Club G40 Forum
Club G40 => Photos and videos => Ongoing Projects => Topic started by: JregGT on November 01, 2010, 07:56:54 pm
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Evening folks, thought as I was making a little ground on the conversion now, I thought i'd try to make a little progress thread, as never tried one before.
The start, picked up my medium blue 91 GT about 5 years ago, ran it pretty standard bar a set of audi 80 wheels for a time. But then i got the bug and it started.
As she stands now, it has an ABD block, ported/polished head, 4 branch/decat mated up to a standard G40 centrepip and backbox. It runs pretty well, but now its just not enough!! May have a little to do with helping my brother put a 2.0l 16v engine into his 79 GLI scirocco, and realising it was in another league!!! :D
I bought a complete engine off this forum, knowing it had a number of problems that needed sorting before the conversion, so thought it was my ideal chance to get what i wanted! The engine had previously been rolling roaded at 153bhp, so I hoped that it would make a good base to start with. I've been taking a few pictures throughout, so will put it into a few posts, hopefully a few of you will comment and enjoy watching the project, as i'm enjoying doing it.
I'll start the pictures with car in question for now.
(http://i32.photobucket.com/albums/d42/JregGT/New%20Wheels/100_1344.jpg)
(http://i32.photobucket.com/albums/d42/JregGT/New%20Wheels/100_1345.jpg)
(http://i32.photobucket.com/albums/d42/JregGT/New%20Wheels/100_1355.jpg)
I've done a lot with the engine, so next couple of posts, i'll get some decent pictures and my plans up.
Cheers for looking folks.
Rich
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I love this, good choice of exterior mods, one of the best colours and very clean :)
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Yeah, looks nice.
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Lovely colour and looks super clean!
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Cheers folks, I do like the colour, never seen in the skin another medium blue, they're always steel ones I come across!!
The pictures are very decieving, the bodywork isn't actually up to much, i'm after pretty much all the panels that can be replaced. In its life before me, it was just a fella run around, and he wasn't really that interested in it! I've recently got a decent pass side front wing, but still after drivers side, the doors and maybe a bonnet! Just a waiting game!
Conversion wise I had a little parcel today which was nice way to start the weekend. A set of 65mm toothed pullies I had been waiting for.
(http://i32.photobucket.com/albums/d42/JregGT/100_1689.jpg)
(http://i32.photobucket.com/albums/d42/JregGT/100_1691.jpg)
The engine spec going in will be -
stage 4 charger ( which needs new scroll seals before fitting)
Boost Return removed
65mm toothed pullies ( as seen above )
GT inlet
De-wedged TB ( not riveted - removed butterfly and chemical metalled )
Green injectors G60 ( just got them back from PP after ultrasonic cleaning )
G40 exhuast manifold with decat and G40 centre and backbox
induction kit
An old map to suit all the above.
Once its in and running, before I do too many miles on it, i'd like to get the map checked/ tweaked, to ensure its correct for the spec.
I've always wanted a G40, but had grown to love my GT shell, so thought the next best would be a conversion.
Cheers for the replies folks, i'll try to keep the updates coming as I get bits done.
Rich
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Haha! We've exactly the opposite problem looking for panels for the girlfriend's steel blue bready!
Cracking car and sweet mod list, watching this with great anticipation!
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Spent some of this morning putting another lick of paint to bits, so in a effort to keep this going with little updates, I thought i'd post a couple more pictures.
I bought a stage 2 second hand subframe around the same time I bought the engine, thinking that a stage 2 may be the very least the chassis needs when the power get doubled!! :o Obviuosly a stage 3 wishbone would of been lovely, but the cost was already mounting, so maybe in the future!#
The frame came in decent used condition, but as it wasn't to be used straight away, i stripped it back to the metal, and gave it a number of coats of Hammerite Rust beater in a rather fetching brown. This is meant to kill any leftover rust, and give a good surface to paint to.
(http://i32.photobucket.com/albums/d42/JregGT/G40/100_1602.jpg)
(http://i32.photobucket.com/albums/d42/JregGT/G40/100_1603.jpg)
Once that had gone off properly, I then started to give it a few coats of black hammerite, over a couple of weekends, but these are the recent pictures.
(http://i32.photobucket.com/albums/d42/JregGT/G40/100_1638.jpg)
(http://i32.photobucket.com/albums/d42/JregGT/G40/100_1639.jpg)
As you can see the subframe is one suitable for G-lader blocks, when i sorted the frame, I also managed to source a used , but reasonable looking set of blocks to put on with the subframe.
There are a million and one things i'd love to be adding/doing at the same time, i'd like to poly bush the TCA and maybe add a couple of strut braces to 'complete' the suspension set up, but lots of it is going to have to wait till the car is back in use.
Cheers Rich
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This is looking good man! my sisters Bready is the same colour.
are the toothed belts you got from Bar-Tek? im thinking of getting them,was it easy to get them shiped over?
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I don't think they are Bar-tek, I got them from PhilJ off clubpolo, he may well get them from them, but i'm unsure, it was just the easiest route for me. They are steel, so are reasonably heavy, compared to alloy PSD ones. But my bottom PSD pulley was ruined and needed to get my hands on a set. But I will certainly be keeping my eyes open for a cheeky alloy set!
Cheers folks
Rich :)
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Tackled the poorly de-wedged T/B. Firstly I drilled out the crappy massive rivets, I got over excited, and didn't take any before pictures, but then remembered, and started to take a few.
(http://i32.photobucket.com/albums/d42/JregGT/G40/100_1615.jpg)
(http://i32.photobucket.com/albums/d42/JregGT/G40/100_1619.jpg)
(http://i32.photobucket.com/albums/d42/JregGT/G40/100_1620.jpg)
After I had removed all the swarf, I popped out the 2 screws and removed the butterfly, so that I could fill the holes with chemical metal. After reading a topic on here, I very slightly countersunk all the holes (can see in the first pic), so that the chemical metal formed a better shape in the butterfly.
(http://i32.photobucket.com/albums/d42/JregGT/G40/100_1624.jpg)
(http://i32.photobucket.com/albums/d42/JregGT/G40/100_1626.jpg)
(http://i32.photobucket.com/albums/d42/JregGT/G40/100_1627.jpg)
Really pleased with how it came out. Took a bit of grease and some jiggling to get back in, but once in and the screws very loctited, I was chuffed. Unfortunatly by then, my camera batteries had ran out. So no completely re-assembled shots.
Cheers folks
Rich
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Nice neat job that mate! 8)
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Made some good progress lately, bar a couple of nuts and bolts, that i've ordered (i'm sure i've said that a few times) I think i've got everything to 'do' the conversion now.
Engine has had a general overhaul now, general paint and replacement, all gaskets that had to be removed to carry out work, have been replaced with new VW gaskets, all sensors have been cleaned along with a new thermostat, as the old one looked like this!
(http://i32.photobucket.com/albums/d42/JregGT/100_1655.jpg)
Engine now looks like this
(http://i32.photobucket.com/albums/d42/JregGT/100_1670.jpg)
(http://i32.photobucket.com/albums/d42/JregGT/100_1671-1.jpg)
(http://i32.photobucket.com/albums/d42/JregGT/100_1673-1.jpg)
I also (fingers crossed) have got my charger sorted, I took a trip to see Pete, who I must say a massive thank you too, for his time, and the information he passed on to me.
All 5 seals have been changed, along with a ropey oil slinger and a couple of loosey goosey circlips, and a fresh timing belt. When cleaning the charger, lots of unexpected 'crap' came out of the charger, which appears to come from a previously chewed up seal. So i'm hoping now, with the new seals, removal of all the 'crap' and a decent oil slinger, that the charger should be a decent unit.
I've got lots of pictures of little updates i've done, like injector jackets, removal of ruined bottom pulley etc, but until I find mt camera lead, they will have to wait till the next update.
Cheers folks
Rich
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Did you do the core plugs dude?
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Lovely attention to detail. Very neat, tidy build!
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very nice looks so very clean!
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Cheers for the positive comments folks, hopefully, the next few weeks up to christmas, should see the biggest updates. If all goes to plan, by mid jan the engine and suspension bits, should all be on and running. Was hoping for just before crimbo, but apparently my girlfriend would rather go to her aunties christmas day, than spend it in the garage with me. And by her, I mean us, and I have no say! But I am expecting a few conversion bits form her, so can't kick up too much of a fuss.
Rich, I didn't do the core plugs, just cleaned the block over, and put some paint on it. Non seemed to be weeping any oil, or obvious signs of failure.
Only bit i really had off the block, was the breather pod as the engine was suffering oil related problems, and i thought the breather may of been blocked. I ran a decent amount of petrol through it, and let it soak for a couple of nights and the petrol was filthy. SO i'm hoping if it was blocked, this will of cleaned it out.
Cheers folks
Rich
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Another little update, nothing too exciting, but its getting there now. Or certainly would be if TPS didn't continue to let me down with bolts!!
Found my camera lead, so can get a few of the pictures i've been taking up here.
Got a complete set of injector jackets, so thought it would be rude not to put them to use/
(http://i32.photobucket.com/albums/d42/JregGT/100_1695.jpg)
(http://i32.photobucket.com/albums/d42/JregGT/100_1700.jpg)
Also gave the supercharger a fresh lick of silver engine enamel, along with the outler dome, and the bracket.
(http://i32.photobucket.com/albums/d42/JregGT/100_1705.jpg)
(http://i32.photobucket.com/albums/d42/JregGT/100_1702.jpg)
(http://i32.photobucket.com/albums/d42/JregGT/100_1704.jpg)
(http://i32.photobucket.com/albums/d42/JregGT/100_1706.jpg)
(http://i32.photobucket.com/albums/d42/JregGT/100_1707.jpg)
Currently waiting on TPS to get me the correct bolts for both sides of the charger, when stripped, the bolts were either wrong, or knackered, so most unlike VW they were very reasonable, so ordered the new bolts, and sholud be back together by the weekend.
This weekend should also see the garage emptied (weather depending), and the Polo rolled in for the big swap. Cannot wait!!!
Cheers folks.
Rich
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Looking good dude!
i have a request if its not too much trouble! do you think you would be able to count the teeth on your pulleys
as im a little bit worried about a set ive just bought not being the correct size it will probly just be me being an old woman but it would be good to know!
cheers!
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I guessed you meant the charger pulley, but can count the others if you want. The charger pulley has 24 teeth. (Just re-read it, and you said, pulleys, i'll count the other for you tomorrow, and drop you a PM)
Made a fair bit of progress, but mainly in sorting the garage, not on the car or engine, but that should soon follow.
Ta Rich ;D
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How's the progress Rich? I've noticed you've started selling GT bits.....?
;-)
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Gone really well, touch wood, I have got tons of pictures to put up, but going to wait till engines back in (and from that you can guess i'm not as far as planned!!)
As we stand at the minute, the GT lump had been removed, the subframe has been fitted with ARB blocks and the wiring has been altered to suit the G40, including hopefully having the alarm back in correctly, and whole loom from the fusebox forward has been re wrapped in VW's finest!!!
It is literally just the engine that has got to be dropped in now, and plumbed up, then fingers crossed we'll be there! Just finding a whole day, to have a go, but I did think i'd update it today with a little look at the gauges i got to keep an eye on things.
I'm not 100% happy with positioning, but for a start they will stay there, I quite fancy shifting the radio and putting the gauges there, but for now it will do.
(http://i32.photobucket.com/albums/d42/JregGT/100_1928.jpg)
(http://i32.photobucket.com/albums/d42/JregGT/100_1929.jpg)
(http://i32.photobucket.com/albums/d42/JregGT/100_1934.jpg)
(http://i32.photobucket.com/albums/d42/JregGT/100_1936.jpg)
(http://i32.photobucket.com/albums/d42/JregGT/100_1939.jpg)
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Oh yes!!! Looking brilliant! Keep up the good work
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Cheers matey, really can't wait now, just been trying not to rush, as not to miss bits. As soon as the engines back in, I will sort the pictures, and get a decent set up.
But i do like this one just after the Gt lump was removed.
(http://i32.photobucket.com/albums/d42/JregGT/100_1777.jpg)
You had any joy with yours over christmas?
Ta Rich
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Well, had a very productive weekend, while off the road, the MOT has run out, so got more work to do before I can get it on the road.
But conversion wise, I am waiting for just the alternator! Everything else engine bay wise is done. List consists of
Fit Alternator
Fit charger and pipework to intercooler and air filter
Fill with oil and water
Fit new petrol tank for MOT
Underseal/Waxoyl car
Then hopefully away we go! The tank is being painted in the evenings this week, then i'll fit saturday and try to fire her up. Then next sat, put her in for a MOT :o
(http://i32.photobucket.com/albums/d42/JregGT/100_1973.jpg)
(http://i32.photobucket.com/albums/d42/JregGT/100_1975.jpg)
Just thought a couple of pictures would do for the minute.
Cheers for looking folks Rich :D
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Bloody hell! Good progress!
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Cheers cheys, i'm hoping to get her on the road this weekend, got an MOT booked for saturday morning, and all being well, I should be using her from then.
How you getting on with the turbo'd motor??
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Righto folks, a little update, as have been trying to put a few gentle miles on her. Upto 700, changed the oil at 500, so going to start increasing the revs a little from now in. Just been giving it regular checks, including all subframe bolts, mounts, anything that could fall off!! I'm checking. Here is how she stands at the minute.
(http://i32.photobucket.com/albums/d42/JregGT/100_1984.jpg)
(http://i32.photobucket.com/albums/d42/JregGT/100_1985.jpg)
Plans this weekend are to give it a very very very much needed decent clean, order a few new bits, and generally carry on enjoying her!!
Rich
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Well the weekend has passed, and my fun has continued, I literally cannot stop smiling while driving her.
Usual routine for the last few weekends went as usual. Get car out of garage sat morning, check all the usual bits and pieces, then set about anything else I had planned.
On the agenda for this week were Change plugs, change lambda, knock up a temp catch tank, as i'd been very lazy and not bothered, and finally was to decided what to do with the air filter. I'm not a massive fan of big cone filters, and did buy a G40 airbox to put it back to standard, but as i'm very new to G40's was unsure if i'd be potentially strangling my engine. So instead i opted to keep it.
So armed with a stainless steel breadbin that was being thrown, I consulted my grandad and we decided it would be ideal to make a heat sheild from. Its not finished as we only got a saturday afternoon on it, but here is how it stands at the minute!
(http://i32.photobucket.com/albums/d42/JregGT/100_2016.jpg)
A couple of progress shots!!
(http://i32.photobucket.com/albums/d42/JregGT/100_2012.jpg)
(http://i32.photobucket.com/albums/d42/JregGT/100_2013.jpg)
(http://i32.photobucket.com/albums/d42/JregGT/100_2015.jpg)
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Sorry for the abrupt ending, my write message was playing up. Nest sat, plan to finish it off with another short bit towards the grill, just to aim the air a touch, and I have an old landrover brake resevoir which I plan to mount in the old charcoal canister hole as my catch tank, as its currently a lucozade bottle cable tied to my expansion tank!!
Cheers for looking folks
Rich
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Right folks, not really a big update, as I have just been having fun driving the car and getting used to it. I'm now just a few miles off 3000 on the G40 engine. So next weekend will see an oil and filter change.
Since the last update, I have finished off the Air guide and oil catch tank.
(http://i32.photobucket.com/albums/d42/JregGT/100_2419.jpg)
(http://i32.photobucket.com/albums/d42/JregGT/100_2420.jpg)
I've also moved the oil pressure and boost gauge, as generally looking at the footwell while getting giddy watching the boost gauge wasn't a good combination! I've moved it to the radio slot, so therefore the radio had to move too!!!
(http://i32.photobucket.com/albums/d42/JregGT/100_2421.jpg)
(http://i32.photobucket.com/albums/d42/JregGT/100_2422.jpg)
I've also made a new BR blanking plate and a leather gasket to go with it. Up to now I had been carefully cleaning the gasket sealer off each time and carefully re-doing it everytime I put some PTFE spray in the charger! When I fitted the gasket, I put a smear of grease on both sides of the leather to get an air tight seal, and touchwood it is working well. I'm still getting around 0.7bar at full chat, which is what i've been getting so far, so pleased with how it turned out.
(http://i32.photobucket.com/albums/d42/JregGT/100_2424.jpg)
Cheers folks
Rich
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charger still ok then mate?
pete
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Yeah, touchwood Pete it is doing well, hoping the decent oil slinger and general lack of other crap in it is doing it some good! I was going to PM you to see how things were and ask for your advice on when to give the charger a bearings and seals re-build! As I said, i'm nearly at 3000miles on it now.
Rich
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what did we actually do - just the oil seals? if there's no noises, should prob be good for another 3k at least, those bearings had only really done a few k
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We did all 5 seals and a belt, Ben did say it hadn't done that many, and touchwood it is sounding and performing well, so i'll give it a few more thou, then be in touch about a full rebuild kit, already managed to salvage a little oven to tuck up the corner of teh garage to use for the bearings!!
Rich
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Just though I'd revive this thread to see how you were getting on with it Rich?
You've done a bloody good job and I'm glad that it all seems to be working ok for you!!
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Cheers Ben, yeah, touchwood its still going strong, not actually managed to get much time on it due to work. But have managed to fit this.
(http://i32.photobucket.com/albums/d42/JregGT/100_2416-1.jpg)
(http://i32.photobucket.com/albums/d42/JregGT/100_2342.jpg)
(http://i32.photobucket.com/albums/d42/JregGT/100_2418-2.jpg)
No pictures of it fitted, because if i'm honest it was such a pain in the a**e to fit, during the process, taking pictures was the last thing on my mind!
I wouldn't even dream of knocking the quality of the exhaust, as it is absolutely superb. But the fitment, was far from what I imagined, I don't know if with all the hype, I had talked myself into it being a fly on job (which they never are!!!) but it certainly wasn't.
I had a number of clearance issues on runner number 1 which I thought, all the work, and hence the price/value was in, to eliminate this problem. I had to modify the engine mount, outlet dome and charger brace to get it to fit properly. Which at the time I really wasn't happy about, and contemplated putting all the stock G stuff back on, as it was really p*****g me off that much!
But now it is on, I managed to take it for a run tonight, and I am very pleased with the results, reasonably subtle lower revs etc, but has a nice tone when pushing it, also seems to of free'd up the revs a touch. Seems to pull very happily toward the redline (not that it didn't before.) But now just seems to have that little bit of extra go in it.
Next up is hopefully an oil cooler setup using a GM coolerplate (unsure of cooler tho yet, more than likely, whatever comes up at the right sort of money.) And oil temp gauge to be added in teh dash with the boost, and oil pressure gauge.
Cheers folks.
Rich :D
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Yup the early manifolds are a pain with some pulley combinations- hence us doing a revision to look like this:
(http://img.photobucket.com/albums/v251/Young_Un/DSC02292.jpg)
I know this doesn't help you now it's on :) but if you ever need more clearance (eaton G60 etc) then try to find a 'mk2' manifold.
Car's coming along well now Rich :)
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Cheers Yoof, I don't see how that number 1 runner can be effected by pulley combinations?? The runner just wouldn't physically fit between the supercharger support and head, so I had to tickle the charger bracket. I understand that the outlet dome could be effected by pullies (which it was, as I had to fettle that too), but not the actual runner of the exhaust. The phase 2 ones certainly look a work of art too! I think if it comes to a point of changing, it would probably be down the turbo route!!
Top work on your car matey. Rich ;D
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Rich- yeah the small support bracket has to go with most aftermarket manifolds, not many people run them anyway.
The pulley combinations was an interesting one, dependant on pulley size, and toothed. v-belt and alternator position and belt length, dictates how much tension the charger requires, which also dictates how close the lader sits to No.1, in some cases charger outlet domes had to be relieved to fit.
Thankfully phase 2 manifold doesn't require any of this!
How's is sound??
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Yeah, I get that bit, just physically the number 1 runner was wider than the gap between the engine mount and head, I don't see how any charger/pulley set up could affect this. Like I said, nothing a little tickle didn't sort, same for the top bracket too, as I wanted it to look 'complete'
Yeah, it sounds really good on a decent hammering, and relatively sedate on a very low rev/early morning pootle. Whether or not it is the placebo effect, it certainly seems to of free'd the car up a bit too. I'm hoping that the standard exhaust was possibly on the limit of the car, so putting the 4branch backwards on, has hopefully free'd up a few horses. I would like to get it rolling road to see what the conversion is actually producing. Although to behonest its plenty enetertaining enough at the minute anyway!!!!
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Evening all, it has been a long time since I have been on here! In the time I've been 'gone' I have bought a house, got married and have had our first child! So the polo has sat giving me puppy dog eyes every weekend for the last 18 months that it hasn't really been used! It has been started and ran up to temperature bi-weekly/monthly and has never failed to start with a decent battery. I last weekend managed to run it around some local private land as the plan was to clean it up, clean the discs/pads off, drop the oil, put it through a MOT and get it sold! Now the dilemma, my love has instantly been rekindled! Why do these cars drag you in and tug on the heart strings! I haven't missed using it if I'm honest. Our family car was/is a MK5 Golf GTI (3 door so must go really)with a few touches and an A4 1.8T estate to replace it. So the polo really fills no purpose. Yet the thought of selling makes me get all fidgety!!
Either way, I will be back on folks, either back in the mix or with a for sale ad.
Hope everyone is well.
Rich