without him i was seriously selling up. So big thanks again.

My engine/chassis finally stands at this:

PSD 65mm toothed pulley kit
Custom made air induction
R1 Jabba charger with boost mod
Custom made intercooler
51mm tb and ported t-piece (big thanks Justin!)
GT inlet
G60 injectors with injector jackets
8mm magnecor leads
Schrick cam
Ported and polished head (man in shed)
1341cc bottom end balanced crank with wossner forged pistons (TSR)
Stainless exhaust and system
Custom made standalone oil supply for G-lader
Lightened flywheel
Helix uprated clutch
Uprated Driveshafts
PPP Stage 3 frame
PPP rear strut brace
Bilstein front shocks

So after many many ££ spent im finally where i wanted to be and im more than happy and im achieving 37.8 MPG which is good.

Just suspension and rolling road to see power, but im not sure if i want to know. I know its the fastest its ever been so i think i will leave it at that.

(http://i443.photobucket.com/albums/qq157/jezza-3/IMG_0467.jpg)

After 2 months of sitting in the garage a good clean and wax was more than needed

(http://i443.photobucket.com/albums/qq157/jezza-3/IMG_0469.jpg)

And finally a good sun set

(http://i443.photobucket.com/albums/qq157/jezza-3/IMG_0476.jpg)

Big thanks to everyone on here that helped me out with advice, parts, charger servicing and everything that made this possible, especially Yoof and Andy of PPP, peteg40, Justin, Antony and TSR for rebuild.

Cheers  8)


Title: Re: My G40 is beggining progress, has now been complete.
Post by: dub-disaster on August 31, 2011, 09:36:33 pm
Great car mate realy enjoyed the ride in it the other day it's a real credit to you and all the effort you put in keep up the good work !
Title: Re: My G40 is beggining progress, has now been complete.
Post by: Etches on August 31, 2011, 09:41:37 pm
Surely this is going to pull some of the biggest if not the best bhp figures with a G40 charger! Well done mate looks awesome
Title: Re: My G40 is beggining progress, has now been complete.
Post by: breadman on September 03, 2011, 12:42:17 am
Well done Jezza for sticking with it.
I've followed this thread from the start and the number of times I've thought "oh no ??? not again - poor ol' Zezza". Many would have thrown the towel in long ago but somehow you managed to keep plugging away and rebuilding it. I'd hate to think what it must of cost you! :o
You really deserve a break with this now, just enjoy it mate.
Good luck with it in the future,
Cheers,
Richard.
Title: Re: My G40 is beggining progress, has now been complete.
Post by: dekerf1996 on January 16, 2012, 09:55:57 pm
Wow, some turn around on this. Only just seen this due to your for sale thread.

Great work here, shame you are selling up now, guess needs must though.

What work did TSR do for the rebuild? was it just the bottom end, or did they sort out the head too?
Title: Re: My G40 is beggining progress, has now been complete.
Post by: Jezza-7 on January 18, 2012, 10:19:39 pm
TSR did all the bottom end while the head was sent to man in the shed. TSR did a really good job and used all vw parts.
Title: Re: My G40 is beggining progress, has now been complete.
Post by: Jezza-7 on February 27, 2012, 08:18:57 pm
Well the red stripe went on and im liking it  ;D

Plus i got some speedlines which im liking too! Hopefully get some wilwood's under them soon

(http://i443.photobucket.com/albums/qq157/jezza-3/IMG_0921.jpg)

(http://i443.photobucket.com/albums/qq157/jezza-3/IMG_0922.jpg)

(http://i443.photobucket.com/albums/qq157/jezza-3/IMG_0920.jpg)
Title: Re: My G40 is beggining progress, has now been complete..... well almost
Post by: Yoof on March 19, 2012, 05:15:46 pm
Looks good on the wheels- when's this G60 getting bolted on?  ;D
Title: Re: My G40 is beggining progress, has now been complete..... well almost
Post by: Jezza-7 on March 20, 2012, 05:25:09 pm
Gonna do a separate section for that. I might make a how to guide but i usually forget to take photos. Charger is almost here now. But i wanna drive the car over summer this year as i didnt get to last year so it will take place over winter. Was gonna ask if you got any red injectors.
Title: Re: My G40 is beggining progress, has now been complete..... well almost
Post by: djtez on March 21, 2012, 09:32:22 am
be interesting to see figures as it stands now then g60..

im pretty much following in your foot steps..

a contacted max rpm about some parts.

keep posted about the g60 build i think im a couple months behind you!
i've got my head done am now on the look for 1341 bottom end or price my own
Title: Re: My G40 is beggining progress, has now been complete..... well almost
Post by: randombadger69 on May 11, 2012, 02:07:51 pm
Nice work, feel your pain on the wounded engine. the new build looks the tits!

What size pistons did you go for?
Title: Re: My G40 is beggining progress, has now been complete..... well almost
Post by: Jezza-7 on May 14, 2012, 06:20:29 pm
Pistons were 77mm so its now a 1341cc. Drives well good off boost and get a good MPG now.
Title: Re: My G40 is beggining progress, has now been complete..... well almost
Post by: Freddy77 on July 03, 2012, 11:54:10 pm
Mate I I just read this thread even though I pretty much know the spec and the performance speaks for its self when you get behind the wheel I really hope my g40 can come along like yours just without the piston melting mishaps on the way! I'm really glad you haven't sold her as I know no matter how much it costs it still keeps that smile going, we need to get mine on the road as soon as poss!
Title: Re: My G40...... finally
Post by: Jezza-7 on April 13, 2013, 03:11:08 pm
Ok, its been a while since i updated this but here we go.

Last time i was planning a G60 charger but im happy with the power.

So since then i have been uming and arh ing about water methanol injection. Got a kit and then thought its a waste of money so scrapped that idea. Plus didnt wanna fork out £300 for another remap.

Fitted a 256mm setup, WOW my car actually stops! Amazing brakes and if anyone wants to get a setup like that, i highly recommend it.

Got some TA coilovers but didn't really like them and wanted something a bit better. After lots of looking around and finding out info i narrowed it down to the B12 and H&R cup kit. I went with the cup kit as i wanted the lower stance so i bought that and fitted it last week. Also was lucky enough to fit some adjustable TCA's. Had the tracking done today and now got the camber a -1 degree and castor and toe are spot on for now. (cant be bothered to go down and get the sheet)

My kit was a 60/40 which i think makes the car sit perfectly. Will drop slightly as well. Only been on a few days and need to bed it in but it handles a lot better, i dont know what all the fuss was about in one of the posts about these handling terrible. I think for £340 its bloody good.

Been playing around with a custom made catch tank and have finally got round to fitting it in place, mainly due to being able to place my new air filter down behind the bumper where the charcoal canister used to sit.

Also got a new bumper as i was getting pissed off with a shitty looking front one. Wasnt genuine but i dont care, it looks a thousand times better. Just need to get the red stripe back on. Also put some fly eye on the headlights, not sure what i think still but kinda looking the dark look it gives the car.

Also bought another private plate.

Its been a long near 4 years now (also been bloody expensive) since having this car and modding it and its finally come to an end where im happy with what i have now. Maybe a respray down the future and thats it.

So here is what i have now ended up with.

(http://i443.photobucket.com/albums/qq157/jezza-3/DSC_0063_zps5ccf1b81.jpg) (http://s443.photobucket.com/user/jezza-3/media/DSC_0063_zps5ccf1b81.jpg.html)

(http://i443.photobucket.com/albums/qq157/jezza-3/DSC_0064_zps24612c6d.jpg) (http://s443.photobucket.com/user/jezza-3/media/DSC_0064_zps24612c6d.jpg.html)

(http://i443.photobucket.com/albums/qq157/jezza-3/DSC_0067_zps7c489309.jpg) (http://s443.photobucket.com/user/jezza-3/media/DSC_0067_zps7c489309.jpg.html)

(http://i443.photobucket.com/albums/qq157/jezza-3/DSC_0066_zpsc1340902.jpg) (http://s443.photobucket.com/user/jezza-3/media/DSC_0066_zpsc1340902.jpg.html)

(http://i443.photobucket.com/albums/qq157/jezza-3/DSC_0068_zpsce5a278c.jpg) (http://s443.photobucket.com/user/jezza-3/media/DSC_0068_zpsce5a278c.jpg.html)

(http://i443.photobucket.com/albums/qq157/jezza-3/DSC_0075_zps45f7fec6.jpg)

(http://i443.photobucket.com/albums/qq157/jezza-3/DSC_0070_zps52d8d590.jpg) (http://s443.photobucket.com/user/jezza-3/media/DSC_0070_zps52d8d590.jpg.html)


Thats all for now, well with this car.
Title: Re: My G40...... finally
Post by: Freddy77 on April 13, 2013, 03:51:15 pm
Looking really good mate, stance is a lot better with that new suspension, hope to find out how well it handles very soon!
Title: Re: My G40...... finally
Post by: z3i on April 13, 2013, 04:19:23 pm
Just read the whole thread james, was a good read. always wondered what your profile picture was... now i know haha

and i love that you kept the G lader. serious man point for manning through 2 engines and still keeping it :D
also love that intercooler soo much! really want to get one made as i dont like the front mount ones.
did the oil cooler make much difference to engine and and oil temps?
Taylor
Title: Re: My G40...... finally
Post by: Jezza-7 on April 13, 2013, 04:30:10 pm
Haha yeah that pic was from the 2nd time round lol. If it wasn't an original it would of gone turbo.

Cant tell about oil temp as i dont have a gauge yet but it kept the engine water temp down to 80 when cruising, even when giving it some it stays around 80/85. Its deffo worth getting one.

Yeah that i/c is a one of a kind. It was designed on the original one and i think it took them 2 go's before it was correct. If you spoke to radtec they still might have the designs but that was about 3 years ago it was made.
Title: Re: My G40...... finally
Post by: Jezza-7 on May 14, 2013, 06:52:55 pm
With red stripe back on and a good clean :)

(http://i443.photobucket.com/albums/qq157/jezza-3/DSC_0131_zpsaefd3ab6.jpg) (http://s443.photobucket.com/user/jezza-3/media/DSC_0131_zpsaefd3ab6.jpg.html)
Title: Re: My G40...... finally
Post by: Etches on May 14, 2013, 07:38:07 pm
Looks spot on this James! Jealous!
Title: Re: My G40...... finally
Post by: z3i on May 14, 2013, 08:54:02 pm
whats the handling like on the road with a stage 3 subframe, no arb and the cup kit? much body roll?
still havnt decided yet, want the adjust ability as ive got all the gear to set it up at work, but dont want to run no arb as (so ive been told) you need hard coilovers to compensate for no arb. but harsh coilovers for commuting will be horrid
thanks
Taylor
Title: Re: My G40...... finally
Post by: Andy on May 14, 2013, 09:17:03 pm
Looks proper moody now, the wheels and lights work really well with that colour.  ;D
Title: Re: My G40...... finally
Post by: Jezza-7 on May 14, 2013, 10:49:26 pm
Cheers tom and andy. Just need a respray as paintwork it a little tatty on the driver side but will do for now.
Title: Re: My G40...... finally
Post by: Jezza-7 on May 14, 2013, 11:08:21 pm
I havent had the chance to really drive it hard with the new suspension as its only been on a few weeks and its not been driven for nearly 2 weeks now. Letting it bed in and settle in but i did go round a few corners to see what it was like and it was better than the bilstein shocks i had. Still got body roll but no where near as much. I would say its not far off a perfect setup for road driving. Bilsteins are ment to be good, but they dont go as low which will help the CoG, plus my setup is 60/40 to transfer that weight. Got the 20mm spacers fitted if i want an even 60mm all around.

To be honest, when i 1st had the kit fitted i thought, well these feel just as harsh as coilovers. But im happy with them and at nearly £200 difference, i went with the right kit. Even though its harsh.

When i 1st had the subframe fitted, it transformed the car handling completely. I remember my mate saying, hit that roundabout about 60mph (was fairly big), with the arb could prob manage 40mph max, i looked at him and said are you sure? He laughed and said yeah. So i did what he said and it was like i was driving a different polo. I felt like i could of pushed the car harder as well.

With the adjus TCA's i also run -1 camber now, whether that will make much difference to handling, where as before it was +2 or something.

Coilovers, are expensive, for the price of just coilovers you could get a subframe and sus kit. Antony, Yoof and andy run coilovers but yoof is track and andy (correct if wrong) has more of a track setup and antony has gone for the tack setup as well. Cause mine is more fast road, yet to have a track day i dont want to run coilovers.

End of the day its all down to personal choice.

Title: Re: My G40...... finally
Post by: z3i on May 15, 2013, 05:49:04 am
Thanks for that mate :)
well as you know im already running the cup kit, so halt way there already :) and yes it is harsh, though i think mine more than normal as the dampers are worn
Cheers bud
Title: Re: My G40...... finally
Post by: Andy on May 15, 2013, 07:11:21 am
andy (correct if wrong) has more of a track setup
Mine's more of a 'garage' setup at the moment, 'til I get it back on the road anyway!
Title: Re: My G40...... finally
Post by: Jezza-7 on May 15, 2013, 07:18:27 pm
andy (correct if wrong) has more of a track setup
Mine's more of a 'garage' setup at the moment, 'til I get it back on the road anyway!

haha see i was wrong.

"The garage setup"
Title: Re: My G40...... finally
Post by: z3i on May 15, 2013, 07:31:13 pm
Lol
Title: Re: My G40...... finally
Post by: z3i on June 30, 2013, 05:55:57 pm
Ended up going with Gaz coilovers and a stage 2 subframe 3 weeks till they arrive :D woop
what bhp figures did you get after the 1341 conversion? your specs are pretty much identical to mine other then different cam

Title: Re: My G40...... finally
Post by: Jezza-7 on July 11, 2013, 12:09:17 pm
Never had it rolling roaded mate
Title: Re: My G40...... finally
Post by: Jezza-7 on February 02, 2014, 10:15:28 pm
Well its been 2 years and 6 months since the engine was rebuilt and mapped, and i finally got round to the rollers!

1st run it spun straight away

2nd run took it to around 7000rpm with 2 guys stood on the door sills it made 171.3bhp & 136.3lbf ft torque, believe it was still slipping as torque should be higher

He said could it go more and i said it had a few rpms left so on the 3rd run around 7300 rpm it made slightly less bhp but oil temp had increased from 80 c to 95c and water temp had gone from 70 c to 90 c think the heat had a slight affect.

All in all i guessed 172bhp and weren't far off and happy with what i got. Hopefully get it done again with some more weight on the front end not half way down the car.

(http://i443.photobucket.com/albums/qq157/jezza-3/DSC_0206_zps9bf26e09.jpg) (http://s443.photobucket.com/user/jezza-3/media/DSC_0206_zps9bf26e09.jpg.html)


Still need to fit the PPP mani as well.



Title: Re: My G40...... finally
Post by: Etches on February 03, 2014, 07:38:52 pm
Yes James! Those are decent numbers and the graph looks strong too  ;D ;D
Title: Re: My G40...... finally
Post by: z3i on February 04, 2014, 10:11:35 am
BAAAAAAAPPPPP!
Title: Re: My G40...... finally
Post by: physicsfool on February 04, 2014, 09:21:25 pm
Little confused, how does 116 at the wheels equate to 170 at the fly? Just curious as I just had my G rr'd end of jan and he accounted for a 25% loss through transmissions resulting in 106 at the wheels and 132 at the flywheel! How is it calculated and is there a standard figure/equation?
Title: Re: My G40...... finally
Post by: PeteG40 on February 04, 2014, 09:23:01 pm
a proper place will do a run down to see the friction coefficient from your gearbox, not just apply a random percentage.

Title: Re: My G40...... finally
Post by: physicsfool on February 04, 2014, 09:38:32 pm
Cheers Pete, how do you calculate a loss coefficient? And isn't the figures above assuming a 45% loss?
Title: Re: My G40...... finally
Post by: PeteG40 on February 05, 2014, 09:36:50 am
After running up to say 7000 rpm  they measure the drag on the rollers as it returns to rest.
Title: Re: My G40...... finally
Post by: Yoof on February 05, 2014, 12:27:57 pm
After running up to say 7000 rpm  they measure the drag on the rollers as it returns to rest.

(In neutral...)

The plot Jezza has shows a poor run, the delta between crank and wheels figure is generally in the region of 30bhp. The torque figure is also low, and at very high rpm. A g40 of this spec is typically ~170lbft around 2250rpm.

More fatties required to stand on the car throughout the run, or better strapping required. Interesting it's still making power at 7600rpm too! Usually they've turned over before then.
Title: Re: My G40...... finally
Post by: Jezza-7 on February 05, 2014, 02:24:09 pm
I might get this rolling roaded again but a local one. A few pages back you can see a graph were it made 149bhp and 134lbf ft which is almost the same torque.

I think as pete says though, more fatties required. It spun on the rollers as soon as the cam started coming to play.

The rev counter was 7000rpm when he stopped the power. He asked if the rpm was accurate and i said it was. I cant remember what the rev limit andy sets it to but im sure its less than 7600 rpm.

Happy with the power and still get 14.2 1/4 miles. Slicks next for a 13 sec i reckon.

Then nitrous!