Club G40 Forum
Club G40 => Photos and videos => Topic started by: grungeisdead on May 11, 2011, 01:19:59 am
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(http://a2.sphotos.ak.fbcdn.net/hphotos-ak-snc6/218068_10150218922606343_511441342_8749819_1802519_n.jpg)
Model:
1984 Polo Coupe S
Comet Blue (Komet Blau)
Engine:
Rebuilt 1272cc 'PY' G40
Garret Turbocharger
Custom Turbo Manifold
Forge Dump-valve
Forge Actuator
540mm x 140mm x 65mm FMIC
Colour Coderd Rocker Cover
Full 3" Stainless Exhaust (Downpipe Back)
Suspension:
Unsure at the moment, to be replaced with
HnR Cup Kit 60/40
G40 Rose-Jointed Steering Arms
G40 Rose-Jointed Track Control Arms
G40 Steering Damper
Powerflex ARB Bushes
Brakes:
VWII Calipers
EBC 239mm X-Drilled/Grooved Discs
Green Stuff Pads
Goodridge Braided Hoses
Wheels and Tyres:
Alleycats 13x7
195/45/13s all round
For sale at £300
To be replaced with
OZ Ruote Type 018-A's
195/45/14s
Interior Styling:
Fully Stripped Bar Door Cards & Dash
Scricco GT2 Seats
Comments:-
Picked this up as an unfinished project, enjoy the progress.
Pics that sold it to me:-
(http://a8.sphotos.ak.fbcdn.net/hphotos-ak-ash4/206879_10150218922781343_511441342_8749824_4613644_n.jpg)
(http://a2.sphotos.ak.fbcdn.net/hphotos-ak-ash4/216083_10150218922826343_511441342_8749825_3474755_n.jpg)
(http://a4.sphotos.ak.fbcdn.net/hphotos-ak-snc6/206452_10150218922861343_511441342_8749826_38019_n.jpg)
(http://a6.sphotos.ak.fbcdn.net/hphotos-ak-ash4/217387_10150218922921343_511441342_8749827_2016712_n.jpg)
Day one:
despite the potential onset of rain, i ploughed on with the car! now got the G40 ecu, G40 engine loom and Mk3 Engine loom re-wrapped and fitted, with oem holes through the bulkhead. Throttle cable fitted, exhausts all fitted (but badly needs a new tailpipe - dtm upswept ftl!) Intercooler is mounted and radiator trial fitted. Sound deadening stripped from the interior and mk3 in-tank fuel pump fitted
So that leaves me with a few jobs left when I get back after the weekend. Fit fuel pump, lines and loom, block off BRV, fit dump-valve, plumb turbo oil lines, fit intercooler pipes, fit rad and plumb in, bleed brakes, mount boost guage, brap and mot!
oh and holesaw vents for intercooler in front-panel.
no piccies unfortunatly bar this one, from when it arrived in the morning, as me phone b82res is dead!
(http://a7.sphotos.ak.fbcdn.net/hphotos-ak-ash4/226541_10150237527046343_511441342_8932523_2807389_n.jpg)
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Me likey
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I love it ! I think it looks great I think mk 2's have the edge when it come to looks over a mk3 abd this one is especialy nice. What turbo and what manifold are you using looks like a philj jobie any good ?? Also where'd you get your down pipe from ??
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Yeah the sharp edges give it that old skool feel, i adore mk1 and mk2 shapes, along with mk1 golfs!
not sure on the turbo and manifold mate, i'll check for markings and get back to you on that, i didnt purchase them so its wherever Kev got them from.
Will grab more details off the turbo too, just know its a Garrett atm!
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looks like a t25 off a saab, could confirm this if you get some closer pics of the housings
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there ya go will
(http://i134.photobucket.com/albums/q104/winter_snowball/2011-05-12205220.jpg)
(http://i134.photobucket.com/albums/q104/winter_snowball/2011-05-12205220.jpg)
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ye, its a t25 and im 99% sure that its off a saab. if the downpipe fitting has 3 bolts it definately is a saab unit, going by the number on the compressor housing it should suit the engine well, virtually the same turbo to what ill be running
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saweet! will be jumping on this later this weekend, so will get lots of pic updates
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You sir are a whore!!!! ;)
MOAR pics please!!!!!!
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Haha that I am Winst!
Got no more pics yet really but should be gettin it up to the unit this week to crack on with it now that the peril n mk3 are on the road
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is it the pic saf or is there reallly sod all room for the boost pipe off the turbo?
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theres plenty of room, but it'll have too many bends to meet the intercooler as it has side mounted take-offs!
will have a play with a load of ally off cuts we've got
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so will mine being a forge intercooler. busy trying to get all my pipes to meet up!
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looking at your boost pipe, id have to cut that too, not too bothered about that but dont wanna spend big moooooooolar!
how much ya thinking treacle?
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seeing as its you (and you seem to be whoring all my spare parts! lol) £40.
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saffy mate - what size is the wurbo? i see compressor side is .48 - whats the exhaust side?
cheers dooooood
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exhaust housing will be a similar size if not the same
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hey kiz, soz for the late reply, not sure on the size, took a pic of the markings for ya tho
(http://i134.photobucket.com/albums/q104/winter_snowball/2011-07-01222148.jpg)
heres some pics of the downpipe ya dub-disaster
(http://i134.photobucket.com/albums/q104/winter_snowball/2011-07-01222047.jpg)
(http://i134.photobucket.com/albums/q104/winter_snowball/2011-07-01222038.jpg)
after taking a two week sabbatical on the cars and playing all the xbox games id missed, i thought id jump back on it!
turbo feed line fitted
(http://i134.photobucket.com/albums/q104/winter_snowball/2011-07-01222111.jpg)
(http://i134.photobucket.com/albums/q104/winter_snowball/2011-07-01222132.jpg)
oil drain line measured up so i can order a suitable hose
(http://i134.photobucket.com/albums/q104/winter_snowball/2011-07-01222026.jpg)
intercooler mounting brackets sprayed
(http://i134.photobucket.com/albums/q104/winter_snowball/2011-07-03163829.jpg)
intercooler fitted
(http://i134.photobucket.com/albums/q104/winter_snowball/2011-07-03213513.jpg)
mk2 g40 oem boost hose
(http://i134.photobucket.com/albums/q104/winter_snowball/2011-07-01222320.jpg)
routing for turbo to intercooler, gotta get a 57->51mm 90 degree bend boost hose
(http://i134.photobucket.com/albums/q104/winter_snowball/2011-07-03213541.jpg)
(http://i134.photobucket.com/albums/q104/winter_snowball/2011-07-03213732.jpg)
trusty friend holesaw made suitable venting for the intercooler
(http://i134.photobucket.com/albums/q104/winter_snowball/2011-07-03213336.jpg)
refitted bumper
(http://i134.photobucket.com/albums/q104/winter_snowball/2011-07-03213202.jpg)
some other piccies
(http://i134.photobucket.com/albums/q104/winter_snowball/2011-07-03213137.jpg)
(http://i134.photobucket.com/albums/q104/winter_snowball/2011-07-03213356.jpg)
(http://i134.photobucket.com/albums/q104/winter_snowball/2011-07-03213453.jpg)
things left to do
gotta sort out the cooling system this week, starting with my choice of rad, as space is rather limited, along with getting the appropriate fittings for the turbo
fit oil cooler, thermostatic plate, new vag oil filter and oil change
fit painted fuel pump bracket, and source mk3 fuel lines
bleed brakes
extend boost piping to throttle body
fit dump valve
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Friday
After last weeks researchin sesh, got a load of parts ordered to complete the puzzle so ill be gettin over to the unit to fit them all when they do.
Also got my solid brake line made up, recut the thread on one of the braided hoses, fitted mk3 fuel lines (thanks to o1mlacey) still need the ones to the lift pump though if anyone can help.
Arun (phataz1) also cut me some holes in the dash for mounting the guages and mounted the fuel pump bracket. Weve just gotta tack a couple of studs to the rear chassis leg for two of the mounting rubbers to finish that off.
Gonna try my hand at welding up the battery tray too, my first attempt but about time I gave it a go!
What are peoples thought on the colour coded arches? I want to take them back to black and put some gti black strips on the lower swage line
Today
Got a solid brake line made up on sunday, fitted it today, along with the last goodridge braided hose and bled the system up with dot 5.1
Few bits turned up today,
Seal for the thermostatic plate, so fitted that along with a vw oil filter and the oil lines. Just gotta mount the cooler.
Boost hoses and alloy pipes came and they accidentally send two alloy pipes! Winner! Came in handy too.
Set azbar on the job of fitting all the boost hoses, all fits snugly
(http://i134.photobucket.com/albums/q104/winter_snowball/2011-07-13000622.jpg)
(http://i134.photobucket.com/albums/q104/winter_snowball/2011-07-13000645.jpg)
(http://i134.photobucket.com/albums/q104/winter_snowball/2011-07-13000554.jpg)
(http://i134.photobucket.com/albums/q104/winter_snowball/2011-07-13000603.jpg)
Back up to the unit as soon as the rad and turbo water line fittings arrive in the post!
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very nice, keep up the hard work
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That's some amount of work for two months. I'm tired just watching. lol.
Looking forward to the finished article. Having said that do we ever get finished?
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haha nah they are never finished, if its not refining, its something breaking =P
new rads arrived today, 380mm core mk2 g40 rad and a top fill early mk2 rad, so ill be bobbing up tonight to get them fitted.
still waiting on me banjo bits for the turbos water lines, grrrr
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banjos, bolts and oil drain line turned up today, but the muppets managed to give me the correct m14 bolt but a m12 banjo! grr. hopefully should be here soon!
taken two evenings of fiddling to get the radiator squeezed into place. props to lou for the help last night. pretty stoked about it now
you can also see the fitted rad hoses and hose adaptor for turbo line
(http://i16.photobucket.com/albums/b12/yousafn/DSC_0489.jpg)
its a rather tight fit, so i need to invest in some sort of heat sheilding
(http://i16.photobucket.com/albums/b12/yousafn/DSC_0502.jpg)
found an oil cooler in the unit, the absolute perfect size. need to measure it up and get one if i cant buy this one of the lads
(http://i16.photobucket.com/albums/b12/yousafn/DSC_0508.jpg)
drain line fitted in this pic
(http://i16.photobucket.com/albums/b12/yousafn/DSC_0491.jpg)
finally got a pic of the guages - got an oil temp to fit in place of the clock, none are wired up at the mo, but the boost guage feed is connected
(http://i16.photobucket.com/albums/b12/yousafn/DSC_0486.jpg)
nearly complete!
(http://i16.photobucket.com/albums/b12/yousafn/DSC_0498.jpg)
still got a healthy job list
fit oil cooler
fit oil cooler lines
need a 76mm jubilee for air filter
heat wrap for turbo
fit downpipe and hang exhaust
plumb turb water lines
fit indicators
fit isv hose to induction piping
fit pipe off manifold for vac hoses
vac hose for ecu
fit fuel pump and accumulator
get fuel lines for intank pump
block off BRV
fit a 6 psi boost switch
rad wiring
fit mk2 engine loom for brakes/temp/wipers etc
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looking good saf - worried about that rad tho mate - that will melt! and when you engine brake it will touch - you dont want that to happen!!!
is there no way you can gain some extra room by undoing all the engine mounts and making sure its the furthest back it can be?
or look at other rads??? needs to be a good amount of clearence dood at least 1" id say very least
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Hey man, anything with a 350mm core would suffice. Got a heat mat for the turbo now, will just see how it goes. Rad was 20 quid so no biggie if it bites the dust!
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The black oil cooler I had didnt fit my lines, but bagged a bargain cooler for a fiver at tatton park. They luckily had the same fittings so got it fitted tonight.
(http://i134.photobucket.com/albums/q104/winter_snowball/2011-08-12002941.jpg)
Stuck a gen vw filter and filled with oil.
With thanks to philpheasant for the fuel lines, I finally got the oem fuel lines to the intank pump fitted. Just need to grab a new fuel filter and wire up the pump and the fuelling sidea complete!
Exhaust is all fitted, just got fit the return line for the turbo water feed, do a few bits of wiring, make up some vac lines and block off the brv ( mates turning down some ally for me )
Hopefully running by the weekend and off for an mot monday!
(http://i134.photobucket.com/albums/q104/winter_snowball/2011-08-12002926.jpg)
(http://i134.photobucket.com/albums/q104/winter_snowball/2011-08-12002846.jpg)
(http://i134.photobucket.com/albums/q104/winter_snowball/2011-08-12002952.jpg)
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Good progress.Realy like this car look foward to seeing it on the road, is the colour original? What cam you got in there ??
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Yeah oem colour dude, its got a GT cam fitted atm
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sweet mate.....sweet
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no pics at the moment but got a few more bits done
cut a section out of the bonnet to allow it to shut properly with the new rad mounting brackets
modded throttle body to house boost pressure switch
all vac lines now connected
got a full set of tyres for the exips, so getting them fitted tomorrow
also picked up a stage 2 subframe and g-lader blocks, so they are going onto the peril, and the PPS frame is going on here
painted up my front struts which were fitted with new vw bearings, just gotta refit my kw shock inserts, and vag top mounts and they can go on the car
lous got my grill and hes cutting out all the sections so its fully open for plenty of airflow to the oil cooler and rad
still after the plug from the loom, for the in-tank lift pump if anyone can chop one out a loom for me!
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Went to see this yesterday - in all honesty its looking epic! Cant wait to get out and have a play in this!
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George (Rolo) worked his magic and stopped the turbo and rad making love, also fitted a jabba induction kit, stage 3 sunny, exips n some yoko's. Just gotta weld up the sump and do a couple of bits of wiring. Wanna get it on the road for gti festival
(http://photos-a.ak.fbcdn.net/hphotos-ak-snc7/s720x720/311714_10150392846851343_511441342_10268323_1948484605_n.jpg)
(http://photos-e.ak.fbcdn.net/hphotos-ak-ash4/s720x720/309577_10150392848481343_511441342_10268340_82378296_n.jpg)
(http://photos-h.ak.fbcdn.net/hphotos-ak-snc7/s720x720/300964_10150392850001343_511441342_10268353_1497797328_n.jpg)
(http://photos-f.ak.fbcdn.net/hphotos-ak-snc7/s720x720/303717_10150392852391343_511441342_10268367_1032075329_n.jpg)
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Oct 11th
spent yesterday fitting a storm single wiper and rehanging the exhaust after it all came off for the turbo relocation, also adjusted the pressure switch to activate at 6 psi and refitted thata
reweld oil drain back to sump as its been leaking
fill with oil
rear lights - brake and fog lights
hazard switch not working
fit lambda
set wheelbase on stage3 subby
wire in-tank pump
fire up and hopefully rejoice!
30th October
lambda fitted and sump welded up.
had to strategically modify the exhaust, with a sledgehammer to clear the driveshaft, as it was fouling.
fitted gen exhaust manifold gaskets, which i thought would involve taking the exhaust off again! but thankfully managed to get it on without taking the turbo or downpipe off
filled up with oil and went to start the beast but there was no spark! so made a relay circuit up to feed power to the coil as for some reason the oe wiring for the coil wasnt giving out any power.
went to start it again and i have a fuel leak at one of the injectors!
so once thats all sorted in the week, i shall have videos of it running for you all
Today
changed all the o-rings on the injectors, refitted fuel rail!
car turned over on the first turn of the key - absolutely buzzing!
exhaust has come off again however, along with the sump, as despite being welded up on the car, it was still leaking slightly. so I'm fitting my spare sump that George (Rolo) welded a screw-on fitting onto, and Chris is sorting out finding a suitable length pipe for me from the local engineering place!
Hopefully the bits will be sorted out, so I can refit everything and take it for a lil spin and then drop it off at the garage for its MOT.
Oh and as you do, I've bought another car! Barnfind Mk1 Golf 3dr in Blue!
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Oil Drain Lines - This has been a pain in the arse!
The first drain line, that was fitted to the car, was a cut down VW jack. but it wasnt welded properly so leaked. Car turned over and ran brilliantly, no smoke, but was losing oil from where the sump fitting was welded. with the inability to get the welding torch on the upper side of the sump, I got Rolo to weld an spare fitting we had in the unit, 1/4" BSP!
stripped the exhaust and sump off, fitted the new sump. got a return line made up, refitted exhaust, fired car up and noticed plumes of oily smoke out the back and oil dripping down the downpipe!
BUGGER!
THe oil drain line was too small a bore!
So got some adaptors and some 3/8" tubing made up, drilled out some of the fittings to put less restriction on the flow, but the oil drain line sat under the subframe, so when the engine rocked backwards under acceleration, it would rip the fitting off! so jacked the engine up, fitted the oil line above it, dropped the engine, snapped the fitting!
BASTARD!
so after spending 50 pounds on fittings and lines that were at best a pikey fix (of which I knew, I was just putting off doing it properly, as I wanted it done quickly) and having to take my sump off three times, I bit the bullet and spunked out 76 quid on some gucci AN10 stainless hosing and aeroquip style fittings.
Made a boo-boo by buying an alloy weld on sump fitting, and was told by Chris that I cant weld alloy to the steel sump!
DOH!
not too bad, as the peril has an alloy sump made by RPM. so trundled off home and whipped that off, went to see Phataz, who welded the fitting to the alloy sump and we went off to the unit happy as larry.
Had a right pain in the arse getting the fittings on, and dethreaded on of the fittings and my good mate accidently dethreaded the alloy sump fitting, so the sump had to come off AGAIN, back to Phataz, who welded on the 2nd weld on sump fitting i had spare.
Another 40 quid on 2 new fittings, to replace the dethreaded aeroquip fittings, and some patience meant I finally had a proper, non-leaking, suitablly large diameter oil return line.
Pics of said oil line & fittings :-
(http://a1.sphotos.ak.fbcdn.net/hphotos-ak-snc7/s720x720/380190_10150459584166343_511441342_10625869_819858381_n.jpg)
(http://a8.sphotos.ak.fbcdn.net/hphotos-ak-snc7/s720x720/302087_10150459585486343_511441342_10625873_1784513370_n.jpg)
I think the 5 minutes the car had ran with the wrong size drain back line had damanged the oil seals, as you can see the leak at the base of the turbo in this pic.
(http://a3.sphotos.ak.fbcdn.net/hphotos-ak-ash4/s720x720/390683_10150459585981343_511441342_10625875_783754161_n.jpg)
So £166 quid lighter, I finally had a kushdi oil line and a buggered turbo! This was one expensive lesson, in doing things properly from the off.
Video of the car as she is now, running and schmokey!
(http://i134.photobucket.com/albums/q104/winter_snowball/th_MOV_0954.jpg) (http://s134.photobucket.com/albums/q104/winter_snowball/?action=view¤t=MOV_0954.mp4)
Does anyone know of companies that supply oil seals for Garrett Turbos?
Also is anyone running restrictors in the oil feed lines?
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bought a rebuild kit and stepped rear oil seal from turbo rebuild uk in blackpool. and it arrived on Friday, just in time for the weekend.
Met up with the boys up at Wards End, and after some quality munch (itchy bum chicken and spring rolls) i had all the tools assembled to attack the turbo rebuild.
got in at half 12 and despite it being most peoples bedtimes. i was far too excited so stripped the turbo down in me living room.
exhaust housing removed and orientation marked in true PTNT fashion
(http://i16.photobucket.com/albums/b12/yousafn/DSC_0965.jpg)
(http://i16.photobucket.com/albums/b12/yousafn/DSC_0967.jpg)
lots of burnt oil and oily residue behind the heat shield
(http://i16.photobucket.com/albums/b12/yousafn/DSC_0968.jpg)
the compressor side
(http://i16.photobucket.com/albums/b12/yousafn/DSC_0970.jpg)
shaft after removing old oil seal but before cleaning out the grooves
(http://i16.photobucket.com/albums/b12/yousafn/DSC_0971.jpg)
new stepped oil seal fitted
(http://i16.photobucket.com/albums/b12/yousafn/DSC_0975.jpg)
back on the car
(http://i16.photobucket.com/albums/b12/yousafn/DSC_0991.jpg)
woop!
(http://i16.photobucket.com/albums/b12/yousafn/DSC_0994.jpg)
VIdeo of the first run up to temp
(http://i16.photobucket.com/albums/b12/yousafn/th_MOV_0989.jpg) (http://s16.photobucket.com/albums/b12/yousafn/?action=view¤t=MOV_0989.mp4)
I also gave a side of the Golf a quick polish
(http://i16.photobucket.com/albums/b12/yousafn/DSC_0997.jpg)
(http://i16.photobucket.com/albums/b12/yousafn/DSC_0998.jpg)
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Well the previous suspension kit was lowered springs on standard shocks, with the bumpstops removed! so on the trip to the MOT station, I managed to mangle the arch and take a chunk out of the tyre down to the cord!
Some new tyres on the front and all was sorted!
Now fitted ta KW 60mm kit on the front, with 15mm Bonrath Lowering top caps and new top mounts, and the suspension is suitably stiff to ensure theres no arch to tyre contact :)
Unfortunatly this cracked the paint on the arch trim, so they have been taken off and will be nitromoored and then back to blacked and put back on the car. On the flip side, the arches were super clean underneath so I'm stoked :)
Just got to whip off the 256mm brakes and discs off the Mk1 Polo tonight, fit them tomorrow, give it a good bleed and then I can get it over to aruns for a bit of welding on the battery tray and although I want to cut out a slightly crispy patch by the drivers jacking point. Its not gone, but was an advisory.
Car now s MOT & TAX so looking forward to driving it, although I dont think it'll be doing many snow miles!
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good to see this up and running mate - youve done a good job. will we be seeing this at aldon in the new year?
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cheers man :) sticking lucas 54 calipers, feredo pads and some 256mm discs tomo so I can actually stop and changing one of the tyres, as it got merked by the collapsed suspension (no bumpstops and dead shocks!) but thats all been replaced by my KW kit.
still need to get an M10 x 1.0 tap for the top of the HnR rear shockers as I ruined the thread on them using the wrong pitch nut last year
Shall be at Aldon if I've not broken it in the meantime!
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Bluey meets Bluey!
(http://a8.sphotos.ak.fbcdn.net/hphotos-ak-snc7/396246_10150578455881343_511441342_11074314_2124718004_n.jpg)
The turbo is an absolute winner! Love it! Only drove it 37 miles and 31 of them involved a massive smile on my face! Woop Woop! Shame it got driven to its graveyard today!
(http://a4.sphotos.ak.fbcdn.net/hphotos-ak-ash4/407672_10150578456301343_511441342_11074316_1708778543_n.jpg)
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driven to its graveyard?????? ???
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aye its being stripped, the engine conversion is going in a series 1 golf i recently purchased, you can see it parked next to the polo in the above picture.
either selling the car as a rolling shell, or putting the HK lump out of the mk1 into it
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hi mate, still have the alley cats for sale? cheers
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nah sold many moons ago