Club G40 Forum

Club G40 => Photos and videos => Ongoing Projects => Topic started by: Etches on May 18, 2011, 07:02:46 pm

Title: Etches G40 (2)
Post by: Etches on May 18, 2011, 07:02:46 pm
Right as many of you know on the 13/01/2011 I had my previous motor stolen from outside my house. Ended up on the back of a truck n scrapped for £100 of which some chinese bloke is enjoying his breakfast eating off it now. But anyways had about a month without a car deciding what to do next really. I ideally wanted a mk1 polo as I think there retro cool, but the amount of dollar for what you get with them is not what i needed. After doing some work on Kays car n having a room full of expensive bits for a polo i decided that i hadnt achieved what i wanted from a mk3 yet. So after a few quick txts i managed to grab this, tdh_syorks old motor.

(http://i137.photobucket.com/albums/q236/etches69/abc25898.jpg)
(http://i137.photobucket.com/albums/q236/etches69/8f680db4.jpg)
(http://i137.photobucket.com/albums/q236/etches69/ab5ca5ef.jpg)

Wank Iphone pic.

Ran it like that for a couple of months not having to do anything to keep the girl running. Other than the driver side window mech breaking nothing went wrong! A problem i bought the car with was a clutch which was about to die a painful death, fortunately got one included with the car. So chucked the clutch n new cable in and that was sorted.

Then the exhaust started getting very loud so had a trip down to exhausts uk , had a hole in the flexi mech. So i got the cat chopped out at the same time and a new flexi chucked on.
On the way home from getting that fixed joe n me enjoyed getting rear ended on shalesmoor rd about on penistone rd! With insurance sorting our whiplash claims within 2 days i brought the car to ADR in chesterfield to get the dent removed. Spot it if you can.

(http://i137.photobucket.com/albums/q236/etches69/e45f46db.jpg)

Tashing around in the skoda they lent me was a ball, but getting back into driving the G it felt like a righht hassle!

Big bang was approaching fast so i needed to get rid of the 13" BBS that provided little traction. Managed to pick up the people choice  :/ , with a little sand paper and spray paint

(http://i137.photobucket.com/albums/q236/etches69/f669f10f.jpg)

Some rear coils i picked up for £20 got blasted on at the same time

(http://i137.photobucket.com/albums/q236/etches69/2615d52f.jpg)

Made a massive school boy error n didnt realise which way coilovers adjusted, ended up with the bbs wheels in the boot and the coilies wound down to the last thread!!
The ride was comfy but the back was lowerd 120mm and the from 40! Massssive speed boat.  Then i thought about all the shit I needed to carry down to pod and ended up winding em all the way up. Which if im brutally honest made the car feel like a waterbed.

Nobody believed me when I said you will feel physically sick when driving it. Only for my mechanic mate nathan to drive it round the block and bounce the back end of the floor on a bump it was that stiff. More adjustment ment the helper spring was loosened and the ride height was still speedboat, but acceptable untill i can get some front coils. After promts from Lee managed to pick up some front clear indis from ECP for cheaps so them n some clear side ones went on before BB.

(http://i137.photobucket.com/albums/q236/etches69/a9b737e0.jpg)

A clean the morning that we left meant that it looked like this

(http://i137.photobucket.com/albums/q236/etches69/224740_10150181896924735_517509734_6990219_1857867_n.jpg)

Here are a few from pod

(http://i137.photobucket.com/albums/q236/etches69/222786_10150181900814735_517509734_6990241_5743177_n.jpg)
(http://i137.photobucket.com/albums/q236/etches69/222912_10150181900929735_517509734_6990242_2397738_n.jpg)
(http://i137.photobucket.com/albums/q236/etches69/227659_10150181899069735_517509734_6990231_7728971_n.jpg)

Managed to get 30 runs on the friday, which resulted in my best time of 14.97 which i was chuffed about.

Got a few engine problems on the way home , turned out to be the AF gauge disconnecting itself causing the lamda not to work, with that fixed and 4 new tires that cost me £220 fitted its driving good for now, shame the mot ran out on the 4th april lol.  MOT is on friday which it should fly through.

Got some good plans for this one

Including using my turbo bits, getting another wishbone frame on PPP this time and more.



Title: Re: Etches G40 (2)
Post by: josé on May 19, 2011, 03:07:32 pm
may i suggest a good alarm if you haven't already got one fitted to deter the thieving rotters from taking this G

nice motor btw  :)
Title: Re: Etches G40 (2)
Post by: Etches on May 19, 2011, 07:13:05 pm
Fortunately came with a cat 1 clifford alarm! Its got a motion sensor so literally beeps at everyone who goes past, can be annoying though.
Title: Re: Etches G40 (2)
Post by: Etches on May 19, 2011, 11:18:56 pm
This one is now on the Big Bang home page

(http://i137.photobucket.com/albums/q236/etches69/meatpodwebsiteimage.jpg)
Title: Re: Etches G40 (2)
Post by: Etches on September 02, 2011, 09:15:14 am
Right not updated this in a while, been a little busy.

Lister was sorting some wheels of kays out so thought it would be rude not to get these done, have had em lying around for about a year!
(http://i137.photobucket.com/albums/q236/etches69/6bda53b3.jpg)

They had the side repeaters smoothed off already and I got Chris to sort out the polo ariel hole.

First of all I wanted to take off the side strips, which Tom managed to seal on so well it took me 2 days to get em off and some paint got taken off in the process :(

(http://i137.photobucket.com/albums/q236/etches69/8e20d933.jpg)

Wing off
(http://i137.photobucket.com/albums/q236/etches69/5ac740ae.jpg)

New wing on
(http://i137.photobucket.com/albums/q236/etches69/00c4e540.jpg)

Old New comparison
(http://i137.photobucket.com/albums/q236/etches69/34586454.jpg)

New wing off
(http://i137.photobucket.com/albums/q236/etches69/0313324f.jpg)

My doors need some proper tlc :( I prepped the wing and trims for undersealing
(http://i137.photobucket.com/albums/q236/etches69/dae31fd6.jpg)
(http://i137.photobucket.com/albums/q236/etches69/26d321b4.jpg)

Fully sealed inside and out
(http://i137.photobucket.com/albums/q236/etches69/22427aa2.jpg)
(http://i137.photobucket.com/albums/q236/etches69/ac5faf4c.jpg)

Just need the paint machine polishing everywhere else now haha
(http://i137.photobucket.com/albums/q236/etches69/7bfcb6c6.jpg)

Coupe S arch trim, cut to fit pop riveted on and tiger sealed
(http://i137.photobucket.com/albums/q236/etches69/89f44fa5.jpg)

Chucked on a ford splitter, still need to do the passenger side arch trim
(http://i137.photobucket.com/albums/q236/etches69/16953d84.jpg)
(http://i137.photobucket.com/albums/q236/etches69/377688d5.jpg)



Title: Re: Etches G40 (2)
Post by: Boris on September 02, 2011, 11:40:26 am
Fortunately came with a cat 1 clifford alarm! Its got a motion sensor so literally beeps at everyone who goes past, can be annoying though.
The motion sensor bubble range can be adjusted so that doesn't happen, I.e. Bubble is within the car and not extending outside.  Just take it to someone who fits them.  ;)
Title: Re: Etches G40 (2)
Post by: Etches on September 01, 2012, 01:21:24 pm
Not updated this in too long!

Since the last update, had front coils fitted with adjustable top mounts and polybushed the control arms.

Now I've been collecting turbo parts for about a year n a half which looks like this

(http://i137.photobucket.com/albums/q236/etches69/19291C32-4719-43C4-A879-BAE3DC09511F-4514-000009905B974691.jpg)

Got a rad brace from Dan which will get some new holes to move the rad across for the intercooler

(http://i137.photobucket.com/albums/q236/etches69/D8E5B534-D23F-4B3B-B578-AE2800BBC076-4514-000009904C82FDC1.jpg)

Ended up lookin like this

(http://i137.photobucket.com/albums/q236/etches69/A94ED7B7-D617-4251-8E9E-E8D029659241-4514-0000099053551D5B.jpg)
(http://i137.photobucket.com/albums/q236/etches69/ADC31BD8-14E5-4220-AC59-03652D14AC28-4514-00000990572E0D69.jpg)

Now the charger has been whipped off

(http://i137.photobucket.com/albums/q236/etches69/3E597A20-AB5E-4D9F-817F-997CF008E988-4514-0000098F491E76C9.jpg)

Turbo has been offered up to see clearance

(http://i137.photobucket.com/albums/q236/etches69/7AC2F77D-3852-4B49-AF7C-3597BEFE890D-4514-0000098F408AAAAA.jpg)

Changed the mount and the sump to one with my fitting on, still got plenty to do yet!
Title: Re: Etches G40 (2)
Post by: Etches on September 08, 2012, 10:09:24 am
Busy week ,

New 268 268 (shrick copy) newman has been put in .
Put the AAV alternator and tensioner set up on, turbo actually mounted with downpipe including new studs and copper nuts all round.
I've also moved the radiator across to allow for the intercoolers inlet and outlet hose. Inlet feeds for water and oil have been sorted for the turbo too and the oil cooler plate is on which  is a tight squeeze and my pressure sender is mounted to that too. Pics to follow
Title: Re: Etches G40 (2)
Post by: Etches on September 10, 2012, 05:46:42 pm
Right then fairly busy last week, cam got changed for a newman G40 turbo cam

(http://i137.photobucket.com/albums/q236/etches69/F875CEBB-E53F-4B14-B3BF-737B6A501450-8864-0000123CDCA4D5FB.jpg)

Changed over the alternator set up to the AAV one which involved changing the bottom pulley, replaced the waterpump and cambelt whilst I was there . Timing was a bake but was easier with two people.

(http://i137.photobucket.com/albums/q236/etches69/3D0C2BA7-0903-4169-96EE-5617F9A39630-8864-0000123CB5F0F172.jpg)

Turbo is now on and all studs and nuts changed

(http://i137.photobucket.com/albums/q236/etches69/6B4E592C-FF76-4E54-BE05-3F074FD14762-8864-0000123B29485DA4.jpg)

Swapped my inlet over to a ported GT one thanks to one of my mates, my old one turned out to be a ported G40 one!

(http://i137.photobucket.com/albums/q236/etches69/397A5D3D-5103-4991-9844-B888C3AC1F53-8864-0000123B1DC72035.jpg)

Plumbed in all the turbo water and oil fittings with custom made lines, here the sump one which another mate welded the fitting to.

(http://i137.photobucket.com/albums/q236/etches69/C6D3F940-44F7-4CA7-A32A-19D3E50715B5-8864-0000123B19D092D5.jpg)

(http://i137.photobucket.com/albums/q236/etches69/EB9A1000-9673-4EDF-B70C-507D7F00CC5A-8864-0000123B156D0102.jpg)

Chucked the oil cooler plate on too which turned out to be a tight squeeze as my oil pressure reg is on one of the take offs

(http://i137.photobucket.com/albums/q236/etches69/622D73E8-F556-4FAF-916E-F8B13C4B6C9E-8864-0000123B076F4DB5.jpg)

Put the oil inlet feed through the rocker cover plus this shows the shiiney forge actuator too

(http://i137.photobucket.com/albums/q236/etches69/63821FD2-D5E9-4AA6-BE34-75ED1971A66B-8864-0000123B033B8CA9.jpg)

The inlet comes from one of the senders in the head, can see the G60 green injectors which have been flow tested and they've got jackets on too

(http://i137.photobucket.com/albums/q236/etches69/5FAC2427-390B-40FF-A170-F3715E519F43-8864-0000123AFE710F1F.jpg)

Bigger throttle body (PSD 51mm) with the switch taken out to make room for  6psi boost one

(http://i137.photobucket.com/albums/q236/etches69/F57DEFA3-FC17-4090-9312-7F2AFC4A7699-8864-0000123AF5408206.jpg)

This is how it stands at the min, still a fair amount of stuff to do

(http://i137.photobucket.com/albums/q236/etches69/D530FC3A-86D1-4558-A53D-6A46870A1D27-8864-0000123B0C112F30.jpg)
Title: Re: Etches G40 (2)
Post by: Etches on September 11, 2012, 04:56:33 pm
Heres of the pic of the exhaust I got done to match the k03 downpipe

(http://i137.photobucket.com/albums/q236/etches69/ccc35120.jpg)

The answer is yes I've gone for using a middle box as a back box lol. It gave me better ground clearance

(http://i137.photobucket.com/albums/q236/etches69/a47290d6.jpg)

Thats why is was a little loud before the turbo went down haha
Title: Re: Etches G40 (2)
Post by: Etches on September 12, 2012, 05:19:05 pm
Another busy day again, most of the front end off for intercooler mods
(http://i137.photobucket.com/albums/q236/etches69/02960205-68E8-4CA7-8280-790832825954-10213-00001501BED4AE04.jpg)

The bumper crash bar is getting chopped a fair amount when I get to borrow an angle grinder. Then next came this, a PPP stage 3 frame!

(http://i137.photobucket.com/albums/q236/etches69/306C24C3-F5E7-4E0E-9C19-615F0B8A1803-10213-00001501B3823711.jpg)

Which fit fine (actually abotu 2 hours which is good time) apart from that it fouled on the downpipe. This is the downpipe with the cut marked out so Exhaust uk can make it actually clear the frame.

(http://i137.photobucket.com/albums/q236/etches69/F6F44ED8-DCD1-43E0-AD8C-BA6F833B7E13-10213-00001501C70D43E9.jpg)

The frame is all on now and bolted up making the camber look like its going to be rather large ..

(http://i137.photobucket.com/albums/q236/etches69/BD42ED22-73F7-4D6A-A60E-D7829E49D666-10213-00001501D2898A53.jpg)

I'm sure this will go back to the degree I've set on my adjustable top mounts!
Title: Re: Etches G40 (2)
Post by: Etches on September 17, 2012, 05:19:02 pm
Right another busy time, started off with abit of pain

(http://i137.photobucket.com/albums/q236/etches69/01135CF7-3CEA-4E41-8C35-7D1E69F492D5-221-0000003CBCE8CD73.jpg)

Phil J's downpipe unfortunately fouled on the subframe so I've cut it above it so exhaust uk can sort that problem out for me.

Next inline was the fan cover  ( I've painted it since )

(http://i137.photobucket.com/albums/q236/etches69/352ACAC1-4EF4-451F-934A-6A14FD60C78E-221-0000003CB6F35CA6.jpg)

Then i've sorted the boost pipes although I'm not happy with the intercooler to turbo bit yet (its not perfect)

(http://i137.photobucket.com/albums/q236/etches69/1F326922-3E15-45BA-8ABC-58504E863640-99-00000000D9C5D8EE.jpg)

Then I needed to make way for the intercooler which took a lot of pissing about and Im still not that happy with the way it sits!

(http://i137.photobucket.com/albums/q236/etches69/BFF43C94-4960-422F-BB75-FD5E575602B8-99-00000000E44F609D.jpg)
(http://i137.photobucket.com/albums/q236/etches69/A1E4F19D-8DBD-43F2-A0EA-F0AED0545CC4-99-00000000E8D6A9A5.jpg)

The bumper iron saw the grinder alot, it may need beefing up in the centre when i've got everything sitting right.

Next step is the oil cooler!


Title: Re: Etches G40 (2)
Post by: Etches on October 11, 2012, 07:14:17 pm
Right then another update

Oil cooler was a right nightmare to fit as its a 16 row one which is rather large heres how it ended up

(http://i137.photobucket.com/albums/q236/etches69/3B065D7D-BF38-44DE-8807-79162EECFB3A-13164-00000990B36EA485.jpg)
(http://i137.photobucket.com/albums/q236/etches69/F9362F87-9F44-4051-A706-2FB175A85977-13164-00000990BE301F35.jpg)

All the other odds and sods included a little wiring gauges etc which ill take a pic of later on and the wideband.

Here's how the bay looks now ( Im currently waiting on a rocker cover atm)

(http://i137.photobucket.com/albums/q236/etches69/3599BB2E-31A1-4266-9DE4-49EBA98B8DBA-13164-00000990B752EFBE.jpg)

Heres it is before I drove it down to EUK to sort out this problem

(http://i137.photobucket.com/albums/q236/etches69/A5957A8A-3B4E-4C9B-B0E0-875DFD06CD60-13164-00000990ACE8731E.jpg)

(http://i137.photobucket.com/albums/q236/etches69/08DA6FF5-E2D8-4F2A-B335-99F7A46BFB08-13164-00000990C35E5707.jpg)

The first run it needed the battery charging (cheers Joe) and it sprung to life without too much groan. Throttle cable needed adjusting and it settled down to about 1100 rpm which i was chuffed without the lambda doing anything.

There are a running issues to sort out yet  (calibrating the pressure switch), adjusting the actuator to 15 psi and getting tracking done on the subframe. Hopefully I can sort these out after i get it back from EUK tomorrow.

In terms of the way it drives, I drove like a granny down to the exhaust place and it sounds naughty. I can't wait to hear it at max boost!
Title: Re: Etches G40 (2)
Post by: dub-disaster on October 11, 2012, 11:39:38 pm
was that a genuine new vw wing or a pattern part? did you trail for it prior to having it painted? if it was a pattern part and a good fit where'd you get it from ??
Title: Re: Etches G40 (2)
Post by: Etches on October 12, 2012, 09:03:27 am
They are pattern pal as you can tell from the passenger side panel gap :/ Annoyed me to hell ! I got em from ECP for 60 for em both which was a good deal.
Title: Re: Etches G40 (2)
Post by: Etches on October 15, 2012, 04:31:32 pm
Couple of teething problems atm . Tappets are making a racket with plenty of oil in which could mean they need a service or replacing. Also it burned a fair amount of oil on the way back from Santa Pod which is worrying considering it didnt do that before the turbo went on, I suppose it could be the turbos oil seals?
Title: Re: Etches G40 (2)
Post by: Etches on November 11, 2012, 05:46:34 pm
Right if you've read the other thread then you know some of the problems i've been having here the suspected diagnosis...

(http://i137.photobucket.com/albums/q236/etches69/301698D0-78BC-4A61-8832-D94730C6609B-1564-000000E41681C5D8.jpg)

head off, cylinders 2,3,4 looks like overfuelling massively.

cylinder 1 closer look

(http://i137.photobucket.com/albums/q236/etches69/3CC5562A-2B2D-49E7-9FB1-DC6902D8C9A6-1564-000000E410F6410A.jpg)

hello melty

(http://i137.photobucket.com/albums/q236/etches69/5BDD1093-040D-4AB7-9F56-B00106DB5C89-1564-000000E4081AEF94.jpg)

Been speaking to PeteG40 and he reckons i'd probably get away with a hone new piston and rings. Although I reckon i'd like to get some forged items.
Title: Re: Etches G40 (2)
Post by: Etches on November 12, 2012, 08:07:36 pm
At the min I'm abit puzzled to the source of the melted piston, Phil J lead me to this post on here;

Anyway, thought this should be useful. A definitive checklist on how to avoid melting your engine for anyone who has built, restored, recently bought or just had a G40 laid up for a while.

First one which has prompted me to write this, Mark’s G40 started misfiring recently, easy fix – unplug the lambda and sorted. The lambda was new a year previously so something has killed it, running too rich or lean. The car had an issue where the fuel pumps wouldn’t prime, turned out the connector for the relay had corroded just enough to stop the contact. Had that not been driven like a vagina, rather than the lambda probably would have taken the engine out. Worth a look for any 40’s that have been laid up.

Another one sometimes forgotten is the wiring in the top of the fuel rail, again corrodes, goes brittle etc.

Fitting a smaller pulley/upping the boost without the fuel to suit a quick way to achieving an extra oil pump. IE a chip for a 68mm pulley and fitting 65mm toothed belts will do it on about the 3rd 145mph run.

Injectors, fuel pumps, shit in the tank and blocked filters will all lead to the same. Easily done with how the tanks corrode. Can you still get the accumulators (yellowish box by fuel pump) from vw? Haven’t asked in a while…

Timing’s always worth a check, both of.

Realistically a G40 shouldn’t melt if its right and it’s always a shame to see them go down.

Sure everyone else can add their bit, might save a few engines.




My injectors were apparently cleaned not long before I got them and the pump always seem'd to work fine before the conversion. The timing did skip afew teeth but I dont think its down to that. I filled the tank up to the brim for the trip down to pod so I think shit in the tank has come up and blocked it somewhere.

I reckon I'm guna get a new tank,filter and clean the injectors before shes running again. Maybe even get some metal fuel lines.

Ordered a set of pistons off phil, hoping to be up and running before christmas
Title: Re: Etches G40 (2)
Post by: Andy on November 12, 2012, 09:43:45 pm
Lambda is extremely unlikely to melt a piston - it's not used on full throttle (i.e. full load). Even on partial throttle where lambda correction is applied there's a control limit applied to how much fuelling correction is permitted. This is supposed to ensure that an utterly fucked probe doesn't cause component damage.

Lift pump failure will cause lean-out at higher fuel flows (high load), but also makes the car harder to start so I think you'd know about that - and it's easy to verify with a fuel pressure gauge.

Inline pump failure seems to cause significant missfires even on lowish powered cars, so I think you might've noticed that. Again, that is easily verified by sticking a pressure gauge on the end of the fuel rail.

Injector failure is a possibility, as is injector wiring harness as Phil said.

Incorrect map for spec probably accounts for some failures too I'd imagine, but that shouldn't be the case here.

Was your car pinking at all? Can't see any obvious det damage on the piston - but Yoof's the person to ask about that.
Title: Re: Etches G40 (2)
Post by: cheys03 on November 12, 2012, 09:58:03 pm
sorry to see you've had this problem. It's something we all fear happening.
Purely out of curiosity, which map is it running?
Title: Re: Etches G40 (2)
Post by: Yoof on November 12, 2012, 11:17:31 pm
Drop the oil into a clear container- see if it seperates, will know if it's bore wash then,

Having said that, if it's bore wash, I'd expect a lack of lubrication on all cylinders, not just one. Without removing the piston I can't really see but it looks like a crack rather than something melted from the top angle.

Piston is free from det and otherwise looks in good shape, what injectors do you have, presume it's a known map from PPP (normal K03) so that's a known quantity- you deffo need to find the root cause, otherwise it will happen again  :'(

I'd get a new knock sensor too  ;)
Title: Re: Etches G40 (2)
Post by: Yoof on November 13, 2012, 09:33:12 am
Tom, here’s a quick list of things to check that should help you find the root cause:

1)   Drain oil into clear container (note some types of plastic will disintegrate with fuel/oil mix) and see if there’s any separation, you can usually smell fuel content in oil, and it will light too (much more easily than oil)

2)   Take pictures of the bores on all cylinders- if a lack of lubrication caused by bore was has led to a melted piston, you’ll see this in the ring on all cylinders, if No.1 has gone first, the other 3 won’t be far behind.

3)   Check injector part numbers, and for cracks on their bodies and the fuel rail, and for any debris in them (they have small filters in the top)

4)   Photograph cylinder head

5)   Check wiring (your knock sensor looks dead) check boost switch (Chris has written an FAQ on this) and that your wiring is correct, this is key- if the 6psi switch is engaged on cruise, then the ECU will assume you’re at a full throttle condition for a given MAP & Speed site, so it will be too rich- lambda won’t correct on WOT either, check CO pot values, you can’t check cam timing or ignition timing now- can you remember what they were?

6)   Check all coolant passages and the pump impeller (although you said it was running normal temp?) usually if the coolant temp is too high expansion tank and then a head gasket after that.
 
7)   Injector clean/test again (post results)

8)   Fuel pump check- G40 will run quite happily without a lift pump until 3500-4000rpm and then will go lean, you can check both are working and their flow rates very easily with a 5litre jerry can and a stop watch, off the top of my head a stock G40 lift pump is 75lph

That should give you enough to go at  :)

Pete
Title: Re: Etches G40 (2)
Post by: Etches on November 13, 2012, 06:57:46 pm
Andy , I dont think the car was pinking. Seemed to run ok on idle but didnt enjoy part throttle too much.

Chris, the map was a ;
Map #G40008- 1341cc chip- As above with altered parameters to suit a 6psi boost switch replacing the standard G40 WOT switch, giving a smoother more progressive drive.

Pete, Separated the oil and its clean as a whistle with no separation. Im using G60 greens injectors which I bought off someone on here. The knock sensor has looked pretty banged up for a while so I'llk defo be replacing that.

I'll crack on with the list asap inbetween dissertation hell! Wossners are in the post ( read plenty of threads with comments from both you and Andy to decide which to go for)


Title: Re: Etches G40 (2)
Post by: Etches on December 14, 2012, 02:02:28 pm
Right an update on this finally! Took the head off to get some work done where PeteG40 mentioned (skim, new valve guides, stem seals, 3 angle valve and seat cut and a pressure test) then also took the injectors to be flow tested and cleaned.


(http://i137.photobucket.com/albums/q236/etches69/56DBF77F-1BA3-4A8F-B0DD-36F7A0027424-5645-000002D3B355551A.jpg)

Head is getting done today but got the results back from the injectors.

Turns out all of the injectors had good spray pattern, 4 of them had flow of 260cc and one of them had a flow rate of 240cc . The guy reckons  i should chuck the "knackered" one and find a new one. They also do turbo rebuilds for 200 so i may also end up going up again!

So i'm looking for a G60 injector now!

Also got the main and big end bearings on order from Rotherham Engine servies, picking up all bottom end seals off Pete next week. Just got to wait on the pistons now from Phil J!
Title: Re: Etches G40 (2)
Post by: Andy on December 14, 2012, 04:33:59 pm
Don't just focus on the injector flow at 85% or 100% duty cycle, did the guy give you an idea of how they flowed at lower duties too? In your car they'll probably not get above 75% duty even on max boost/full throttle, so it's worth knowing what they do across the opening range.
Title: Re: Etches G40 (2)
Post by: Etches on December 15, 2012, 08:41:29 am
Cheers Andy, I've messaged him so hopefully he gives me some info. I didn't get a print out as it was either £30 for the verbal results or £50 for a print out (rediculous I know).
Title: Re: Etches G40 (2)
Post by: Etches on January 12, 2013, 09:20:40 am
Bit of an update now;

(http://i137.photobucket.com/albums/q236/etches69/9FD7E041-0BB8-4AD7-8150-9442A899C839-6840-000003F9198DCE13.jpg)

Bottom end totally ripped apart and to the engine shop for a full  clean and  for a 2mm overbore for the wossner pistons

The heads come back RES where its had

head skim, 8 valve guides, stem seals, cam oil seal, three angle valve cut 3 angle seat cut

(http://i137.photobucket.com/albums/q236/etches69/4F0C5AA3-E8E8-4333-BC1B-3731F752F7D3-6840-000003F9154FCF0B.jpg)

I've got to get some 315cc injectors and some big end bolts.
Title: Re: Etches G40 (2)
Post by: Etches on January 16, 2013, 08:25:39 pm
(http://i137.photobucket.com/albums/q236/etches69/818DCE11-174C-46F5-BD3E-6BA67BA319A3-11031-000006AF666ED256.jpg)

Got these in the post today - Cheers Phil!

Means they can be given to RES for the bores to be matched!
Title: Re: Etches G40 (2)
Post by: gaz g40 on January 16, 2013, 09:19:17 pm
Just had my bottom end done the pistons look too good to fit lol you going for rods aswell? I got the PEC ones
Nice build thread too got mine to start soonish
Title: Re: Etches G40 (2)
Post by: PeteG40 on January 16, 2013, 09:55:24 pm
showed my K1 rods to yoof... he thinks they're probably just same as his PEC, but with a different logo...
Title: Re: Etches G40 (2)
Post by: Etches on February 06, 2013, 05:14:59 pm
Couple of Updates,

Seems my cars list of parts needed is getting larger as the Mrs polo has rinsed my starter motor alternator radiator and loads of other bits. Then again i suppose it gives me an excuse to buy brand new ones!

I've ordered some 315CC SAAB injectors as running up to 200 bhp will need a bit more fuel and they give me a bit of headroom . Engine has been bored honed and decked so will be picked up for the engine shop this week hopefully.

 Then it just leaves picking up some conrod bolts, nuts and main bearing bolts before she can go back together! Definately should be done for Big Bang hopefully including having it mapped by PPP, pics to follow of the block..
Title: Re: Etches G40 (2)
Post by: Etches on February 20, 2013, 08:00:33 pm
Finally got the engine back! (£130 for a 2mm overbore and decking the face as there was a little corrosion)

(http://i137.photobucket.com/albums/q236/etches69/E2DAF24A-940C-4E9B-B564-1CFBC81B4A32-290-0000001212386360_zpsd345fd4b.jpg)

(http://i137.photobucket.com/albums/q236/etches69/952CD869-455E-4AC6-8965-08C9D27B2E6A-290-00000012103F0BCD_zps0a79b2c7.jpg)

(http://i137.photobucket.com/albums/q236/etches69/37C92275-930F-4FCA-B6E1-A334D8482E7A-290-000000120A50DAD2_zpsc4542111.jpg)

Now all I need for the rebuild is  conrod nuts and bolts, main bearing bolts and the crank bolt!
Title: Re: Etches G40 (2)
Post by: Etches on March 11, 2013, 07:33:53 pm
Couple of updates, I have now got new bend end bolts nuts and thrust washers just need to pick the oil seals up now off Pete/Sam. Spent about £20 on paint ending up with 2 cans of VHT Aluminium Engine Enamel for the head, gearbox and inlet inc brackets etc, 1 can of VHT Black engine enamel for the block and 1 can of VHT exhaust manifold black just to give the downpipe and turbo manifold a quick coat before the heat wrap , heres a quick pick of the block after 5 thin coats
(http://i137.photobucket.com/albums/q236/etches69/05251543-4967-4CC5-90F0-20A3D14C23B0-130-000000015282A432_zpsc2bc063d.jpg)
(http://i137.photobucket.com/albums/q236/etches69/67CA3425-9620-4325-BE7C-F7534BD5888D-2082-00000119ECAD9268_zps504d2c8c.jpg)

Also took all the conrods off the old pistons, cleaned up the fecked one so its now a paper weight;

(http://i137.photobucket.com/albums/q236/etches69/34765098-F344-4909-8958-531341AA03E3-2082-00000119DAA8E68A_zps5dd26384.jpg)
(http://i137.photobucket.com/albums/q236/etches69/6929610C-C81E-4E43-84B3-F4AA84798901-2082-00000119B6126713_zpscb28b254.jpg)
(http://i137.photobucket.com/albums/q236/etches69/0222AB18-DE6A-4D1C-9805-DC9E85AA8D73-2082-00000119BA9CF61A_zps37f5a019.jpg)
Title: Re: Etches G40 (2)
Post by: Etches on March 17, 2013, 06:35:53 pm
Just a little update, waiting on paint pens  before cracking on with the bottom end. Washed the car for the first time since October, i'm just glad i polished and waxed before. Got to fetch the timing belt bottom pully bolt which is the last piece in the puzzle.

(http://i137.photobucket.com/albums/q236/etches69/0C59844A-55A7-4628-8BD5-ABD0E365234D-5091-000002AB1782B6B2_zps158527d3.jpg)

(http://i137.photobucket.com/albums/q236/etches69/FEC1A0D1-E974-41C7-97DA-D8432CB9004B-5091-000002AB1C61EEA9_zps9660b6ad.jpg)

(http://i137.photobucket.com/albums/q236/etches69/8A316BE1-9BE2-4B35-8787-7FB33DF86B87-5091-000002AB256FCA5A_zps62da3557.jpg)

(http://i137.photobucket.com/albums/q236/etches69/B70CEC46-6FF0-4AA3-81A0-7D9FFE01F382-5091-000002AB12EAF714_zpsa24871f7.jpg)
Title: Re: Etches G40 (2)
Post by: Etches on March 17, 2013, 09:03:33 pm
Sorted these out in front of the tv this evening

New pistons (77mm),compression and oil scraper rings, gudgeon pins and clips, conrod bolts and nuts.

(http://i137.photobucket.com/albums/q236/etches69/4C82B809-D6BD-47AF-A46D-E5D80F037ECA-5091-000002BAC61AF550_zpsdfc97f3a.jpg)

(http://i137.photobucket.com/albums/q236/etches69/1942D4F6-A8AA-4527-BF05-9D051ECC5377-5091-000002BACE1CBA44_zpse12730aa.jpg)

(http://i137.photobucket.com/albums/q236/etches69/6EF3E20A-666D-416D-AE3F-0D3763F94943-5091-000002BACA363A75_zps927128c6.jpg)
Title: Re: Etches G40 (2)
Post by: Etches on March 19, 2013, 06:03:17 pm
Had a whole afternoon of play today

finally got the last bolt I needed, this is the whole lot of parts minus the pison stuff

(http://i137.photobucket.com/albums/q236/etches69/1869A57E-3C9A-46C4-BC33-E9967796CBD8-137-00000001142B421A_zps5640286a.jpg)

crank in then main bearings all torqued up

(http://i137.photobucket.com/albums/q236/etches69/B4733BCA-BAF8-48D7-9D6D-BDDA147B3934-137-0000000118B7EA8D_zps472ce8b6.jpg)

Pistons were then dropped in, definately takes a nack to use the piston ring compressor. Took me 40 mins to do the first one being very careful as the oil ring kept popping out!

(http://i137.photobucket.com/albums/q236/etches69/07E6BFDB-0579-4C07-A477-49EF4262BAFA-137-0000000124732BE6_zps684ac319.jpg)

Big ends need torquing up tomorrow before more can be done but I'm happy so far as it turns really smoothly

(http://i137.photobucket.com/albums/q236/etches69/5797F39F-F522-42DE-A054-C402CDC12852-137-0000000126E1ADAB_zpse79cee12.jpg)

(http://i137.photobucket.com/albums/q236/etches69/50B6715B-12FB-4BC8-81A9-74DFE77340A7-137-000000011B0634EE_zpsaebe6996.jpg)
Title: Re: Etches G40 (2)
Post by: XRrich on March 19, 2013, 07:05:42 pm
Looks beautiiiful, makes me wanna rip mine apart and start getting my hands dirty
Title: Re: Etches G40 (2)
Post by: Etches on March 19, 2013, 07:39:54 pm
Minus the few paint runs on the top deck haha. Gets expensive dude, hopefully will be worth it for a reliable 0 miler engine!
Title: Re: Etches G40 (2)
Post by: z3i on March 19, 2013, 08:27:22 pm
Coming along nicely :) Love seeing engine build threads. is the other Coupe your daily?
did you ever find the cause of melty piston?
Taylor
Title: Re: Etches G40 (2)
Post by: Etches on March 19, 2013, 10:52:56 pm
Other ones the mrs polo! Engine blew up in that on the motorway so its had a new engine recently.

Never ended up finding a cause for it although I'll have changed the entire engine and fuel system just to be sure lol .
Title: Re: Etches G40 (2)
Post by: Etches on March 21, 2013, 12:07:11 am
Worked on this for 3 hours, which has meant 7 hours in total!

Made a gasket in the pic above for this oil pump cover

(http://i137.photobucket.com/albums/q236/etches69/AB8CB509-1980-4651-911E-13252A30C7E1-137-000000283FCAF537_zpsa0d9b413.jpg)

Also made one for the other side which cost a total of £5 including liquid gasket just to make sure.

New oil pump, chain and both oil seals which were an absolute bitch to get in !

(http://i137.photobucket.com/albums/q236/etches69/08A7389C-379A-4744-9020-709A37508778-128-0000000128CF1D59_zps2670a6c4.jpg)
(http://i137.photobucket.com/albums/q236/etches69/2603021B-4FFE-4FC3-98DD-A546695B41E9-128-00000001310393CE_zpsba2f5011.jpg)

Got a new bottom pulley off Pete for a good price , bolt was from vw for £2.50


(http://i137.photobucket.com/albums/q236/etches69/0D29BF03-C034-4439-BE6B-0A6693A70B83-128-00000001389455E2_zpsa9090635.jpg)

Then chucked the sump on!
(http://i137.photobucket.com/albums/q236/etches69/D7D31CC0-1134-4493-ABBA-8AA8E5F38718-128-0000000140D1E729_zps2b8a95eb.jpg)

(http://i137.photobucket.com/albums/q236/etches69/9CFFBA5B-0C45-460C-9AF0-34808CF3358C-128-000000013C839177_zps2c9335c1.jpg)

Just got to buy a new rad and lambda which Kay's car knicked off me then I will have everything to get it running again!
Title: Re: Etches G40 (2)
Post by: Etches on March 22, 2013, 09:59:34 pm
Minor update,

(http://i137.photobucket.com/albums/q236/etches69/2DD0D93E-E15A-4550-834D-254AFE178196-1818-000000C6EF36C7F2_zps48a4dba6.jpg)

(http://i137.photobucket.com/albums/q236/etches69/CD8C156B-171B-4B2F-A55E-7DB55C2257A2-1818-000000C6F3AA438E_zpsaaa61511.jpg)
Title: Re: Etches G40 (2)
Post by: Etches on March 23, 2013, 07:18:53 pm
Did a little today

(http://i137.photobucket.com/albums/q236/etches69/DA0D32FC-A2C9-4DB3-BFE7-6CFC7BB14694-1818-0000012FF5F111E9_zpsdb796af9.jpg)

(http://i137.photobucket.com/albums/q236/etches69/E849D3CC-EC6C-4E70-BFB6-D69B173B73E3-1818-0000012FF9C393A3_zps1733507e.jpg)

sorted the crankshaft sprocket bolt and sealed the sump although i ended up snapping a bolt.
Title: Re: Etches G40 (2)
Post by: Etches on March 24, 2013, 10:54:33 pm
Todays work;

(http://i137.photobucket.com/albums/q236/etches69/919557F9-9E59-4AAB-BC8F-2C21BEA253B6-1818-000001A0B342CF28_zps6cad05dc.jpg)

(http://i137.photobucket.com/albums/q236/etches69/D2F2A6C8-B4A8-4D7C-8395-4ACE87596972-1818-000001A0B7D4D330_zps01385ad5.jpg)

(http://i137.photobucket.com/albums/q236/etches69/C9FE32FC-757B-416F-9EC3-53BC5A872835-1818-000001A0BBA8BF1D_zps099571ad.jpg)

New saab 325cc injectors

(http://i137.photobucket.com/albums/q236/etches69/D71B2110-BC92-4467-8930-8F6813BCF9B3-1818-000001A0C3A4ED43_zps8e4cbda5.jpg)

(http://i137.photobucket.com/albums/q236/etches69/2CFCE4E0-3320-4D10-8ACE-D8A7861F72C5-1818-000001A0C813DD89_zps567a4b0c.jpg)

(http://i137.photobucket.com/albums/q236/etches69/2A7CA5C1-8FFC-47E6-A4B8-E8BF27551C4D-1818-000001A0CC700298_zpse4f1d6af.jpg)

(http://i137.photobucket.com/albums/q236/etches69/33274CC4-922F-4F06-B11E-C6D80158CF93-1818-000001A0D38F1335_zps9213ea01.jpg)
Title: Re: Etches G40 (2)
Post by: Etches on March 27, 2013, 03:17:08 pm
Small update, waiting for the weather to clear then I can chuck the engine in,

pre paint before heat wrap

(http://i137.photobucket.com/albums/q236/etches69/B78937E1-C782-4EA5-8182-FB5464DCE5FC-770-00000059B3B4EEA2_zpsa706554e.jpg)

(http://i137.photobucket.com/albums/q236/etches69/84EF639E-60DC-4D4E-A165-F495CA171BCD-770-00000059AFCD461B_zps1649278e.jpg)
Title: Re: Etches G40 (2)
Post by: z3i on March 27, 2013, 08:09:27 pm
Looking really smart! enjoying the updates :)
is the manifold custom made?
Title: Re: Etches G40 (2)
Post by: Etches on March 27, 2013, 08:26:03 pm
Manifold and downpipe is off Phil J , had the downpipe adjusted so that it fit better with a stage 3 frame and a full custom 2.5" exhaust :)
Title: Re: Etches G40 (2)
Post by: Etches on March 29, 2013, 12:26:45 am
Todays Update,

Gearbox was literally clogged full of muck and grease.

(http://i137.photobucket.com/albums/q236/etches69/F2518B77-9E88-489D-9E18-A4FCA9761B1D-926-0000007B50B0C3F1_zpsfcb25c01.jpg)

90% of a can of Gunk and 5 kettles of boiling water, then about 2 hours of drilling with wire wheels;

(http://i137.photobucket.com/albums/q236/etches69/CD15FE89-C215-4440-89F3-6D31C5F4071C-926-0000007B47A32CFB_zps6c9e8dfd.jpg)

Used the rest of the can to clean the engine bay , not great but good enough for me

(http://i137.photobucket.com/albums/q236/etches69/4BAF35B9-002B-42DE-BDF9-2EFEA19252B1-926-0000007B43482EDF_zps0c54546e.jpg)

Had a look at my old turbo, the shaft can be moved about 7-8 mm and there is oil in the boost outlet. Thanks to Paul for sorting me a newer one. Managed to clock the turbo using a rubber mallet and then swapped over the actuator and new studs etc.

(http://i137.photobucket.com/albums/q236/etches69/7AE4E9A4-1A70-4951-928A-FA9D75BCF652-926-0000007B3FA094E5_zps7f5563a7.jpg)

Needed to trial fit it to make sure it was clocked in the correct position;

(http://i137.photobucket.com/albums/q236/etches69/C6CAB3BE-3648-4C00-988A-291FD11A232A-926-0000007B3B233414_zpsea5ac0c6.jpg)

Wiped the gearbox with turps and prepped for paint

(http://i137.photobucket.com/albums/q236/etches69/F20BB55B-5271-4B02-9B15-67FA09A1FCDA-926-0000007B36F7562A_zpsf4ccea87.jpg)

Cleaned the turbo up with the wire wheel and turps too, still undecided wether to spray it yet

(http://i137.photobucket.com/albums/q236/etches69/347ED2AD-FE45-4ADE-9E3A-0D1FFA0323DD-926-0000007B32AFFAF0_zps4af0e2a0.jpg)

Gearbox and mount sprayed with 2 coats waiting for another tomorrow

(http://i137.photobucket.com/albums/q236/etches69/4A629EEE-1781-4D7A-A9E1-6220124AF7AA-926-0000007B2DAE66B4_zps3fa0bdbe.jpg)
Title: Re: Etches G40 (2)
Post by: Etches on April 01, 2013, 10:23:58 pm
Put the turbo on the manifold , cleaned the dizzy which refuses to get any cleaner (N) and sorted out a new vw thermo housing and stat. Chucked the throttle body on too, just waiting for the boost switch to come back from a mate off Club G40 (calibrated to 6 psi) . Ordered a fair few bits off the eBay and stuff from ECP but will update with them when its all here

(http://i137.photobucket.com/albums/q236/etches69/132795F1-59DA-452C-B8B1-BEF3804F2B58-587-0000002CE30F3295_zps627d9974.jpg)
Title: Re: Etches G40 (2)
Post by: Andy on April 02, 2013, 09:59:12 am
Nice clean engine!
Title: Re: Etches G40 (2)
Post by: Etches on April 02, 2013, 03:15:42 pm
Cheers Andy, too bad the dizzy isn't coming up clean enough. It's not meant to be a show car so I'm happy :) , although the actual shell its going in isn't the best haha
Title: Re: Etches G40 (2)
Post by: Etches on April 04, 2013, 07:11:25 pm
Todays updates;

Recent purchases, which also includes some BP8EVX NGK Plugs

(http://i137.photobucket.com/albums/q236/etches69/A065CF27-F15C-4F4D-99B3-E2FBAB90DC05-1173-0000007361C743B4_zps669370f2.jpg)

Race fuel pump, Bosh Lambda, Spal Performance 11" Slimline fan, then service bits.

Had to make some brackets for the new fan, used the metal from the slam panel I had going spare.

(http://i137.photobucket.com/albums/q236/etches69/435EEA4C-33D4-4488-9C5F-E1F03B4CCBCA-1173-0000007359211EF9_zpse5edbb02.jpg)

Also painted the radiator brace bar I got of Dan Knight a while back which will be going on

(http://i137.photobucket.com/albums/q236/etches69/817CA39B-021D-4B2B-AE98-B2AC6522F5AB-1173-000000735D51C912_zpsa5566d39.jpg)

Then heatwrapped my downpipe which was an absolute mission by myself, the cable ties supplied wern't long enough for 2.5" downpipe so I used wire intially then used jubilee clips to secure it well

(http://i137.photobucket.com/albums/q236/etches69/E19BD29D-B2CE-48F7-A35D-9D0B15431CBB-1173-0000007366698754_zpsc71bb7af.jpg)

(http://i137.photobucket.com/albums/q236/etches69/73E8AD4A-1B61-4DF4-B8FB-E348F92884A0-1173-000000736A2D5DE8_zps39af5fb0.jpg)

(http://i137.photobucket.com/albums/q236/etches69/e67b0cef-4f48-4536-b634-e48b4fba625c_zps1232332a.jpg)

The dye from the wrap after I had soaked it went everywhere, good thing its water based tbh!
Title: Re: Etches G40 (2)
Post by: metz on April 04, 2013, 08:47:25 pm
your'e making a decent job of this. look forward to seeing the finished article.
Title: Re: Etches G40 (2)
Post by: Etches on April 07, 2013, 10:01:40 pm
Yesterdays update as Club G wasnt working;

Todays had a fair 8 hours plus work,

(http://i137.photobucket.com/albums/q236/etches69/B77C668A-ADB8-4D8B-B1C2-BAF23AE93B13-3114-00000174DCF0368E_zpsc2f079a7.jpg)

(http://i137.photobucket.com/albums/q236/etches69/70BD65C1-A765-4E02-8145-BC1ABF0A297F-3114-00000174E15A065C_zps9a8f9e6a.jpg)

Flywheel with new bolts clutch then gearbox on in front of the motor,

Engine in

(http://i137.photobucket.com/albums/q236/etches69/1BBDDD26-3D3E-40AA-9047-708678045F99-3114-00000174E5FDEBC2_zpsae27e892.jpg)

(http://i137.photobucket.com/albums/q236/etches69/355DB6F4-CBC4-433E-A982-F556380B365D-3114-00000174EA1DEE68_zps12633ac8.jpg)

Subframe and everything on underneath bar the downpipe, that and the turbo will get chucked on tomorrow
(http://i137.photobucket.com/albums/q236/etches69/BC799C4D-3764-4B5A-B2AB-C016829CD2D8-3114-00000174F6C6A374_zpsc0101537.jpg)




Today's :



After a trek in the peaks came home and fitted a small slot of work in;

(http://i137.photobucket.com/albums/q236/etches69/8851391C-C96A-41B6-B9D7-FCB50F40099D-3665-000001B67852B49F_zps2eeb65e1.jpg)

Turbo went on

(http://i137.photobucket.com/albums/q236/etches69/B4C11D10-7F3D-40AD-96CE-64B85F07003E-3665-000001B67C050F24_zpscfc595e4.jpg)

(http://i137.photobucket.com/albums/q236/etches69/0B38ABC7-0FAD-44DE-8798-1A916A453ABE-3665-000001B684DDD990_zpsbc0dea46.jpg)

Then dropped her down , first time since oct . Just need a few more bits before shes running.

(http://i137.photobucket.com/albums/q236/etches69/E6FD64E5-F9B4-427A-9741-70109C82F38B-3665-000001B68D2BBF96_zpsf8ce9751.jpg)

(http://i137.photobucket.com/albums/q236/etches69/3D9B6A22-3C79-4A85-8714-4F0F7E35F738-3665-000001B691894B5C_zps45a47f17.jpg)
Title: Re: Etches G40 (2)
Post by: Etches on April 14, 2013, 09:17:34 pm
 Todays updates,

New racing fuel pump and inline filter comparison

(http://i137.photobucket.com/albums/q236/etches69/F362FE48-EF1D-4594-90BE-F90709ACA187-699-0000004F071DB091_zpsbccfa536.jpg) (http://s137.photobucket.com/user/etches69/media/F362FE48-EF1D-4594-90BE-F90709ACA187-699-0000004F071DB091_zpsbccfa536.jpg.html)

New Header tank

(http://i137.photobucket.com/albums/q236/etches69/1086EDD5-2343-4107-A932-E12956E5C289-699-0000004F0C476BC2_zps050401e7.jpg) (http://s137.photobucket.com/user/etches69/media/1086EDD5-2343-4107-A932-E12956E5C289-699-0000004F0C476BC2_zps050401e7.jpg.html)

Sorted out the Rest of the boost piping and switch etc

(http://i137.photobucket.com/albums/q236/etches69/78EB2780-711B-4F90-93A4-48655040FD03-699-0000004F11970519_zps54a9dbae.jpg) (http://s137.photobucket.com/user/etches69/media/78EB2780-711B-4F90-93A4-48655040FD03-699-0000004F11970519_zps54a9dbae.jpg.html)

New fuel stuff on

(http://i137.photobucket.com/albums/q236/etches69/3538ACD4-36FD-4593-B0FE-88B1601F239A-699-0000004F0234910F_zps138d24eb.jpg) (http://s137.photobucket.com/user/etches69/media/3538ACD4-36FD-4593-B0FE-88B1601F239A-699-0000004F0234910F_zps138d24eb.jpg.html)

Its ready run although I chucked some coolant in and it pissed out the thermo housing so I'm going to get a new oring tomorrow
Title: Re: Etches G40 (2)
Post by: DKnight on April 16, 2013, 09:45:56 pm
great read this, only just seen it!

what fuel pump did you go for?

Title: Re: Etches G40 (2)
Post by: Etches on April 16, 2013, 10:00:08 pm
Cheers Dan!! I hope yours is sorted soon. I went for the Sytec 250BHP pump off eGay

http://www.ebay.co.uk/itm/SYTEC-MOTORSPORT-LINE-HIGH-PRESSURE-INJECTION-FUEL-PUMP-250BHP-MLR-GB-/400457498932?_trksid=p5197.m1992&_trkparms=aid%3D111000%26algo%3DREC.CURRENT%26ao%3D1%26asc%3D14%26meid%3D7010512680499394653%26pid%3D100015%26prg%3D1006%26rk%3D1%26sd%3D400457498932%26
Title: Re: Etches G40 (2)
Post by: Etches on April 18, 2013, 09:58:57 pm
Small update, went to start her up today and appears the starter motor I had spare is fooked. Another buy needed cos kays Polo had my G40 one!

Fitted a magnetic sump plug

(http://i137.photobucket.com/albums/q236/etches69/E8039C06-67EE-4F3A-A254-DDEB3911951C-1106-0000007BC0A907E2_zps0ee82fa2.jpg) (http://s137.photobucket.com/user/etches69/media/E8039C06-67EE-4F3A-A254-DDEB3911951C-1106-0000007BC0A907E2_zps0ee82fa2.jpg.html)
Title: Re: Etches G40 (2)
Post by: Etches on April 28, 2013, 09:34:37 pm
Right, not updated this in a while as I've been so busy!

Got her running after changing the starter motor, sounded ok a little smoky but the oil pressure light came on.

Then this happend ;

(http://i137.photobucket.com/albums/q236/etches69/AA137549-3690-429B-A66D-674A0B4E30F7-2386-000000F7BDD8992F_zps3efddd96.jpg) (http://s137.photobucket.com/user/etches69/media/AA137549-3690-429B-A66D-674A0B4E30F7-2386-000000F7BDD8992F_zps3efddd96.jpg.html)

stripped the t-piece threads, ordered a VDO one to replace it from vw heritage.

Was shitting myself thinking everything had gone to pot as my oil pressure gauge read terrible figures. Nath managed to get a mechanical

pressure tester which had readings of 85psi when cold at 18psi warm, so that cheered me up.

So wen't to start her and drive away but I couldn't engage the clutch, assumed it was the self adjusting clutch so got a manually adjustable one.

Still couldn't engage the clutch, this was 10AM on thursday and I was due to leave for Big Bang on friday.

Decided that the only route for the problem was to take the gearbox off (90 mins later , subframe, drive shafts, exhaust engine mounts, gearbox and clutch plate) were off and I had put the friction plate on the wrong way wrong !!!

So Swapped the clutch plate round, changed the foobared release bearing too and chucked it all back together in 5 hours and after un seizing the rear brakes the G had its maiden voyage!

(http://i137.photobucket.com/albums/q236/etches69/null_zps6b690f50.jpg) (http://s137.photobucket.com/user/etches69/media/null_zps6b690f50.jpg.html)

Only have the boost kept at 0.5 bar with the actuator for the run in period, managed 50 miles driving around before the trip down to big bang.

(http://i137.photobucket.com/albums/q236/etches69/null_zpsa79b6644.jpg) (http://s137.photobucket.com/user/etches69/media/null_zpsa79b6644.jpg.html)

(http://i137.photobucket.com/albums/q236/etches69/null_zps96e7c4ac.jpg) (http://s137.photobucket.com/user/etches69/media/null_zps96e7c4ac.jpg.html)

Also picked up this for an absolute bargin, just need to get 2 x 0.5mm injectors for it!

(http://i137.photobucket.com/albums/q236/etches69/null_zps3ce37850.jpg) (http://s137.photobucket.com/user/etches69/media/null_zps3ce37850.jpg.html)
Title: Re: Etches G40 (2)
Post by: gaz g40 on April 29, 2013, 09:05:55 am
Awesome job man car look brilliant nice tidy engine bay aswell
Title: Re: Etches G40 (2)
Post by: Etches on May 02, 2013, 07:08:32 pm
Cheers Gaz means alot man!

(https://fbcdn-sphotos-c-a.akamaihd.net/hphotos-ak-ash3/941963_10151584698183699_450377942_n.jpg)

Nice pic from last weekend
Title: Re: Etches G40 (2)
Post by: gaz g40 on May 02, 2013, 07:22:02 pm
No probs dude. You from sheffield? Think i saw you two year ago at elsecar show
Title: Re: Etches G40 (2)
Post by: Jester on May 02, 2013, 08:49:24 pm
been looking forward to some full car photos to be put up, as said looks awesome, amazing job on the bay too.
Title: Re: Etches G40 (2)
Post by: Etches on May 14, 2013, 10:15:15 am
After a brain fart whilst chucking the vac pipes together I'd plugged the BOV pre throttle which had been restricting the boost for the 500 miles i'd done so far( Cheers Andy). I've cranked the actuator rod up and swapped the vac pipes over. Now seeing around 0.9 bar so a little tweaking is needed. The map is far better after turning the boost up and swapping the pipes over, still a little blip of leaness 20% throttle but its pretty decent for an off the shelf one!

One of my rear top mounts popped through the rear turret so I needed to sort that out the other day, just used some bits off the old suspension so that was all good. Still got the oil leak from the oil cooler sandwich plate but I've ordered a thermostatic one now so that can go on in 100 miles with the oil and filter swap.

All I can say is that I nearly shit myself when the boost went up to 0.9 bar haha, feels wrong having a polo with the amount of power its got lol, cant imagine what 200+ would feel like . Needs the tracking sorting out again and some more bits ordering but I'm too busy with uni and that finishes in 2 weeks!
Title: Re: Etches G40 (2)
Post by: Etches on May 21, 2013, 09:19:11 pm
Cleaned the car for the lowdown meet (Y)

(http://i137.photobucket.com/albums/q236/etches69/null_zps07a0fd74.jpg) (http://s137.photobucket.com/user/etches69/media/null_zps07a0fd74.jpg.html)

(http://i137.photobucket.com/albums/q236/etches69/null_zps66e8cfb5.jpg) (http://s137.photobucket.com/user/etches69/media/null_zps66e8cfb5.jpg.html)

(http://i137.photobucket.com/albums/q236/etches69/null_zpsbc553b08.jpg) (http://s137.photobucket.com/user/etches69/media/null_zpsbc553b08.jpg.html)

(http://i137.photobucket.com/albums/q236/etches69/4e5d6435-6381-4ffc-abc7-febc5ff8ba92_zps94ae1ca7.jpg) (http://s137.photobucket.com/user/etches69/media/4e5d6435-6381-4ffc-abc7-febc5ff8ba92_zps94ae1ca7.jpg.html)
Title: Re: Etches G40 (2)
Post by: Etches on July 10, 2013, 11:52:48 am
Right then, not updated this for ages as I've been so busy finishing uni exams, dissertation getting it through MOT etc so I'll get you right up to date.

Mot Time came the week after uni finished, this was the emmissions...

(http://i137.photobucket.com/albums/q236/etches69/null_zps7848eec9.jpg) (http://s137.photobucket.com/user/etches69/media/null_zps7848eec9.jpg.html)

Also failed on a couple other bits including steering rack boot, wipers, bulb and horn.

Managed to sort all them out other than the emissions so was all good for a bit until I could sort that problem out.

Next came the splitting of my oil cooler line

(http://i137.photobucket.com/albums/q236/etches69/null_zpsfd3228eb.jpg) (http://s137.photobucket.com/user/etches69/media/null_zpsfd3228eb.jpg.html)

Fecking shit, never buy a cheap one off ebay even if it does have braided hoses and more rows for cheaper than the mocal version!

My road loves me...

(http://i137.photobucket.com/albums/q236/etches69/null_zps85b0b8b2.jpg) (http://s137.photobucket.com/user/etches69/media/null_zps85b0b8b2.jpg.html)

The p-slot wheels I've had on my car for a while were just a stepping stone to let me get the wheels I actually wanted. Impulse came me and a couple of mates went to fetch these...

(http://i137.photobucket.com/albums/q236/etches69/null_zps42a678d8.jpg) (http://s137.photobucket.com/user/etches69/media/null_zps42a678d8.jpg.html)

All of em had 4 coats of paint and maybe one layer of powder coat, I attempted to remove the paint...

(http://i137.photobucket.com/albums/q236/etches69/null_zps5f38dde6.jpg) (http://s137.photobucket.com/user/etches69/media/null_zps5f38dde6.jpg.html)

(http://i137.photobucket.com/albums/q236/etches69/null_zps675468e5.jpg) (http://s137.photobucket.com/user/etches69/media/null_zps675468e5.jpg.html)

(http://i137.photobucket.com/albums/q236/etches69/null_zps9a1bfd8d.jpg) (http://s137.photobucket.com/user/etches69/media/null_zps9a1bfd8d.jpg.html)

Nitromors is completely shat, I spent hours on em and still couldn't get the finish I wanted.

A quick conversation with a local lad led to me taking them to BatchGlow, shot and powder £30 a wheel.

(http://i137.photobucket.com/albums/q236/etches69/null_zpsaf8b2deb.jpg) (http://s137.photobucket.com/user/etches69/media/null_zpsaf8b2deb.jpg.html)

Which looked completely sick. I got lucky with these as they were advertised as 4x98 et 20 M05s but they actually fit 4x100 and have the vw centre bore !

Heres a comparison of the offset difference between my old set and the new..

(http://i137.photobucket.com/albums/q236/etches69/null_zpsfeafdc8a.jpg) (http://s137.photobucket.com/user/etches69/media/null_zpsfeafdc8a.jpg.html)

As the offset was 18mm further outwards I needed to raise the coils up to see what the deal was with fitting. Mk1 rear coils need modifying slightly so the working travel of the adjustability isn't to low so these were sorted off Kiz

(http://i137.photobucket.com/albums/q236/etches69/null_zps7fcc985d.jpg) (http://s137.photobucket.com/user/etches69/media/null_zps7fcc985d.jpg.html)

Difficult to fit when you are chucking a few things on the thread of the coil strut , took a couple of days but it got sorted eventually,

A trip to my mates garage a couple of fridays ago enabled us to sort the timing, CO emissions, solder some wiring (my terrible rushed version needed redoing) and fitting a new blue temp sender. Managed to get the emissions through which is decent and it runs better now!

After that got the tyres with new valves all sorted and fitted (Y)

(http://i137.photobucket.com/albums/q236/etches69/null_zpsb92a9b64.jpg) (http://s137.photobucket.com/user/etches69/media/null_zpsb92a9b64.jpg.html)

(http://i137.photobucket.com/albums/q236/etches69/null_zpsbc802670.jpg) (http://s137.photobucket.com/user/etches69/media/null_zpsbc802670.jpg.html)

(http://i137.photobucket.com/albums/q236/etches69/null_zps888e8324.jpg) (http://s137.photobucket.com/user/etches69/media/null_zps888e8324.jpg.html)

(http://i137.photobucket.com/albums/q236/etches69/null_zps9b59f231.jpg) (http://s137.photobucket.com/user/etches69/media/null_zps9b59f231.jpg.html)

Also I've got some other bits and bobs to sort, including some new seats, relocating both battery and washer bottle, and this strut brace Stinky Pete made for me.

(http://i137.photobucket.com/albums/q236/etches69/null_zpsadb1b1cd.jpg) (http://s137.photobucket.com/user/etches69/media/null_zpsadb1b1cd.jpg.html)

Weld in for the harnesses to be attached to. Just needs a good clean now before fuelled society and bugjam!
Title: Re: Etches G40 (2)
Post by: Etches on July 12, 2013, 02:56:23 pm
Bit of a better angle

(http://i137.photobucket.com/albums/q236/etches69/null_zps482093e3.jpg)
Title: Re: Etches G40 (2)
Post by: z3i on July 12, 2013, 03:26:13 pm
They look awesome! Really like them, suit the car so well! And refurbs at that price?! Bargain!!
car is looking good man :)
you turned the boost up yet?
Title: Re: Etches G40 (2)
Post by: Etches on July 12, 2013, 04:01:27 pm
Cheers man, had the boost at a bar for a while now! Just need to sort the mist (order the jets n bits) before I can sort turning it up to 22-23 psi! Will be sending off my spare ecu for a bigger sensor and ppp map. Hopefully sorted for vw action
Title: Re: Etches G40 (2)
Post by: gaz g40 on July 13, 2013, 09:30:34 pm
Nice work dude. U gunna bugjam a take it then? Gunna be runnin up the strip? Am off in my passat as gees at body shop :(
Title: Re: Etches G40 (2)
Post by: NeilG40 on July 13, 2013, 09:38:49 pm
Nice work dude. U gunna bugjam a take it then? Gunna be runnin up the strip? Am off in my passat as gees at body shop :(

Which bodyshop have you used, I thinking about finally getting mine back on the road but it could do with a respray and some rust sorting out?
Title: Re: Etches G40 (2)
Post by: gaz g40 on July 14, 2013, 09:20:43 am
DC paintworks in doncaster mate. Fair priced and always busy with work which means hea got a good rep :) where u based?
Title: Re: Etches G40 (2)
Post by: NeilG40 on July 14, 2013, 09:22:43 am
About 4 doors down from your house ;D
Title: Re: Etches G40 (2)
Post by: Etches on July 16, 2013, 10:07:26 am
Just a few pics from fueled society

(http://i137.photobucket.com/albums/q236/etches69/null_zps1990def9.jpg) (http://"http://s137.photobucket.com/user/etches69/media/null_zps1990def9.jpg.html")

(http://i137.photobucket.com/albums/q236/etches69/null_zps7ee8fd20.jpg) (http://"http://s137.photobucket.com/user/etches69/media/null_zps7ee8fd20.jpg.html")

(http://i137.photobucket.com/albums/q236/etches69/null_zpsd94e5f1c.jpg) (http://"http://s137.photobucket.com/user/etches69/media/null_zpsd94e5f1c.jpg.html")

a fuzzy one from the lowdown meet!

(http://i137.photobucket.com/albums/q236/etches69/null_zps9d55abae.jpg) (http://"http://s137.photobucket.com/user/etches69/media/null_zps9d55abae.jpg.html")
Title: Re: Etches G40 (2)
Post by: Etches on July 22, 2013, 05:13:09 pm
Lowdown meet, by  my mate Fraser

(http://i137.photobucket.com/albums/q236/etches69/null_zpsf03bc6e5.jpg)
Title: Re: Etches G40 (2)
Post by: Alexiskayak_7 on July 23, 2013, 12:22:57 pm
It's great etches!!!
I'm lovin it with the black mo's
Title: Re: Etches G40 (2)
Post by: Etches on August 11, 2013, 07:05:52 pm
Cheers man!

Did some work on this at the weekend, finally got round to fitting some parts I've had in the cellar for a while.

Got a mate to weld me some shizzle together (Y)

(http://i137.photobucket.com/albums/q236/etches69/null_zps927bcbf8.jpg) (http://s137.photobucket.com/user/etches69/media/null_zps927bcbf8.jpg.html)

Got the brace made up by a mate by Stinky Pete , was a little short but still fit. My mate Bradders TIG welder had fun

(http://i137.photobucket.com/albums/q236/etches69/null_zps95b92789.jpg) (http://s137.photobucket.com/user/etches69/media/null_zps95b92789.jpg.html)

Wanted one to stiffen up the back end and to mount harnesses to.

Got some seats cheap as an inbetween , ended up chopping the frames down as my head touched the roof.

(http://i137.photobucket.com/albums/q236/etches69/null_zpse3686ce5.jpg) (http://s137.photobucket.com/user/etches69/media/null_zpse3686ce5.jpg.html)

Need to spray the frames up, but lobbed em in all the same.

(http://i137.photobucket.com/albums/q236/etches69/null_zps3e6242cb.jpg) (http://s137.photobucket.com/user/etches69/media/null_zps3e6242cb.jpg.html)

Needed harness mount points in the centre  so had to take all the crap out first, no rust holes yet!

(http://i137.photobucket.com/albums/q236/etches69/null_zps67744599.jpg) (http://s137.photobucket.com/user/etches69/media/null_zps67744599.jpg.html)

and the new OMP mounts

(http://i137.photobucket.com/albums/q236/etches69/null_zps3d11cc47.jpg) (http://s137.photobucket.com/user/etches69/media/null_zps3d11cc47.jpg.html)

Just need to sort some exterior surface rust before Leeds now!
Title: Re: Etches G40 (2)
Post by: Jester on August 18, 2013, 04:09:43 pm
Nice to meet you on the Saturday, didn't get to catch up with you Sunday, but was cool to see your g40 on the stand, looked sweet.

got a photo;
(http://farm8.staticflickr.com/7310/9536486583_fb60120f9f_b.jpg)
Title: Re: Etches G40 (2)
Post by: Etches on August 19, 2013, 02:57:30 pm
Must have been early doors you popped up to my car dude as it had the bonnet open for 90% of the day! Annoying that I missed you and didn't see Pete either! Yours looks immaculate  ;D
Title: Re: Etches G40 (2)
Post by: Jester on August 20, 2013, 02:27:33 pm
yea spotted it straight away, I got to have a good nosey under the bonnet as came back for a second look later haha, looked nice in there, never seen a turbo'd one in the flesh but can tell you've put alot of work in!

I never saw Pete either haha
Title: Re: Etches G40 (2)
Post by: Etches on August 20, 2013, 02:48:30 pm
Still needs a fair amount sorting out, I mainly wish I'd properly cleaned and painted the bay with the engine out! Plenty of stuff to be doing out over winter though. If only the body work was as immaculate as yours  :o
Title: Re: Etches G40 (2)
Post by: z3i on August 20, 2013, 03:22:41 pm
No ones car is as clean as Jesters! Infact its probably cleaner than when it rolled off the production line!!
Title: Re: Etches G40 (2)
Post by: Etches on August 28, 2013, 02:23:21 pm
Just cleaned, polished at waxed this for Vw Action. First time its been waxed since my ownership....

(http://i137.photobucket.com/albums/q236/etches69/null_zps69cbcbf5.jpg)

(http://i137.photobucket.com/albums/q236/etches69/null_zpsa0c6e920.jpg)

(http://i137.photobucket.com/albums/q236/etches69/null_zps3748d7c2.jpg)

(http://i137.photobucket.com/albums/q236/etches69/null_zps094f52d1.jpg)
Title: Re: Etches G40 (2)
Post by: Etches on August 29, 2013, 03:31:51 pm

After the final layer of Poorboys Natty wax strawberry mmmmmmmm strawberrrys


(http://i137.photobucket.com/albums/q236/etches69/null_zpsfd20a3f0.jpg)
Title: Re: Etches G40 (2)
Post by: Etches on August 29, 2013, 08:15:03 pm
Current spec sheet with a little missed off thats at home in the pipeline, ps never add stuff up

1992 Mk2f Polo G40 Alpine White
Chassis:
   Polo Performance Parts Stage 3 Sub frame including Wishbone conversion, Rose Joints and rear engine mount.
   Front Coilover Conversion with TA Technics
   Rear Coilovers Raceland with 1” Nylon spacer
   Bonrath Camber adjustable Polyurethane top mounts
   Powerflex Polybushes Inner and Outer TCA bushes
   Custom Rear Strutbrace TIG welded
   G40 Steering rack with Damper
   G40 239 vented Disc Brakes
   Compomotive M05s alloy wheels 14 x 6 et 20 with Falken 195/45/14 tyres
   Tuner Hex Wheel bolts
Engine:
   Wossner 77mm Forged Pistons (2mm overbore and decked)
   Full rebuild including; Mahle bearings, Febi Oil pump, Chain and Crank seals
   Head rebuild including; Stem Seals, Cam seal, 3- angle valve cut, pressure test and skim
   Newman Turbo 268/268 Camshaft
   Clutch – Helix Motorsport Paddle Clutch
   G40 ATV Gearbox
   K03 Turbo including Custom braided hoses and return feed to sump
   Forge Adjustable Actuator
   Ported GT Inlet manifold
   Pit Stop Developments 51mm G40 Throttle Body
   Custom Tubular Turbo Manifold
   Turbo downpipe (heat wrapped) leading to a 2.5” stainless 1 box system with custom mounts EUK
   SPAL Slim line Fan
   Custom Alloy Catch tank
   G60 Green injectors with PPP Map #G40008 utilizing 6psi Boost switch (circa 180bhp)
   Forge 008p Dump Valve
   Custom 420bhp Front Mount Intercooler with blue Silicon 57mm Boost Pipe
   Jabba Motorsport Induction Filter
   Sytec Racing Fuel Pump
   Magnetic Sump Plug
Interior:
   Cobra Racing Bucket seats with custom mounts
   OMP Harness Mounts
   Rally Design Oil Temp, Oil Pressure Gauges
   AEM Wideband Air/Fuel Gauge
   Tim Turbo Boost Gauge
   Factory black roof lining, sun visors, leather gaiter and carpet.
   Black GT Door Cards with Audi Window winders.
   G40 160 Clocks, Leather Gear Knob and Steering Wheel
Shell/Bodywork:
   De-Locked Passenger and Driver handles
   H4 OSRAM Night breaker Bulbs
   Clear Indicators with Silva Tech bulbs
   Badge less Grill and Pressed Metal Plates
   Front and Rear Original G40 Badges
   Re-painted smoothed wings
   G40 rear arches
   Mk2 Polo Coupe Front Arches
   Re-painted Boot Lid
   G40 Rear Lights
   Clifford Proximity Alarm with Immobilizer and central FOB locking,
Title: Re: Etches G40 (2)
Post by: Jimmy B on September 11, 2013, 11:09:01 am
Now thats some serious specs!
Title: Re: Etches G40 (2)
Post by: z3i on September 14, 2013, 04:47:02 pm
Whats your rocker cover off mate? id like one in gloss black :)
Title: Re: Etches G40 (2)
Post by: Etches on September 17, 2013, 09:17:10 pm
Mk2 alloy rocker Talor

Small Update,

Raid snap off and OMP Trecento 300mm wheel.

(http://i137.photobucket.com/albums/q236/etches69/null_zps2e4ac11a.jpg)

(http://i137.photobucket.com/albums/q236/etches69/null_zps168ecbd1.jpg)

It's the start of an OMP covered interior hopefully.
Title: Re: Etches G40 (2)
Post by: Etches on October 03, 2013, 07:28:25 pm
Few updates;

Two new Stack gauges, I will be getting Oil Temperature and Oil pressure ones shortly. Also heavy duty connection block, 150 amp fuse holder with fuse and battery terminals. All from here http://www.vehicle-wiring-products.eu which is a really decent website for all your electrical needs. Battery is going to be relocated in the boot when I manage to find a decent priced box for it.

(http://i137.photobucket.com/albums/q236/etches69/null_zps4aa76183.jpg)

Moved the AFR into the heater vent so I could use the pod for the new boost gauge.

(http://i137.photobucket.com/albums/q236/etches69/null_zps049071b8.jpg)

Drove to Bury the other night and collected two Alpine white doors and an Alpine bonnet. Need to sort out the central locking before swapping them over but it should tidy up the currently rusty looking doors.

(http://i137.photobucket.com/albums/q236/etches69/null_zpsd6c04267.jpg)

A quick one of the stack volts gauge. If anyone has a boss rubber cover laying around gimmmie a shout as I need one!

(http://i137.photobucket.com/albums/q236/etches69/null_zps514f9f32.jpg)
Title: Re: Etches G40 (2)
Post by: Etches on October 07, 2013, 09:03:42 am
New panels, going to be sorted out over the winter months for spring freshness next year.

(http://i137.photobucket.com/albums/q236/etches69/null_zps3991a62c.jpg) (http://s137.photobucket.com/user/etches69/media/null_zps3991a62c.jpg.html)

Didn't realise how bright these are

(http://i137.photobucket.com/albums/q236/etches69/null_zpsbac84cc6.jpg) (http://s137.photobucket.com/user/etches69/media/null_zpsbac84cc6.jpg.html)

bright like a christmas tree   :o
Title: Re: Etches G40 (2)
Post by: Etches on October 08, 2013, 05:41:02 pm
Managed to scoop a facebook competition prize from here ;http://www.dirtyjoks.co.uk/

(http://i137.photobucket.com/albums/q236/etches69/null_zps593b4dd3.jpg)

Used the Orchard Autocare Perfection product, smells awesome and produces a really good shine!


(http://i137.photobucket.com/albums/q236/etches69/null_zps945f71cd.jpg)

(http://i137.photobucket.com/albums/q236/etches69/null_zps87fd8c8d.jpg)

Paints all ready, just need to sort the trims the day before GTI Fest
Title: Re: Etches G40 (2)
Post by: Etches on October 10, 2013, 03:30:30 pm
Update;

Polo's having textured bumpers it's a nightmare to keep them looking properly black, Haslam mentioned this stuff so hopefully it lasts a while. Saying that I've only heard good things about it.

(http://i137.photobucket.com/albums/q236/etches69/null_zps47e5d784.jpg)

It's been a couple of months in the making but I've finally got all the pieces I needed to relocate the battery to the boot.

(http://i137.photobucket.com/albums/q236/etches69/null_zps38caa7da.jpg)

This is the kit car alloy battery tray which is finished in crackle black, seriously light weight and had 8 mounting points so it's fixed solid in the boot.

(http://i137.photobucket.com/albums/q236/etches69/null_zpsf0df7e3e.jpg)

Used a dual 25mm connection block to join the bay wiring to the new 25mm wire I had to go the battery. Can see my brown battery tray (from the rust) which needs addressing at some point. I wrapped over the wire a few times with insulation tape to squeeze the wire into the hole I had drilled in the bulkhead, now its fixed solid so no rubbing hopefully.

(http://i137.photobucket.com/albums/q236/etches69/null_zps8ee5ad3f.jpg)

I used a mega fuse holder with a 150amp fuse as this would blow before the wire would melt (200amp), bitch is that 5m of the cable just wasnt enough to route the wire round the side of the boot so at some point I'll have to extend it from the fuse terminal so it shouldn't be too messy. The battery tray came with a ratchet strap so it's held firmly down now, fingers crossed this solves a major rattle I had up front from the rusty battery tray. I did want the battery behind the passenger seat but the frames I'm using at the minute won't budge any further, at some point in the future I will fix the buckets properly and decide wether I want to move it further.

(http://i137.photobucket.com/albums/q236/etches69/null_zpsd7942ed8.jpg)
Title: Re: Etches G40 (2)
Post by: Etches on October 20, 2013, 01:46:18 pm
Had a mission on tuesday through the peaks to Crewe 150 mile round trip in the G after the weekend going down to santa pod. Finally broke the 3k barrier since the rebuild. First issues appeared with the G on the way home. Speedo stopped working (dodgy cable) which had fluctuation in readings for a while so that was expected to go pop at some point, lost 1st and 2nd gear (I assumed it to be a loose gearbox mount bolt as having a subframe tends to work the bolt out) and one of the exhaust hangers snapped on the backbox. Sorted the mount issue the following day by putting a 10mm longer bolt through it, then went down to exhausts uk to sort my backbox (25 year garuntee)

(http://i137.photobucket.com/albums/q236/etches69/null_zpsf1807072.jpg)

(http://i137.photobucket.com/albums/q236/etches69/null_zps9f0b8ffa.jpg)

(http://i137.photobucket.com/albums/q236/etches69/null_zpseaaec7ee.jpg)

They ended up doubling one mount and lowering the exhaust a bit to lose a bit of the rigidity which caused the failure. They also braced the backbox to strengthen it against flexing at the joint. More updates paydayish
Title: Re: Etches G40 (2)
Post by: Etches on May 01, 2014, 10:40:53 pm
So ... exhale.

This hasnt been updated since October wtf! Shit loads of bits n bobs has happened since then and I've managed to keep some pics.

Due to the impending job/house move decided after a couple of trips buckets wern't a viable option, back to the standard in my opinion;

(http://i137.photobucket.com/albums/q236/etches69/1aabec2f-cf9f-4255-b348-fe1763be231f_zps89013db4.jpg) (http://s137.photobucket.com/user/etches69/media/1aabec2f-cf9f-4255-b348-fe1763be231f_zps89013db4.jpg.html)

With the need to get rid of shit for me moving away from Sheff, ended up doing a swap instead which went against the idea of selling stuff haha (cheers Martin)

(http://i137.photobucket.com/albums/q236/etches69/435A3D1D-1F0F-40EE-A163-20C4D52FC089_zpsyyhwxyns.jpg) (http://s137.photobucket.com/user/etches69/media/435A3D1D-1F0F-40EE-A163-20C4D52FC089_zpsyyhwxyns.jpg.html)

Briefly took a moment to look how far I'd come in 2 years of ownership

(http://i137.photobucket.com/albums/q236/etches69/B5901B5B-6BC1-4D0F-8CA4-938534CEC7B9_zpsdehb32hi.jpg) (http://s137.photobucket.com/user/etches69/media/B5901B5B-6BC1-4D0F-8CA4-938534CEC7B9_zpsdehb32hi.jpg.html)

(http://i137.photobucket.com/albums/q236/etches69/066D63A4-1155-476E-9035-33CAB56C64D7_zpstk7y54xb.jpg) (http://s137.photobucket.com/user/etches69/media/066D63A4-1155-476E-9035-33CAB56C64D7_zpstk7y54xb.jpg.html)

After a trial fit I decided that seeing as I had a sunroof, I couldnt have a full cage anyway without sorting that issue or sitting the seats on the actual floorpan. So the plan was to sort out a decent half cage out,

(http://i137.photobucket.com/albums/q236/etches69/FB542C2B-D9BE-4205-A20B-6C9250A6F889_zpsmawq6lwn.jpg) (http://s137.photobucket.com/user/etches69/media/FB542C2B-D9BE-4205-A20B-6C9250A6F889_zpsmawq6lwn.jpg.html)

Whilst this was happening began 40 hours of solid labour of moving and driving for 1200 miles in this beast

(http://i137.photobucket.com/albums/q236/etches69/CAD84EE3-6728-4D56-925D-22F8BD4B4257_zps23rwlnw5.jpg) (http://s137.photobucket.com/user/etches69/media/CAD84EE3-6728-4D56-925D-22F8BD4B4257_zps23rwlnw5.jpg.html)

So now I live in Cumbria and work here

(http://i137.photobucket.com/albums/q236/etches69/43966D07-F7F5-4E5F-B2D8-88DE537EC5A2_zpsiilexqxg.jpg) (http://s137.photobucket.com/user/etches69/media/43966D07-F7F5-4E5F-B2D8-88DE537EC5A2_zpsiilexqxg.jpg.html)

The G found its way to a new home, a little bit better than a really steep road where its had multiple gearbox and engine swaps

(http://i137.photobucket.com/albums/q236/etches69/AB3F19DE-0B23-4B40-A73D-DC1ACA564876_zpsag5tbz25.jpg) (http://s137.photobucket.com/user/etches69/media/AB3F19DE-0B23-4B40-A73D-DC1ACA564876_zpsag5tbz25.jpg.html)

Old leads were looking manky on the inside so treated the G to a set of magnecores

(http://i137.photobucket.com/albums/q236/etches69/36F7FA32-03F0-460B-9DD5-A8C6A9893172_zpsogxrsjun.jpg) (http://s137.photobucket.com/user/etches69/media/36F7FA32-03F0-460B-9DD5-A8C6A9893172_zpsogxrsjun.jpg.html)

With the Cage ready to go in it went down the other afternoon, where a nightmare went down

(http://i137.photobucket.com/albums/q236/etches69/416C6E14-51E9-4616-BC18-0706986B0422_zpsl22lpitx.jpg) (http://s137.photobucket.com/user/etches69/media/416C6E14-51E9-4616-BC18-0706986B0422_zpsl22lpitx.jpg.html)

(http://i137.photobucket.com/albums/q236/etches69/26C0E5DF-40E9-420E-8F53-4EA294D2AF20_zpsrbnnosee.jpg) (http://s137.photobucket.com/user/etches69/media/26C0E5DF-40E9-420E-8F53-4EA294D2AF20_zpsrbnnosee.jpg.html)

Hello fire and fuel lines! Good thing my fire extinguisher was to hand as my mate .Brad. put it out fairly quickly, just a bit of scorched paint and had to bridge the broken fuel lines which was very lucky really.

Turned out like this - Cheers .Brad. awesome skills man

(http://i137.photobucket.com/albums/q236/etches69/DB53F872-42F0-4A74-AFA4-885E0F53D3D1_zps3vsvdjnq.jpg) (http://s137.photobucket.com/user/etches69/media/DB53F872-42F0-4A74-AFA4-885E0F53D3D1_zps3vsvdjnq.jpg.html)

Spotted this in Brads unit and had to have it, now got the bottle nicely in the boot!

(http://i137.photobucket.com/albums/q236/etches69/51D4ED13-FA69-4857-8BE2-3E4CCB4B3D5F_zpsbgcchhe8.jpg) (http://s137.photobucket.com/user/etches69/media/51D4ED13-FA69-4857-8BE2-3E4CCB4B3D5F_zpsbgcchhe8.jpg.html)

This is currently how I'm looking, already started to re route wiring to tidy it up and I've ordered some tesa tape to re cover them too. Got some plans for before Bujam and before Action too.

(http://i137.photobucket.com/albums/q236/etches69/3A7931AE-5F58-4DF7-8B16-AA70B78CAAD0_zpsb1r4q41m.jpg) (http://s137.photobucket.com/user/etches69/media/3A7931AE-5F58-4DF7-8B16-AA70B78CAAD0_zpsb1r4q41m.jpg.html)

It's not running properly at the min, shitting itself at 10psi so got loads of things to pick through over the next coming weeks aswell as sorting some stuff for the MOT. Worst part is the fact the pedal box  has bent and is touching the steering column, got a spare which Brad is guna stitch for me to try and prevent future failures aswell as plating the bulkhead.

(http://i137.photobucket.com/albums/q236/etches69/6EB9F26C-31B1-44C2-926F-FAAE23B49FEE_zpsnl5op1dj.jpg) (http://s137.photobucket.com/user/etches69/media/6EB9F26C-31B1-44C2-926F-FAAE23B49FEE_zpsnl5op1dj.jpg.html)

Till next time.
Title: Re: Etches G40 (2)
Post by: Etches on May 04, 2014, 08:47:10 pm
Had a fair old crack this weekend on the car, pedal box has been bent and getting worse for a while. Managed to source a used one, so had the ball ache of getting the old en off. This was the issue found with the old box;

(http://i137.photobucket.com/albums/q236/etches69/13A9D432-C003-4958-819B-2B1C7E2B9D56_zpskz9zn1rf.jpg) (http://s137.photobucket.com/user/etches69/media/13A9D432-C003-4958-819B-2B1C7E2B9D56_zpskz9zn1rf.jpg.html)

(http://i137.photobucket.com/albums/q236/etches69/189B3660-AFF4-42AD-B39F-089A74FABECC_zpssgde5tgl.jpg) (http://s137.photobucket.com/user/etches69/media/189B3660-AFF4-42AD-B39F-089A74FABECC_zpssgde5tgl.jpg.html)

(http://i137.photobucket.com/albums/q236/etches69/77290394-55D0-4D90-8090-80F4409F483F_zpso7yfi5ku.jpg) (http://s137.photobucket.com/user/etches69/media/77290394-55D0-4D90-8090-80F4409F483F_zpso7yfi5ku.jpg.html)

Cracked around the spot welds, was rubbing on the steering column too which wasn't pleasant.

Used one got stitch welded around the join on one side,

(http://i137.photobucket.com/albums/q236/etches69/C2D2F3E4-B547-4611-9D62-1D7D9C116741_zps81rf95nz.jpg) (http://s137.photobucket.com/user/etches69/media/C2D2F3E4-B547-4611-9D62-1D7D9C116741_zps81rf95nz.jpg.html)


Extra bracing and triangulation to stop it bending/ cracking again

(http://i137.photobucket.com/albums/q236/etches69/E78E3266-0821-4E77-B591-1D72C979EBB6_zpsm0kngyvd.jpg) (http://s137.photobucket.com/user/etches69/media/E78E3266-0821-4E77-B591-1D72C979EBB6_zpsm0kngyvd.jpg.html)

(http://i137.photobucket.com/albums/q236/etches69/A02E0BD8-E415-4C5C-895C-322659C0CCB0_zpslz4deryf.jpg) (http://s137.photobucket.com/user/etches69/media/A02E0BD8-E415-4C5C-895C-322659C0CCB0_zpslz4deryf.jpg.html)

Feels much better now so I can concentrate on the mods before bugjam. Its defo a job for winter sorting the full bias pedal box set up!

Cheers for the welding again Bradley!
Title: Re: Etches G40 (2)
Post by: Etches on May 26, 2014, 10:34:00 pm
Mot is coming up so it prompted a bit of work, well that and this.....

(http://i137.photobucket.com/albums/q236/etches69/89ED0D5E-D7A8-438F-8D75-426967B3FD4E_zpsacnhjoki.jpg) (http://s137.photobucket.com/user/etches69/media/89ED0D5E-D7A8-438F-8D75-426967B3FD4E_zpsacnhjoki.jpg.html)

Happened just after a 220 mile trip so thank god i was 2 streets away from my house and I could drive in first gear there haha! Fingers crossed it was caused by the warping of the pedal box so a new cable should see the problem fixed till winter!

First job for the Mot was the handbrake/ braking system. Its been shite for a while so it needed a refurb. Driver side wasnt too bad.

(http://i137.photobucket.com/albums/q236/etches69/C7884020-44BE-4A25-B439-66E6B1163030_zpsrb1hzyie.jpg) (http://s137.photobucket.com/user/etches69/media/C7884020-44BE-4A25-B439-66E6B1163030_zpsrb1hzyie.jpg.html)

(http://i137.photobucket.com/albums/q236/etches69/3087AEDA-A70E-4209-9FD4-7AD11CBBC65D_zpsnfstkuoe.jpg) (http://s137.photobucket.com/user/etches69/media/3087AEDA-A70E-4209-9FD4-7AD11CBBC65D_zpsnfstkuoe.jpg.html)

(http://i137.photobucket.com/albums/q236/etches69/7E5EDF50-9F44-4B58-A26B-8A2CC56D4617_zpssya9xxfz.jpg) (http://s137.photobucket.com/user/etches69/media/7E5EDF50-9F44-4B58-A26B-8A2CC56D4617_zpssya9xxfz.jpg.html)

Mintex shoes and new handbrake cables. Came to the passenger side, wasnt so pretty...

(http://i137.photobucket.com/albums/q236/etches69/3CD2FB0C-E1C0-4668-A72A-CA2D23F88024_zpscq5wme2f.jpg) (http://s137.photobucket.com/user/etches69/media/3CD2FB0C-E1C0-4668-A72A-CA2D23F88024_zpscq5wme2f.jpg.html)

Clearly the cylinder is shot (hence a very spongey brake pedal and shite handbrake) . Ordered a 11mm brake pipe spanner to sort these as no where in Barrow sells it! Waiting for that to sort a new cylinder out and bleed the system.

After chucking the washer bottle in the boot, takes a while for the fluid to reach the jets. Got a tiguan 1 way valve to sort that issue

(http://i137.photobucket.com/albums/q236/etches69/4C056767-50BB-4E52-85EE-07DEE94E9ED1_zpskwehwfps.jpg) (http://s137.photobucket.com/user/etches69/media/4C056767-50BB-4E52-85EE-07DEE94E9ED1_zpskwehwfps.jpg.html)

Then a school boy mod, got a section of boot to delete this properly but sorted a bung for the time being, that and swap my rear sprayed vw badge for a black plastic one.

(http://i137.photobucket.com/albums/q236/etches69/94CA0568-664E-47A5-A790-F020EBCF8FBB_zps3aj6amrg.jpg) (http://s137.photobucket.com/user/etches69/media/94CA0568-664E-47A5-A790-F020EBCF8FBB_zps3aj6amrg.jpg.html)

Update soon for the front brake assembly!
Title: Re: Etches G40 (2)
Post by: AdzCM on May 27, 2014, 02:51:10 pm
Did you ever get the 10psi boost problem sorted?

Thanks a bunch for the pics of the welding job on the pedal. Think mine is on the way out. I have the paddle clutch in and it has to be adjusted far too much for it to engage the clutch fully [no slack in clutch fork I.e. release bearing touching pressure plate all the time] - also my brake pedal moves to the side a bit as I press the clutch pedal [read that Taylor said this happens when the pedal box is shot]

Is yours fine now with the extra triangular supports welded in? Must get this done!

Adrian
Title: Re: Etches G40 (2)
Post by: Etches on May 27, 2014, 09:53:10 pm
Its odd , it only does it part throttle then going to full. When I fully plant it, its fine. Needs a new map and properly setting up. Pedal box has been fine pal, just hope it doesnt keep snapping cables!


Update :)

Old v new

(http://i137.photobucket.com/albums/q236/etches69/237E10E8-41F7-4196-9123-DE4B4FC11D6B_zpsmyftonfx.jpg) (http://s137.photobucket.com/user/etches69/media/237E10E8-41F7-4196-9123-DE4B4FC11D6B_zpsmyftonfx.jpg.html)

All together on the pass side

(http://i137.photobucket.com/albums/q236/etches69/CA4F2D82-0A6D-4244-AA66-7E9A31F00C08_zpsldsnumii.jpg) (http://s137.photobucket.com/user/etches69/media/CA4F2D82-0A6D-4244-AA66-7E9A31F00C08_zpsldsnumii.jpg.html)

Managed to get some more new parts , Corrado 22mm master cylinder

(http://i137.photobucket.com/albums/q236/etches69/66876E96-BAE2-4765-8B4E-714A11568439_zps5yhmzqj0.jpg) (http://s137.photobucket.com/user/etches69/media/66876E96-BAE2-4765-8B4E-714A11568439_zps5yhmzqj0.jpg.html)

Chucked the brake reservoir in the dish washer then assembled!

(http://i137.photobucket.com/albums/q236/etches69/D03A12EB-3B58-45EA-AA75-1A4F19A3BC35_zpsstuuzc15.jpg) (http://s137.photobucket.com/user/etches69/media/D03A12EB-3B58-45EA-AA75-1A4F19A3BC35_zpsstuuzc15.jpg.html)

Got some new toys  (H)
(http://i137.photobucket.com/albums/q236/etches69/AD32E360-914F-4CA6-BBE2-D51FFF0A172F_zps5pn6ancn.jpg) (http://s137.photobucket.com/user/etches69/media/AD32E360-914F-4CA6-BBE2-D51FFF0A172F_zps5pn6ancn.jpg.html)
Title: Re: Etches G40 (2)
Post by: z3i on May 27, 2014, 09:55:56 pm
http://i1042.photobucket.com/albums/b426/p1rik/image_zps03289657.jpg

The way forward, definitely doing this september
yeah Adrian your pedal box is probably on its way out, they normally have a little movement side to side, but if your brake pedal moves a fair amount when depressing the clutch its about time
your paddle clutch will annihilate it
when i had mine (toms now) in i went through two pedal boxes in about 6 months!! wrecks them! on my third with a normal clutch now! and even that snapped a cable in france! so box came back off, never found the problem in the end. but not long until pedal box :D

Also wheres that rado master cylinder from tom? looks good quality :)

Taylor
Title: Re: Etches G40 (2)
Post by: Etches on May 28, 2014, 06:55:24 am
I'm defo doing mine this winter aswell Taylor, cba with the standard one as its still mega heavy now. The above picture is a decent solution but I still havnt found the place to pick the OMP pedal set up! Plus mine actually needs a paddle anyways so may aswell do it.

Its a VW in box part I got off Sam a couple of years ago dude, really nice part actually. I'm guna re do the whole braking system this winter already got a rear disc convertion , willwood fronts with a bias pedal box etc. This is mainly for the MOT and summer tanning!
Title: Re: Etches G40 (2)
Post by: z3i on May 28, 2014, 07:31:46 am
Wilwood and pedal box will be pretty formidable!!!
Omp don't make pedal boxes, the one in the pic is and opm universal box notice how similar they are :P
Title: Re: Etches G40 (2)
Post by: Etches on May 31, 2014, 09:58:19 pm
Been messing about with the G again today.

Old
(http://i137.photobucket.com/albums/q236/etches69/FAA8CEA6-2BE7-4308-B555-F6556585FB1D_zpszc2ut0mi.jpg) (http://s137.photobucket.com/user/etches69/media/FAA8CEA6-2BE7-4308-B555-F6556585FB1D_zpszc2ut0mi.jpg.html)

New
(http://i137.photobucket.com/albums/q236/etches69/1B952E16-FABF-48DF-B8C6-F931036B902C_zpsyncrzrw1.jpg) (http://s137.photobucket.com/user/etches69/media/1B952E16-FABF-48DF-B8C6-F931036B902C_zpsyncrzrw1.jpg.html)

Used an Ezi Bleed kit, which I might add is awesome. Looked like the fluid hadnt been changed in years

(http://i137.photobucket.com/albums/q236/etches69/08A9E1EB-E499-45BC-8E0E-D856D4D81495_zpshcda50pu.jpg) (http://s137.photobucket.com/user/etches69/media/08A9E1EB-E499-45BC-8E0E-D856D4D81495_zpshcda50pu.jpg.html)

Really really nasty!

Went over a significant amount of the loom today too, included lengthening a few bits to tidy it up out the way. Tesa tape is absolutely banging, looks the business

(http://i137.photobucket.com/albums/q236/etches69/6C45A05B-F129-4644-AB60-FB0947DD3EF7_zps5m0clflf.jpg) (http://s137.photobucket.com/user/etches69/media/6C45A05B-F129-4644-AB60-FB0947DD3EF7_zps5m0clflf.jpg.html)
Title: Re: Etches G40 (2)
Post by: Etches on June 01, 2014, 08:51:07 pm
Todays job was general tidying up, sorted the horn wiring. Found two blown fuses, stopped an oil leak at a sender then gave the old girl a full wash.

(http://i137.photobucket.com/albums/q236/etches69/18A4A64F-336D-412F-BCC5-AD3317C151FD_zpso7ib9xss.jpg) (http://s137.photobucket.com/user/etches69/media/18A4A64F-336D-412F-BCC5-AD3317C151FD_zpso7ib9xss.jpg.html)
Title: Re: Etches G40 (2)
Post by: Jester on June 01, 2014, 09:33:06 pm
Looking really nice Tom, I like the cage setup
Title: Re: Etches G40 (2)
Post by: Etches on June 03, 2014, 10:05:44 pm
Cheers dude, wish I was positive..

MOT booked for monday. Started prodding around a few rusty holes and it got out of hand lol

1st spot
(http://i137.photobucket.com/albums/q236/etches69/8C99B730-1C10-42CA-B212-E72415383BE2_zpse2258jys.jpg) (http://s137.photobucket.com/user/etches69/media/8C99B730-1C10-42CA-B212-E72415383BE2_zpse2258jys.jpg.html)

(http://i137.photobucket.com/albums/q236/etches69/4A4C191D-3E1F-415E-B98D-F7643153D2EB_zpsvjdkhrpm.jpg) (http://s137.photobucket.com/user/etches69/media/4A4C191D-3E1F-415E-B98D-F7643153D2EB_zpsvjdkhrpm.jpg.html)

(http://i137.photobucket.com/albums/q236/etches69/E1A66151-68D4-43F0-B152-308E35459222_zpsumnjlosx.jpg) (http://s137.photobucket.com/user/etches69/media/E1A66151-68D4-43F0-B152-308E35459222_zpsumnjlosx.jpg.html)

Oops!

The rest..

(http://i137.photobucket.com/albums/q236/etches69/C8375BF3-88E0-4A8D-99C0-AE33F4625A4D_zpsaz44aasi.jpg) (http://s137.photobucket.com/user/etches69/media/C8375BF3-88E0-4A8D-99C0-AE33F4625A4D_zpsaz44aasi.jpg.html)

(http://i137.photobucket.com/albums/q236/etches69/9798C014-E4F6-4C7D-B49B-CC84E178F70C_zpsnttgi3js.jpg) (http://s137.photobucket.com/user/etches69/media/9798C014-E4F6-4C7D-B49B-CC84E178F70C_zpsnttgi3js.jpg.html)

(http://i137.photobucket.com/albums/q236/etches69/419B0537-BF85-4350-9847-E0820BA50B0C_zpsl1cvof2z.jpg) (http://s137.photobucket.com/user/etches69/media/419B0537-BF85-4350-9847-E0820BA50B0C_zpsl1cvof2z.jpg.html)

Plenty of late nights required this week.. ie needs to be finished thursday night!  (N)
Title: Re: Etches G40 (2)
Post by: higgo on June 03, 2014, 10:31:30 pm
Bet your gutted but also glad you started the poking...... least now you can stop it before it gets worse. Love this car, makes me actually like my white mk3 as I can imagine its as cool as this (It really isnt!)
Title: Re: Etches G40 (2)
Post by: JoeH on June 03, 2014, 10:54:03 pm
I always tend to fill the sills full of some decent waxoil on any polo's i've had, as holes in sill gets em all eventually, imo.
Hope you get it done.
Title: Re: Etches G40 (2)
Post by: Etches on June 04, 2014, 10:14:01 am
Cheers Higgo, I've only ever owned alpine white mk3s since 2007 haha!

Joe man, only problem with doing that is that if you put waxoil on the inside is that its flammable, dont really fancy another fire at least till next year haha!

Will get some pics up tnite how I get on, not welded before so its guna be some good practise haha!
Title: Re: Etches G40 (2)
Post by: Etches on June 05, 2014, 12:19:27 am
Straight 5 hour stretch tnite!

Marked out danger zones

(http://i137.photobucket.com/albums/q236/etches69/3CEE53D5-EF70-4DFB-A53A-D21E0C5D6C11_zpswnttg8wl.jpg) (http://s137.photobucket.com/user/etches69/media/3CEE53D5-EF70-4DFB-A53A-D21E0C5D6C11_zpswnttg8wl.jpg.html)

All the shit cut out

(http://i137.photobucket.com/albums/q236/etches69/D640E25F-82CA-4816-858B-84B6ABF57E93_zpsbgjlw6ms.jpg) (http://s137.photobucket.com/user/etches69/media/D640E25F-82CA-4816-858B-84B6ABF57E93_zpsbgjlw6ms.jpg.html)

Metal cut

(http://i137.photobucket.com/albums/q236/etches69/30FCE600-EA84-4C00-86F1-78122D52989E_zpsyu178ooe.jpg) (http://s137.photobucket.com/user/etches69/media/30FCE600-EA84-4C00-86F1-78122D52989E_zpsyu178ooe.jpg.html)

Managed to do two

(http://i137.photobucket.com/albums/q236/etches69/6A1FED01-5E7B-4F55-89A0-DAA303893C21_zpsfrce1dmv.jpg) (http://s137.photobucket.com/user/etches69/media/6A1FED01-5E7B-4F55-89A0-DAA303893C21_zpsfrce1dmv.jpg.html)

My appreciation for welders has gone up ten fold, I practised for about half an hour pre welding on the car and managed to find the setting I preferred. Only managed to blow a few holes but sorted em, not pretty but its solid as fuck.

Will get ground back tomorrow undersealed , high build then painted. Should manage to get to bed normal time hopefully!
Title: Re: Etches G40 (2)
Post by: Etches on June 05, 2014, 10:15:02 pm
Yeah , I've not enjoyed this job haha. What a ballache!!

Sorted the final two, the small one was an absolute bastard. Ran out of gas which made it difficult!!

(http://i137.photobucket.com/albums/q236/etches69/981CD91A-3790-493C-BB12-5F1EE8B1D995_zpsjfxukmm4.jpg) (http://s137.photobucket.com/user/etches69/media/981CD91A-3790-493C-BB12-5F1EE8B1D995_zpsjfxukmm4.jpg.html)

All cleaned and undersealed,

(http://i137.photobucket.com/albums/q236/etches69/EBD4903B-E04E-4A22-9789-F1F229467766_zpsiqlqcovz.jpg) (http://s137.photobucket.com/user/etches69/media/EBD4903B-E04E-4A22-9789-F1F229467766_zpsiqlqcovz.jpg.html)
Title: Re: Etches G40 (2)
Post by: Etches on June 11, 2014, 06:08:45 pm
Got the MOT monday , flew through with minors for a little bit of crumpled sill from jacking up and an oil drip.

(http://i137.photobucket.com/albums/q236/etches69/F012CB70-DE32-4872-9934-F9FE5DAE080C_zpsublyfhb2.jpg) (http://s137.photobucket.com/user/etches69/media/F012CB70-DE32-4872-9934-F9FE5DAE080C_zpsublyfhb2.jpg.html)

On the way home to sheff lost all boost, got a massive blow from the turbo manifold-turbo section. Guna whip that off to check , fingers crossed its just the gasket! Polo show next week so best be an easy fix.
Title: Re: Etches G40 (2)
Post by: Etches on June 11, 2014, 07:37:18 pm
Just spent the last half an hour to find this,

(http://i137.photobucket.com/albums/q236/etches69/17BA46B5-AF0C-4C4C-A577-860A013ECC01_zpszhotknln.jpg) (http://s137.photobucket.com/user/etches69/media/17BA46B5-AF0C-4C4C-A577-860A013ECC01_zpszhotknln.jpg.html)

(http://i137.photobucket.com/albums/q236/etches69/11759541-776A-433A-B705-3ED3304A5E54_zpsjdzpfiaq.jpg) (http://s137.photobucket.com/user/etches69/media/11759541-776A-433A-B705-3ED3304A5E54_zpsjdzpfiaq.jpg.html)

(http://i137.photobucket.com/albums/q236/etches69/E9B762A7-FA9D-4F8E-BF51-3C362045C5CC_zpsoeeoh0ud.jpg) (http://s137.photobucket.com/user/etches69/media/E9B762A7-FA9D-4F8E-BF51-3C362045C5CC_zpsoeeoh0ud.jpg.html)

The old tubular - cast argument comes to mind lads!! Guna take it somewhere to get welded up properly. Bloody annoying!
Title: Re: Etches G40 (2)
Post by: z3i on June 11, 2014, 07:40:47 pm
Ah Dayum!! Message Phil J lol
Title: Re: Etches G40 (2)
Post by: PeteG40 on June 11, 2014, 08:46:53 pm
when i saw the pics all i thought was 'flange' haha
Title: Re: Etches G40 (2)
Post by: Andy on June 11, 2014, 08:52:57 pm
Where did you get your oil drain line from please? Looks decent.

Make sure you mark up the exact orientation of the flange in relation to the manifold, don't want to find the downpipe etc. doesn't fit properly after you get it re-welded!
Title: Re: Etches G40 (2)
Post by: Etches on June 11, 2014, 10:06:52 pm
Just looked through 30 pages of Pm's Andy and couldnt find the chap off here who I bought em from! Do you run a gasket on the feed?

Fortunately there is a weld bead which shows the orientation but Ill Sharpie marker it to be sure!

Its lasted 6k miles so not very good at all, fortunately I've just nabbed those poly engine mounts so hopefully that stops the engine moving as much.
Title: Re: Etches G40 (2)
Post by: z3i on June 11, 2014, 11:57:06 pm
when i saw the pics all i thought was 'flange' haha

Such a child....
Title: Re: Etches G40 (2)
Post by: Etches on June 14, 2014, 07:07:21 pm

Managed to find some lad in Barrow to sort my manifold using a beast of a tig

(http://i137.photobucket.com/albums/q236/etches69/3433B8C1-85F9-4B1F-9942-0C13EE670F22_zpsf4kqocht.jpg) (http://s137.photobucket.com/user/etches69/media/3433B8C1-85F9-4B1F-9942-0C13EE670F22_zpsf4kqocht.jpg.html)

He did a really good job welding from both sides!

(http://i137.photobucket.com/albums/q236/etches69/C4C7464A-E14E-4686-9E3C-C47831258C7A_zpsyze0e4pg.jpg) (http://s137.photobucket.com/user/etches69/media/C4C7464A-E14E-4686-9E3C-C47831258C7A_zpsyze0e4pg.jpg.html)
Title: Re: Etches G40 (2)
Post by: Etches on June 17, 2014, 08:16:42 pm
Been a really rushed week as I'm going to the polo show on friday, sorted the manifold

(http://i137.photobucket.com/albums/q236/etches69/C93F2D8C-AD54-48B2-8484-448E23310437_zpsv7gnv4ng.jpg) (http://s137.photobucket.com/user/etches69/media/C93F2D8C-AD54-48B2-8484-448E23310437_zpsv7gnv4ng.jpg.html)

All back together, had a difficulty bolting the turbo to the manifold as the welds had given less room for nuts when fully tight.

(http://i137.photobucket.com/albums/q236/etches69/4F8501EF-A0F3-4174-B89F-057CB759B5FC_zpspm9iozfl.jpg) (http://s137.photobucket.com/user/etches69/media/4F8501EF-A0F3-4174-B89F-057CB759B5FC_zpspm9iozfl.jpg.html)

Happy I snapped these up last week, higher shore engine mount bushes and powder coated mounts

(http://i137.photobucket.com/albums/q236/etches69/D8FB41CD-F354-4FB4-8380-E0F0142DDEBB_zpssftydwl3.jpg) (http://s137.photobucket.com/user/etches69/media/D8FB41CD-F354-4FB4-8380-E0F0142DDEBB_zpssftydwl3.jpg.html)

Hopefully these should minimise the engine rocking.

Also managed to put the driver sill trim back on

(http://i137.photobucket.com/albums/q236/etches69/E214BBF7-6365-4B9D-85FB-C7FE74187DC1_zpshpa5ltub.jpg) (http://s137.photobucket.com/user/etches69/media/E214BBF7-6365-4B9D-85FB-C7FE74187DC1_zpshpa5ltub.jpg.html)

Might get round to chucking those mounts on and give it a wash before friday
Title: Re: Etches G40 (2)
Post by: PeteG40 on June 17, 2014, 09:00:29 pm
Is drivers one in right looks upside down compared to others
Title: Re: Etches G40 (2)
Post by: Yoof on June 18, 2014, 09:16:28 am
Just looked through 30 pages of Pm's Andy and couldnt find the chap off here who I bought em from! Do you run a gasket on the feed?

Fortunately there is a weld bead which shows the orientation but Ill Sharpie marker it to be sure!

Its lasted 6k miles so not very good at all, fortunately I've just nabbed those poly engine mounts so hopefully that stops the engine moving as much.

It will happen again- a poor design.

If you look at a good manifold design, the flange will be oversized to allow the pipe/collector to protrude through it, giving more surface area for stresses to be distributed through, and generally more than one face to weld.

I'd be tempted to brace the turbo dude, and revise anything that's bolted to it (exhaust downpipe, boost pipes etc)

Least you've got it fixed for Polo Show  ;D
Title: Re: Etches G40 (2)
Post by: z3i on June 18, 2014, 10:21:45 am
When you going pedal box? Decided which to go for?
Title: Re: Etches G40 (2)
Post by: Etches on June 18, 2014, 11:28:16 pm
PeteG40- Turns out the driver one was upside down!

Pete - Yeah I know dude, since I've had it on its been nothing but trouble. All of the turbo braces I've seen have been quite extravagant designs. Ill have a think and see whats available to brace the turbo to. If it starts costing too much though would make me start to re evaluate the manifold itself! If it lasts till sept I'll be happy as it will be having an overhaul this winter.

If I were to source another manifold I'd struggle to rule out getting a roller bearing turbo though.

Taylor - I'm desperate to sort the pedal box man its happened again, even with all the bracing. Scrubbing on the steering column again ffs . I'm thinking a willwood floor mounted one. Going to be a lot of work to sort out though!


Got busy today. Changed all of the engine mounts for the poly ones and gave the bay a once over

(http://i137.photobucket.com/albums/q236/etches69/2014-06/4BFCC92F-B613-4EA7-8F0B-DC5F47CF0EF0_zps6mgvio7k.jpg) (http://s137.photobucket.com/user/etches69/media/2014-06/4BFCC92F-B613-4EA7-8F0B-DC5F47CF0EF0_zps6mgvio7k.jpg.html)

Then managed to give the outside a quick wash

(http://i137.photobucket.com/albums/q236/etches69/2014-06/AA961F6A-62FA-470D-9FC0-1A5C8FA55A81_zpsv7yekz8o.jpg) (http://s137.photobucket.com/user/etches69/media/2014-06/AA961F6A-62FA-470D-9FC0-1A5C8FA55A81_zpsv7yekz8o.jpg.html)

I've filled the boot with loads of polo stuff to sell at polo show :)
Title: Re: Etches G40 (2)
Post by: z3i on June 18, 2014, 11:56:59 pm
It's cracked again already!!! Shit! That sucks!!

I wanted floor mounted but the floor goes up at quite an angle
Yeah whatever we do its going to require some serious surgery! Mines got to last my trip to Wales next week and then she's getting stripped and fully rebuilt ready for Switzerland 2015 :)
Title: Re: Etches G40 (2)
Post by: Etches on June 19, 2014, 12:10:28 am
Tbf I'm prob going to chop and reweld the floor and maybe the bulkhead. Get some thicker plate on it too. All good fun I suppose.

Mine will have done about 8k miles and it will get a freshen up haha
Title: Re: Etches G40 (2)
Post by: Andy on June 19, 2014, 06:06:44 am
Is your battery tray and bulkhead behind the servo solid? Mine wasn't, and that's why my pedal box used to move!
Title: Re: Etches G40 (2)
Post by: Etches on July 04, 2014, 01:43:06 pm
Sorry Andy just spotted your comment, well the battery tray itself is a little rusty and lets droplets of water through. So i'd take a stab in the dark at the fact its structural integrity is lower than it should be. Its probably a contributing factor tbh. Its got to last till action so fingers crossed it doesnt completely go !
Title: Re: Etches G40 (2)
Post by: Etches on July 04, 2014, 08:57:12 pm
This is the start of a fairly heft update,

Did loads of little bits like putting a bigger washer bottle pump in as the mk1 golf one wasnt cutting the mustard.  Then had a trip to the Polo Show which I might add really surprised me, had a right laugh!

Jordons abused daily
(http://i137.photobucket.com/albums/q236/etches69/2014-06/498F76B2-84EB-4319-BFC2-F1AFFF00CC60_zpsqjmkz1df.jpg) (http://s137.photobucket.com/user/etches69/media/2014-06/498F76B2-84EB-4319-BFC2-F1AFFF00CC60_zpsqjmkz1df.jpg.html)

Max's bike carb'd g40
(http://i137.photobucket.com/albums/q236/etches69/2014-06/75296316-180D-43DB-B7F2-812651478A08_zps26eioawd.jpg) (http://s137.photobucket.com/user/etches69/media/2014-06/75296316-180D-43DB-B7F2-812651478A08_zps26eioawd.jpg.html)

(http://i137.photobucket.com/albums/q236/etches69/2014-06/0B60899A-9813-4C6E-BE9B-10D75AA63D4A_zpsrrwzvvik.jpg) (http://s137.photobucket.com/user/etches69/media/2014-06/0B60899A-9813-4C6E-BE9B-10D75AA63D4A_zpsrrwzvvik.jpg.html)

It was so hot, paddling pool was needed

(http://i137.photobucket.com/albums/q236/etches69/2014-06/02AAA185-A204-42CA-8556-3950D3CAF4A8_zpswjtmapa0.jpg) (http://s137.photobucket.com/user/etches69/media/2014-06/02AAA185-A204-42CA-8556-3950D3CAF4A8_zpswjtmapa0.jpg.html)

700 miles in a weekend which wasnt too bad! Got plenty of raggage.

Anyways needed some more feeds for the oil so I got another brass vdo tpiece, was a right farce fitting the sender in here
(http://i137.photobucket.com/albums/q236/etches69/2014-07/5B4E22E7-7DD0-4EF6-BA4F-FA53B56EE554_zpsaufvtzu6.jpg) (http://s137.photobucket.com/user/etches69/media/2014-07/5B4E22E7-7DD0-4EF6-BA4F-FA53B56EE554_zpsaufvtzu6.jpg.html)

Nearly completed my collection now

(http://i137.photobucket.com/albums/q236/etches69/2014-07/74897BF2-C57B-46BB-A040-86DA63080AE6_zps9cdfnqxj.jpg) (http://s137.photobucket.com/user/etches69/media/2014-07/74897BF2-C57B-46BB-A040-86DA63080AE6_zps9cdfnqxj.jpg.html)

then a school boy mod for the lads, chrome bonnet struts!
(http://i137.photobucket.com/albums/q236/etches69/2014-07/6CA67407-6463-476E-8D6F-3627D574E8B0_zpswgxibqe8.jpg) (http://s137.photobucket.com/user/etches69/media/2014-07/6CA67407-6463-476E-8D6F-3627D574E8B0_zpswgxibqe8.jpg.html)

Got loads of bits waiting to be done, need to make a few bits so will be an update tomorrow if some parts get delivered.
Title: Re: Etches G40 (2)
Post by: Etches on July 05, 2014, 08:54:49 pm
Bigger update on hold as parts havnt arrived!

Managed a little bit today, sorted the boot which will get sound deadened and then carpet over at some point.

(http://i137.photobucket.com/albums/q236/etches69/C71A4230-4760-40D1-B62A-854DD2407064_zpsshkgzris.jpg) (http://s137.photobucket.com/user/etches69/media/C71A4230-4760-40D1-B62A-854DD2407064_zpsshkgzris.jpg.html)

(http://i137.photobucket.com/albums/q236/etches69/E606A41E-8AEF-4861-B013-E53CB3B785C8_zpsy151e36v.jpg) (http://s137.photobucket.com/user/etches69/media/E606A41E-8AEF-4861-B013-E53CB3B785C8_zpsy151e36v.jpg.html)

Needs another touch up coat but doesnt look half bad, got a bit of overspray but that can get sorted.

Got some powder coated wiper arms which really make a difference

(http://i137.photobucket.com/albums/q236/etches69/6F1764D2-9EA4-4F54-AC3C-BA7BAA6DD12D_zpsesoj9ucs.jpg) (http://s137.photobucket.com/user/etches69/media/6F1764D2-9EA4-4F54-AC3C-BA7BAA6DD12D_zpsesoj9ucs.jpg.html)

Just waiting on parts now before fuelled and bugjam!
Title: Re: Etches G40 (2)
Post by: SamG40 on July 07, 2014, 09:18:16 pm
Does Max live in Sheffield and work on the Wicker? If so if its on bike carbs thats why it sounded so loud when I saw him pull out of his work the other week. I rode past him today whilst he was stood getting something out of the boot if its the same car.

You are making some real progress on this now Tom.
Title: Re: Etches G40 (2)
Post by: Etches on July 08, 2014, 09:41:18 pm
He does Sam! That will have been him lol, it does sound really really nice actually. This is his bay

(http://i137.photobucket.com/albums/q236/etches69/maximus_zpse254ab03.jpg) (http://s137.photobucket.com/user/etches69/media/maximus_zpse254ab03.jpg.html)


Cheers mate, trying to keep up the progress really.

Boot now looking well tidy

(http://i137.photobucket.com/albums/q236/etches69/2014-07/72545FFE-B970-4753-9B52-BA60F07DBB48_zpswceck5rr.jpg) (http://s137.photobucket.com/user/etches69/media/2014-07/72545FFE-B970-4753-9B52-BA60F07DBB48_zpswceck5rr.jpg.html)

Door off

(http://i137.photobucket.com/albums/q236/etches69/2014-07/2CEB27F8-5C2C-4203-9253-632AC9B32917_zpskuoxq7um.jpg) (http://s137.photobucket.com/user/etches69/media/2014-07/2CEB27F8-5C2C-4203-9253-632AC9B32917_zpskuoxq7um.jpg.html)

Transferring central locking motor and gubbins to new doors

(http://i137.photobucket.com/albums/q236/etches69/2014-07/4FD48B77-1DDF-4A6E-97BD-FA29F3A0CA29_zps0xncfjvj.jpg) (http://s137.photobucket.com/user/etches69/media/2014-07/4FD48B77-1DDF-4A6E-97BD-FA29F3A0CA29_zps0xncfjvj.jpg.html)

Title: Re: Etches G40 (2)
Post by: Etches on July 10, 2014, 11:37:40 pm
Door number 1 took an age, first time messing around with locks etc and I unhooked the inner handle to lock by accident. managed to sort it all out and chuck the door and a new wing mirror on. Door number two time came...

(http://i137.photobucket.com/albums/q236/etches69/2014-07/60D152FE-C4DE-49FE-8BC4-AD59370F772E_zpshaijykjq.jpg) (http://s137.photobucket.com/user/etches69/media/2014-07/60D152FE-C4DE-49FE-8BC4-AD59370F772E_zpshaijykjq.jpg.html)

This is supposed to be a new door lol, ground it all back, made a repair patch as this is where the inner swing handle is mount. Welded it and sprayed it up. Everything back together including new winder motor and another wing mirror plus the central locking stuff.

(http://i137.photobucket.com/albums/q236/etches69/2014-07/5DD2B6BA-35E4-41A6-B49E-DBCCB39F9077_zpsv5lpgecx.jpg) (http://s137.photobucket.com/user/etches69/media/2014-07/5DD2B6BA-35E4-41A6-B49E-DBCCB39F9077_zpsv5lpgecx.jpg.html)

Both doors are now on this is the pass side, which is much less rusty just needs a minor fuss

(http://i137.photobucket.com/albums/q236/etches69/2014-07/CEA491B2-FD2F-4BFA-9512-FB16993414F2_zpsdbmd2ufd.jpg) (http://s137.photobucket.com/user/etches69/media/2014-07/CEA491B2-FD2F-4BFA-9512-FB16993414F2_zpsdbmd2ufd.jpg.html)

Managed a quick oil and filter swap before packing up, oil came out pretty mucky after 4.5k miles so I'm glad I changed it all.


Boot all packed for fuelled society this weekend!

(http://i137.photobucket.com/albums/q236/etches69/2014-07/5BEF2746-CB2F-4551-B12D-937DAB31A308_zpsxhvvczav.jpg) (http://s137.photobucket.com/user/etches69/media/2014-07/5BEF2746-CB2F-4551-B12D-937DAB31A308_zpsxhvvczav.jpg.html)
Title: Re: Etches G40 (2)
Post by: Etches on July 16, 2014, 01:37:06 pm
New goodies arrived

(http://i137.photobucket.com/albums/q236/etches69/47F38D8E-3FEF-4A4A-8F41-218DF5E8642B_zpsgj5n3kcu.jpg) (http://s137.photobucket.com/user/etches69/media/47F38D8E-3FEF-4A4A-8F41-218DF5E8642B_zpsgj5n3kcu.jpg.html)

New to old comparison

(http://i137.photobucket.com/albums/q236/etches69/0D92B426-DD84-42DD-97C5-47115B2B0B2A_zpso4pal0ft.jpg) (http://s137.photobucket.com/user/etches69/media/0D92B426-DD84-42DD-97C5-47115B2B0B2A_zpso4pal0ft.jpg.html)

(http://i137.photobucket.com/albums/q236/etches69/D29051C1-0527-44D4-8AD7-BE7B85C4C871_zps9um8wzay.jpg) (http://s137.photobucket.com/user/etches69/media/D29051C1-0527-44D4-8AD7-BE7B85C4C871_zps9um8wzay.jpg.html)

Finally after 2 years fitting my radiator brace bar , comparison between the old/new

(http://i137.photobucket.com/albums/q236/etches69/D3760498-8EE4-4170-9B09-2B3C69D80495_zpsmxmxip8n.jpg) (http://s137.photobucket.com/user/etches69/media/D3760498-8EE4-4170-9B09-2B3C69D80495_zpsmxmxip8n.jpg.html)

All together

(http://i137.photobucket.com/albums/q236/etches69/58918B2A-64F7-42C1-A0EB-B2BE74726B94_zps3slpwd55.jpg) (http://s137.photobucket.com/user/etches69/media/58918B2A-64F7-42C1-A0EB-B2BE74726B94_zps3slpwd55.jpg.html)

(http://i137.photobucket.com/albums/q236/etches69/4BE775E7-AE16-4606-ADC3-03C0F8D298FA_zpsjpoyimxx.jpg) (http://s137.photobucket.com/user/etches69/media/4BE775E7-AE16-4606-ADC3-03C0F8D298FA_zpsjpoyimxx.jpg.html)
Title: Re: Etches G40 (2)
Post by: Etches on August 09, 2014, 10:10:36 am
Minor update, been busy heading up to shows. First Bugjam....

(http://i137.photobucket.com/albums/q236/etches69/222F3EC0-C094-4FCA-8357-62245C543E2A_zpspkrwpl6p.jpg) (http://s137.photobucket.com/user/etches69/media/222F3EC0-C094-4FCA-8357-62245C543E2A_zpspkrwpl6p.jpg.html)

(http://i137.photobucket.com/albums/q236/etches69/A173E070-9817-4117-A106-90AAB38D5350_zpswfbxib8i.jpg) (http://s137.photobucket.com/user/etches69/media/A173E070-9817-4117-A106-90AAB38D5350_zpswfbxib8i.jpg.html)

Cheers to Liam Holloway for those pics!

G40 Rally through the peakdistrict too Tatton Park

(http://i443.photobucket.com/albums/qq157/jezza-3/DSC_1216_zpsplf84qjg.jpg) (http://s443.photobucket.com/user/jezza-3/media/DSC_1216_zpsplf84qjg.jpg.html)

(http://i443.photobucket.com/albums/qq157/jezza-3/DSC_1207_zpsff2jvwis.jpg) (http://s443.photobucket.com/user/jezza-3/media/DSC_1207_zpsff2jvwis.jpg.html)

(http://i443.photobucket.com/albums/qq157/jezza-3/DSC_1209_zpsl9od5nar.jpg) (http://s443.photobucket.com/user/jezza-3/media/DSC_1209_zpsl9od5nar.jpg.html)

Cheers for those James!

Tatton - bonnet lifters have broke already :(

(http://i137.photobucket.com/albums/q236/etches69/499fb3e7-2f59-4eba-8dc9-0bb209f9c22f_zpse8bcf531.png) (http://s137.photobucket.com/user/etches69/media/499fb3e7-2f59-4eba-8dc9-0bb209f9c22f_zpse8bcf531.png.html)

Came home with something I didnt expect. (cheers Pete :) )

(http://i137.photobucket.com/albums/q236/etches69/CDDFEAD8-C306-4840-B75C-D1B9D52C4A50_zpssvjopdrl.jpg) (http://s137.photobucket.com/user/etches69/media/CDDFEAD8-C306-4840-B75C-D1B9D52C4A50_zpssvjopdrl.jpg.html)

Ported polished, jabbsport bigger exhaust valves (BVH) which will be getting sorted by RES with the new guides and stems.

(http://i137.photobucket.com/albums/q236/etches69/4C6986C1-C98F-4C01-AD3E-8F7A58240F7C_zpszbiu2x4m.jpg) (http://s137.photobucket.com/user/etches69/media/4C6986C1-C98F-4C01-AD3E-8F7A58240F7C_zpszbiu2x4m.jpg.html)

(http://i137.photobucket.com/albums/q236/etches69/219AC7DA-0508-4F98-8A8B-E0FC85C80FA9_zpst4z2doqg.jpg) (http://s137.photobucket.com/user/etches69/media/219AC7DA-0508-4F98-8A8B-E0FC85C80FA9_zpst4z2doqg.jpg.html)

Went to clive at Autotronix to get my bigger injectors cleaned and tested

(http://i137.photobucket.com/albums/q236/etches69/F47AEA5B-2BF9-4AA6-8105-5DE80D3A45E8_zps8nw7hzos.jpg) (http://s137.photobucket.com/user/etches69/media/F47AEA5B-2BF9-4AA6-8105-5DE80D3A45E8_zps8nw7hzos.jpg.html)

20 quid for power runs and its only just outside dinnington M1 Jnc 31!

Sorting some bits out for action(from ppp), hopefully in time though!
Title: Re: Etches G40 (2)
Post by: Etches on August 23, 2014, 08:12:16 pm
Been busying around on this before action.

Stuck bonrath poly top mounts on the rear.
(http://i137.photobucket.com/albums/q236/etches69/4CBF724C-1AB3-4EBE-B069-2414F60A4A88_zpshjoehljb.jpg) (http://s137.photobucket.com/user/etches69/media/4CBF724C-1AB3-4EBE-B069-2414F60A4A88_zpshjoehljb.jpg.html)

Throttle body off
(http://i137.photobucket.com/albums/q236/etches69/8F75D9BA-F34F-48F3-90A3-0A32921CF171_zpswlqj8rtt.jpg) (http://s137.photobucket.com/user/etches69/media/8F75D9BA-F34F-48F3-90A3-0A32921CF171_zpswlqj8rtt.jpg.html)

Injectors changed
(http://i137.photobucket.com/albums/q236/etches69/B7B9DD13-8BA7-4188-8DA1-A2E14953B672_zpszpirnneq.jpg) (http://s137.photobucket.com/user/etches69/media/B7B9DD13-8BA7-4188-8DA1-A2E14953B672_zpszpirnneq.jpg.html)

Had a aquamist kit a while, just been collecting new bits including a .3 nozzle, new lines and I've got a filter and right angle on the way. Picked up some devils own meth too which was on offer. Just need to make a bracked for the tank and find a home for the pump and should be good.

(http://i137.photobucket.com/albums/q236/etches69/E20565CD-70F0-431B-8790-0DB71592FDCE_zpskd9dvqtn.jpg) (http://s137.photobucket.com/user/etches69/media/E20565CD-70F0-431B-8790-0DB71592FDCE_zpskd9dvqtn.jpg.html)

Got a new ecu with 1.5 bar map sensor in on the way aswell as a PPP chip to match.
Title: Re: Etches G40 (2)
Post by: Etches on August 25, 2014, 06:53:12 pm
Did a little bit today, still waiting on stuff being delivered  but managed to get some done.

(http://i137.photobucket.com/albums/q236/etches69/D3FEF932-643C-4980-A30C-2B67B3F07556_zpsgctq6uag.jpg) (http://s137.photobucket.com/user/etches69/media/D3FEF932-643C-4980-A30C-2B67B3F07556_zpsgctq6uag.jpg.html)

Pump and boost switch fitted (waiting on right angle nozzle adaptors for the pump)

(http://i137.photobucket.com/albums/q236/etches69/6762A590-1085-4492-B5E1-1EB321E75106_zpsiqcti9p9.jpg) (http://s137.photobucket.com/user/etches69/media/6762A590-1085-4492-B5E1-1EB321E75106_zpsiqcti9p9.jpg.html)

Made a temporary mount for the bottle.

(http://i137.photobucket.com/albums/q236/etches69/43ED71A2-7C30-4901-9951-5C775A63A239_zpskcpwwif8.jpg) (http://s137.photobucket.com/user/etches69/media/43ED71A2-7C30-4901-9951-5C775A63A239_zpskcpwwif8.jpg.html)

Need to crack on ready for thursday!
Title: Re: Etches G40 (2)
Post by: dubstar on August 25, 2014, 08:23:48 pm
Impressive Tom, it's looking a beaut. Envious of all the shows you're getting to. It's my own fault, I need to crack on!
Title: Re: Etches G40 (2)
Post by: Etches on August 27, 2014, 10:18:11 pm
Cheers Ross , I've been busy dude! Off the road in 2 weeks though :)

Tonight's activities, a good few hours went down. Including parts delivery of which 2/5 fit ! Bloody hell!

(http://i137.photobucket.com/albums/q236/etches69/8FCB6750-19EE-494B-AE44-7B4BE06C3BD3_zpstm9iyro9.jpg) (http://s137.photobucket.com/user/etches69/media/8FCB6750-19EE-494B-AE44-7B4BE06C3BD3_zpstm9iyro9.jpg.html)

Stripped the old loom, added a few bits and wrapped that shit up.

(http://i137.photobucket.com/albums/q236/etches69/8D862648-E547-46FF-80DA-83274DF45ED9_zpssaye5srj.jpg) (http://s137.photobucket.com/user/etches69/media/8D862648-E547-46FF-80DA-83274DF45ED9_zpssaye5srj.jpg.html)

Tapped a thread in my boost pipe for the .3mm jet with right angle bend

(http://i137.photobucket.com/albums/q236/etches69/36149F0A-855F-405D-860E-9E426EC44BE0_zpskconh0se.jpg) (http://s137.photobucket.com/user/etches69/media/36149F0A-855F-405D-860E-9E426EC44BE0_zpskconh0se.jpg.html)

Fitted the bottle which had to be altered to avoid the bonnet

(http://i137.photobucket.com/albums/q236/etches69/51D58C15-BDBD-4C7A-8850-328745B45B53_zpsiufuhfj3.jpg) (http://s137.photobucket.com/user/etches69/media/51D58C15-BDBD-4C7A-8850-328745B45B53_zpsiufuhfj3.jpg.html)

Everything is in order now

(http://i137.photobucket.com/albums/q236/etches69/FB487FE6-09F7-4CDB-A07C-24320BFC264B_zpsjdlfiedr.jpg) (http://s137.photobucket.com/user/etches69/media/FB487FE6-09F7-4CDB-A07C-24320BFC264B_zpsjdlfiedr.jpg.html)

(http://i137.photobucket.com/albums/q236/etches69/02BE60FC-9BC9-4F04-813A-CAC5BDE9B59F_zpsqg8enseh.jpg) (http://s137.photobucket.com/user/etches69/media/02BE60FC-9BC9-4F04-813A-CAC5BDE9B59F_zpsqg8enseh.jpg.html)

I've cut it close to the wire, will have to put the chip in the ecu (it's due to be delivered) before setting off tomorrow!
Title: Re: Etches G40 (2)
Post by: JoeH on August 28, 2014, 12:43:24 pm
Did you put new seals on the injectors? if so where the do you get em from?
Title: Re: Etches G40 (2)
Post by: Etches on August 28, 2014, 12:54:47 pm
New orings and pintle caps, got em refurb'd cleaned, tested and posted for £55 from Autotronix. Can post em out to em too, Clive is a really nice guy. Mainly deals with Mx5nuts lot which is where I got his details from.
Title: Re: Etches G40 (2)
Post by: Etches on September 27, 2014, 05:13:49 pm
Right, lets rewind to thursday pre action 28th August. Drove down to sheffield with a massive air leak which was stripped threads on the inlet manifold, swapped it out for a g40 manifold and didnt leak. Was out testing the G at 22psi and had a boost creep which caused it to overboost at 7k rpm . Something went pop , reduced power and temps went crazy...

(http://i137.photobucket.com/albums/q236/etches69/IMG_8439_zps6b8f59ba.jpg) (http://s137.photobucket.com/user/etches69/media/IMG_8439_zps6b8f59ba.jpg.html)

Last thing you needed at 2am day before a show!

(http://i137.photobucket.com/albums/q236/etches69/IMG_8443_zps14e735eb.jpg) (http://s137.photobucket.com/user/etches69/media/IMG_8443_zps14e735eb.jpg.html)

Had a right laugh at Action but needed a recovery the 200 miles home, cheers AA

(http://i137.photobucket.com/albums/q236/etches69/bbecbf57-e685-4f71-a44f-70e3b9de99c4_zps299a5524.jpg) (http://s137.photobucket.com/user/etches69/media/bbecbf57-e685-4f71-a44f-70e3b9de99c4_zps299a5524.jpg.html)
Fast forward to now (I've been on holiday in between)

Head off,

(https://farm4.staticflickr.com/3873/15366801201_cf5d970126_b.jpg) (https://flic.kr/p/ppUSCi)Untitled (https://flic.kr/p/ppUSCi) by t_etches69 (https://www.flickr.com/people/128179653@N02/), on Flickr

(https://farm4.staticflickr.com/3857/15369962145_ce884689b2_b.jpg) (https://flic.kr/p/pqc5gk)  (https://flic.kr/p/pqc5gk) by t_etches69 (https://www.flickr.com/people/128179653@N02/), on Flickr

3rd cylinder

(https://farm4.staticflickr.com/3906/15369960415_3276e53b2a_b.jpg) (https://flic.kr/p/pqc4Kv)  (https://flic.kr/p/pqc4Kv) by t_etches69 (https://www.flickr.com/people/128179653@N02/), on Flickr

Head Gasket - Went in 3 places!

(https://farm4.staticflickr.com/3877/15366798291_0d72943974_b.jpg) (https://flic.kr/p/ppURL8)  (https://flic.kr/p/ppURL8) by t_etches69 (https://www.flickr.com/people/128179653@N02/), on Flickr

Plugs -- ends seem to have burnt significantly shorter

(https://farm4.staticflickr.com/3888/15183261230_43f7714998_b.jpg) (https://flic.kr/p/p8GbA3)  (https://flic.kr/p/p8GbA3) by t_etches69 (https://www.flickr.com/people/128179653@N02/), on Flickr
Title: Re: Etches G40 (2)
Post by: z3i on September 28, 2014, 07:31:50 am
Woah!! It's blow it to pieces! How much boost were you running before it did that?
Did you angle torque the bolts up? If seen head gaskets blow due to people not doing that and the uneven load can cause one to go pretty quick!
That's mad! Though glad it's only a head gasket and nothing worse :)
Was it genuine?
Title: Re: Etches G40 (2)
Post by: Etches on June 26, 2015, 01:02:15 pm
Jesus - Just got the 120 Day warning for posting in here lol! Need to sort my act out.

Been very busy with work amd uni recently so not had much spare time for the G.

Current state it's in , no engine in , no front brakes , no front end ..... lol!

Managed to source some Calibra front calipers, goodridge hoses , grooved golf gti 256 discs and some what look like Yellow Stuff pads, so they will be on by the end of the week hopefully (cheers Martinn!). I've got the full set of Mk4 golf rear calipers to sort too but need a handbrake cable piece first, hopefully manage to get this sorted before it comes back onto the road.

Engine wise , the new BVH has been to Sheffield Engine Services for a skim, new stems and guides, 3 angle cut seats and a pressure test. Also got a new set of tappets for it too when i fetch it so should be nice.

Gearbox, it's out of the car waiting to be pulled apart. Got the diff ready to go in aswell as some other seals which I've collected over the past few months. Also got a custom driveshaft for the drivers side but I need a rattle gun to get the hub nut off or a scaff bar!

The K03s turbo I had sourced turned out to have a crack in the exhaust housing, so thats been off to Midland Turbos for a rebuild, new housing bearings and oil seals. Should boost solid now (fingers crossed).

I've been putting off doing the battery tray for too long now, probably the source of many snapped pedal boxes, so thats the first thing on the list after she's back on wheels. Pics to follow.

Need to get my arse in gear to see it ready for bugjam!

Calibra Calipers , Brembo 256 grooved vented discs, Hel braided lines and EBC yellow stuff pads.

(https://c1.staticflickr.com/1/499/18277539274_b769b7f235_o.jpg) (https://flic.kr/p/tR8aDu)Untitled (https://flic.kr/p/tR8aDu) by thomas etches (https://www.flickr.com/photos/128179653@N02/), on Flickr

(https://c1.staticflickr.com/1/275/18900077145_739e51d52c_o.jpg) (https://flic.kr/p/uN8Qt4)Untitled (https://flic.kr/p/uN8Qt4) by thomas etches (https://www.flickr.com/photos/128179653@N02/), on Flickr

Just sorted the clips out on the calipers and shes back on wheels. Engines been pulled and gearbox off ready to be dismatled!
Title: Re: Etches G40 (2)
Post by: physicsfool on June 29, 2015, 08:43:56 am
Sounds like a decent to do list, I popped the VW11s on and bled the system. Made a world of difference. Maybe see you at VW fest again
Title: Re: Etches G40 (2)
Post by: Etches on June 29, 2015, 10:26:51 pm
Yeah those brakes were decent Martin, these ones seem ok, just getting the clip on was annoying!

Wish I was there this year dude, I'm at Jap Fest this year spotting my next car haha!

Bit of progress

(https://c1.staticflickr.com/1/343/19027309039_bcc0e07b3f_o.jpg)[/url]Untitled (https://flic.kr/p/uZnW5p) by thomas etches (https://www.flickr.com/photos/128179653@N02/)

Engine bay looking a sorry state, going to give it a pressure wash and stitch the chassis legs aswell as doing the Yoofington brace mod.

(https://c1.staticflickr.com/1/300/19187352756_0246394054_o.jpg)[/url]Untitled (https://flic.kr/p/vewcuQ) by thomas etches (https://www.flickr.com/photos/128179653@N02/)

Engine nicely on the stand ready for a fuss over , collecting the head this week. Got a little problem with the pukka oil drain , it bloody leaks! Need to get another one made up, prob will be a few quid :( .

(https://c1.staticflickr.com/1/438/19027308099_916fdbfcf5_o.jpg)[/url]Untitled (https://flic.kr/p/uZnVNc) by thomas etches (https://www.flickr.com/photos/128179653@N02/)

Thought the 256 brakes would fill the wheels a little bit more than they do! Everything needs a clean up though, check that dust out!

(https://c1.staticflickr.com/1/377/19025879438_428c1f7f78_o.jpg)[/url]Untitled (https://flic.kr/p/uZfB77) by thomas etches (https://www.flickr.com/photos/128179653@N02/)

Special Delivery!  8)

(https://c1.staticflickr.com/1/516/19217138431_a7cdc194a2_o.jpg)[/url]Untitled (https://flic.kr/p/vh9RJX) by thomas etches (https://www.flickr.com/photos/128179653@N02/)

Rebuilt K03s new exhaust housing every nut/bolt and seal changed. Even threw in a new actuator which I dont need. Should look nice with a fresh head and cast manifold though. Keep up the motivation!!
Title: Re: Etches G40 (2)
Post by: Yoof on June 30, 2015, 12:24:58 pm
Looks great, when did you move to Australia  ;D
Title: Re: Etches G40 (2)
Post by: Etches on June 30, 2015, 12:37:39 pm
FlickR Problems :( Shall see what I can do haha!
Title: Re: Etches G40 (2)
Post by: Etches on September 15, 2015, 06:51:35 pm
Uni assignment ( 9000 words) handed in which leaves me free till november when I start up again!

First couple of tasks are all structural, stitch both chassis legs in the engine bay plus weld in a yoofington support on the passenger side. Then it's time to plate the bulkhead around the pedal box and replace the battery tray! Pics to come this weekend hopefully!