Club G40 Forum
Club G40 => Photos and videos => Ongoing Projects => Topic started by: POLOMON on November 01, 2012, 11:51:05 am
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Hi All,
Given not many know about my car i thought i may aswell get a build thread up, only with the help of the members on here have i got where i have now! so this is a small thank you and to give you an insight on what i have actually been doing. Ofcourse with any build thread they dont show the stress you go through but hey, im sure you all know what that is like anyway! Would we change it for anything in the world? Well... ye, a nice lottery win and let someone else do the work lol....
So, started off roughly 12 months ago as a 1 lady owner (not great i know) full vw service history (also, not great) VW polo breadvan 1.0 catalyst. Nothing special, discovered tucked away in a small coutry garage by my cousin, quick call to me and i was later on the blower speaking to the garage to see what they knew! Sales chappy wanted ONE THOUSAND POUNDZZZ! Yes, really! Or my corsa and £800 and well, that was taking the piss so i left disheartened. Later my mum found out and got on the line to the guy, god knows what happened but it later got collected for £300 with 12 months tax and MOT which it had neither of when i went asking! lol.
Not alot happened the first few weeks as i was still collecting parts and paying my mum back for actually getting the car, it was a full on impulse buy and well i was caught off guard at the end of the month with no money!
Couple of weeks went by, nothing much changed but i soon ended adding a few bits:
(http://i134.photobucket.com/albums/q89/photo123_2007/Polo/IMG-20120129-00248.jpg)
ended up with abit of this:
(http://i134.photobucket.com/albums/q89/photo123_2007/Polo/IMG-20120131-00262.jpg)
Added some nice wheels in 7 and 8" flavour off Guy (Mclovin) :
(http://i134.photobucket.com/albums/q89/photo123_2007/Polo/IMG-20120205-00269.jpg)
Thinking to myself i wanted a nice tidy 16v hybrid conversion i started tidying my bay out abit, not thinking much into it more working it out as i went:
(http://i134.photobucket.com/albums/q89/photo123_2007/Polo/IMG-20120215-00276.jpg)
Decent steering arm angles achieved also with the coilover conversion :D
(http://i134.photobucket.com/albums/q89/photo123_2007/Polo/IMG-20120215-00278.jpg)
Thinking more with going N/a a custom 2" PipeWerx exhaust was purchased and fitted:
(http://i134.photobucket.com/albums/q89/photo123_2007/Polo/IMG-20120218-00289.jpg)
On the ramps at PipeWerx:
(http://i134.photobucket.com/albums/q89/photo123_2007/Polo/IMG-20120218-00290-1-1.jpg)
Done:
(http://i134.photobucket.com/albums/q89/photo123_2007/Polo/IMG-20120219-00292.jpg)
Found me a bora to compare ride heights, as you do haha:
(http://i134.photobucket.com/albums/q89/photo123_2007/Polo/IMG-20120406-00334.jpg)
At this point i was fairly happy, money was coming in for the 16v conversion and i had a few bits to keep me going until i could afford the fancy bits.
(http://i134.photobucket.com/albums/q89/photo123_2007/Polo/IMG-20120422-00359.jpg)
(http://i134.photobucket.com/albums/q89/photo123_2007/Polo/IMG-20120517-00405.jpg)
Thats where the boredom started and i did this:
(http://i134.photobucket.com/albums/q89/photo123_2007/Polo/IMG-20120520-00417.jpg)
(http://i134.photobucket.com/albums/q89/photo123_2007/Polo/IMG-20120521-00418.jpg)
Then the weight saving started, all sound proofing was removed bar the door bits, never got around to that!
(http://i134.photobucket.com/albums/q89/photo123_2007/Polo/IMG-20120521-00422.jpg)
Got my fuel lines inside and did abit more in the engine bay:
(http://i134.photobucket.com/albums/q89/photo123_2007/Polo/IMG-20120525-00433.jpg)
(http://i134.photobucket.com/albums/q89/photo123_2007/Polo/IMG-20120527-00444.jpg)
(http://i134.photobucket.com/albums/q89/photo123_2007/Polo/IMG-20120527-00445.jpg)
This is where the fun really started, the full rebuild!
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This is where it got interesting, i started the big strip down for the 16v and a general paint, thats it really.... things kinda spiraled, as they do....
I started stripping and removing things and causing havoc as i went:
(http://i134.photobucket.com/albums/q89/photo123_2007/Polo/IMG-20120617-00462.jpg)
(http://i134.photobucket.com/albums/q89/photo123_2007/Polo/IMG-20120623-00483.jpg)
(http://i134.photobucket.com/albums/q89/photo123_2007/Polo/IMG-20120623-00484.jpg)
(http://i134.photobucket.com/albums/q89/photo123_2007/Polo/IMG-20120623-00485.jpg)
(http://i134.photobucket.com/albums/q89/photo123_2007/Polo/IMG-20120623-00486.jpg)
(http://i134.photobucket.com/albums/q89/photo123_2007/Polo/IMG-20120623-00488.jpg)
After that episode i had to then consider fitting things back on! soooo, out came the thinking cap and a hammer.... :P
New location for the fuse box and wiring loom through the inner arch as can be seen in this below pic:
(http://i134.photobucket.com/albums/q89/photo123_2007/Polo/IMG-20120617-00461.jpg)
Loom tucked down the inner wing, conduit and plenty of tape to keep it safe, no... the wheel is nowheere near on lock ;-)
(http://i134.photobucket.com/albums/q89/photo123_2007/Polo/IMG-20120610-00454.jpg)
Now the heater was removed i had a huge void in the dash so both radio and heater areas got blanked with carbon sheet. Also in this pic is another of my issues, wiring!
(http://i134.photobucket.com/albums/q89/photo123_2007/Polo/IMG-20120715-00515.jpg)
Loom started off like this stripped, fixed the prone weak spots, extended when applicable and fitted roughly:
(http://i134.photobucket.com/albums/q89/photo123_2007/Polo/IMG-20120706-00500.jpg)
As things started to progress i added more and more to the centre console eventually having a much more practical dash space:
(http://i134.photobucket.com/albums/q89/photo123_2007/Polo/IMG-20120827-00654.jpg)
The dash panel bolts are now all gold anodised, a pic i shall get later in the week.
The large space next to battery cut off will be the fire extinguisher and kill switches i plan, not yet done.
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During this time all sorts of bits were coming in, only got a couple of pictures but im sure you can all see whats been done.
Everything was painted,cleaned usual stuff. Everything bar the rear beam, driveshafts and front ARB is new and upgraded, nothing is stock, if your doing something i saw fit to do it properly and upgrade at the same time:
(http://i134.photobucket.com/albums/q89/photo123_2007/Polo/IMG-20120619-00466.jpg)
(http://i134.photobucket.com/albums/q89/photo123_2007/Polo/IMG-20120619-00465.jpg)
(http://i134.photobucket.com/albums/q89/photo123_2007/Polo/IMG-20120619-00471.jpg)
(http://i134.photobucket.com/albums/q89/photo123_2007/Polo/IMG-20120619-00474.jpg)
(http://i134.photobucket.com/albums/q89/photo123_2007/Polo/IMG-20120620-00479.jpg)
Everything was thoroughly cleaned before refit:
(http://i134.photobucket.com/albums/q89/photo123_2007/Polo/IMG-20120619-00467.jpg)
Now the fronts, also thoroughly cleaned:
(http://i134.photobucket.com/albums/q89/photo123_2007/Polo/IMG-20120728-00553.jpg)
(http://i134.photobucket.com/albums/q89/photo123_2007/Polo/IMG-20120729-00559.jpg)
Now at this time i was in the mood for painting so i carried in with the engine bay:
(http://i134.photobucket.com/albums/q89/photo123_2007/Polo/IMG-20120708-00504.jpg)
(http://i134.photobucket.com/albums/q89/photo123_2007/Polo/IMG-20120708-00502.jpg)
(http://i134.photobucket.com/albums/q89/photo123_2007/Polo/IMG-20120708-00503.jpg)
Now i have no real pictures of the next few steps BUT, it involved abit of spraying and over spray and i was left with this:
(http://i134.photobucket.com/albums/q89/photo123_2007/Polo/IMG-20120810-00579.jpg)
The colour is a rare american/canada market green that was realsed for a few months before being removed from the options list (presumably due to lack of sales in said colour)... im still not sure i like it either!
(http://i134.photobucket.com/albums/q89/photo123_2007/Polo/IMG-20120810-00579.jpg)
Now something that had always happened with the high offset wheels is the wheels caught the arb, sooo i made some nice lockstops:
(http://i134.photobucket.com/albums/q89/photo123_2007/Polo/IMG-20120720-00520.jpg)
Polished a few bits:
(http://i134.photobucket.com/albums/q89/photo123_2007/Polo/IMG-20120810-00578.jpg)
(stainles steel water pipe)
(http://i134.photobucket.com/albums/q89/photo123_2007/Polo/IMG-20120706-00499.jpg)
The build up then started, I must stress now that i was NEVER intending a show bay and it most definitely will never be one, i just wanted a easy to work in space nice and clean and thats it! ;D
(http://i134.photobucket.com/albums/q89/photo123_2007/Polo/IMG-20120812-00582.jpg)
(http://i134.photobucket.com/albums/q89/photo123_2007/Polo/IMG-20120812-00581.jpg)
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Now that was done i got abit bored, moved back to inside the car and got the fuel system inside, less chance of damage there:
All items are to be upgraded, the fuel pump is a uprated BMW item, other items are stock, i ran out of free cash at this point (had just settled on my engine of choice, i needed G smiles!....) (http://i134.photobucket.com/albums/q89/photo123_2007/Polo/IMG-20120715-00513.jpg)
(http://i134.photobucket.com/albums/q89/photo123_2007/Polo/IMG-20120715-00512.jpg)
Nice big battery box, i will run a k1100 motorbike item eventually, but for now, a stock item will suffice!
(http://i134.photobucket.com/albums/q89/photo123_2007/Polo/IMG-20120630-00493.jpg)
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Now the fun part, engine collection.... No pictures but it was eventful towning a trailer in a heavily lowered pug 306 1.4 down the M62 with a G in the back....
Said pug, just so my mate feels loved haha (this is a current pic of the car finished....) :
(http://i134.photobucket.com/albums/q89/photo123_2007/random%20cp%20things%20and%20intresting%20dub%20pics/IMG-20120916-00698.jpg)
Engine had the big ends off to check hear (all good) a new headgasket, a clean, usual stuff really.
(http://i134.photobucket.com/albums/q89/photo123_2007/Polo/IMG-20120818-00589.jpg)
(http://i134.photobucket.com/albums/q89/photo123_2007/Polo/IMG-20120818-00588.jpg)
Then the fun part, in she went!
(http://i134.photobucket.com/albums/q89/photo123_2007/Polo/IMG-20120819-00591.jpg)
(http://i134.photobucket.com/albums/q89/photo123_2007/Polo/IMG-20120820-00593.jpg)
(http://i134.photobucket.com/albums/q89/photo123_2007/Polo/IMG-20120820-00597.jpg)
(http://i134.photobucket.com/albums/q89/photo123_2007/Polo/IMG-20120825-00643.jpg)
(http://i134.photobucket.com/albums/q89/photo123_2007/Polo/IMG-20120825-00640.jpg)
(http://i134.photobucket.com/albums/q89/photo123_2007/Polo/IMG-20120927-00715.jpg)
Once she was done she had a small tart up, nothing special:
(http://i134.photobucket.com/albums/q89/photo123_2007/Polo/IMG-20120910-00684.jpg)
Rocker cover, throttle body, charger, few other alloy bits are getting polished, like i say, not for show appearance, just because im sad haha.
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The gearbox was never painted as i want a good quality item to keep long term with a diff and low miles. If anyone has one, hit me up :D
I know shes not to everyones tastes, way too low for a G40, too low for a polo, not a perfect track machine BUTTTT, i never did it for that, i did it for me and for me only. As always all comments and criticisms greatly welcome ;D
I'll write a ''spec'' list later, im having a break now haha.
Thanks for looking.
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I hate how i have to phrase this but, "Spec" as follows:
Engine:
G40 PY engine, 120k miles approx. recent minor rebuild.
51mm throttle body
ported charger (spec unknown, quite a heavy port though)
lightened flywheel
smaller pulley (size escapes me)
Stainless 4 branch
2" stainless system
chip to suit
mk1 golf radiator
slimline fan
Soon to be a few more bits....
Running gear:
KW type 2 rear coilovers
Raceland mk1 golf front coilovers
Larger golf CV's
Powerflex TCA inners
G-lader poly outer
Solid ally arb mounts
2" engine lift front, 2" gearbox, 1" back
type 2's and mintex fast road pads
rear disk conversion
fuel and brake lines inside car
G-lader rear beam mounts
Rover rear ARB
7 and 8x13 powertechs
Interior:
Fibreglass buckets
No trim bar dash plastics
MOMO 320mm wheel
grip taped floor/pedals
Battery in boot area
Boost/Oil temp/oil pressure gauges in radio insert
battery cut off in dash
sound proofind/deadening removed
Couple of asis pics from a couple of weeks ago :-)
(http://i134.photobucket.com/albums/q89/photo123_2007/Polo/IMG-20121002-00721COPY_zps50a30456.jpg)
(http://i134.photobucket.com/albums/q89/photo123_2007/Polo/IMG-20121010-00742_zps075fd4cd.jpg)
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You mentioned a front ARB upgrade, what was this? Where is the rear beam ARB from as mine 100% does not have that!
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Hi, sorry justin the wording isent very clear I ment driveshafts, rear beam and front arb are the only thing that are originally from the car and not upgraded.
The wording is so badly spelt as the "add reply" box kept jumping about when it had a few pictures and lines in it. Not sure if that's normal but its a pain in the arse.
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nice project mate enjoyed ready through it..... how does it ride with kw coilovers?
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But the rear bar, it has an anti roll bar on it. Where did you get that from?
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Cheers Gaz, tbh its hard to say, with it being so low it doesent handle exactly as it should given whats done, howeverrrr when mot came I did lift it about 3" and add stock wheels, now bar the stock wheels it handled bloody well! Nice and smooth tbh, was very impressed.
Justin, sorry, forgot to reply to that bit! The arb is (iirc) a rover 200 item with rover 400 front antiroll bar front drop links ;-)
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fair play man! quick?
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Not too bad eric.... Got to find a decent ATV and diff and then more power like.
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Looks really good ben.
Is it running just the standard 113bhp then?
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Erm..... lol... Not quite max..... :D
As i say, hopefully gearbox and FMIC next month, ready for charger rebuild and some additional porting/injectors/map. The usual, then see where i end up. 180 bhp and i'll be happy (ish) :-)
I need to get a few more pics, if i remember i'll get on it at dinner, Pics of seats and the bay now its abit tidier :-)
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Woah, nice.
Just been looking at that G60'd G40 underneath your thread. Thats pretty good!
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Id like to have a go in one with a diff one day. Interested to see the difference. Not sure if id benefit from one in a valver
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nice one ben looking really good.
i'll need that jig one day aswell :)
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Any updates ben?
Don't suppose you know of anyone selling a decent G40 charger?
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Sorry, forgot to get pics! ::) Sorry dont know anyone, i want full blend so may be selling mine in a few months, other than that, not sure sorry Max.
Nothing really to show anyway tbh max, Fitted a oil cooler setup with external thermostat
(http://i134.photobucket.com/albums/q89/photo123_2007/Polo/IMG-20121111-00771.jpg)
Took a picture of the engine bay, so much more to do looks wise, effort/CBA :-\
(http://i134.photobucket.com/albums/q89/photo123_2007/Polo/IMG-20121110-00768.jpg)
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Ah great. Well i wont be needing it for a while anyway. Its for the coupe btw.
Engine bay looks great tbh. Maybe get the cam cover powdercoated in a decent colour?
And polished dizzy etc?
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Did you read the previous page lol, about half way down is some plans, ? Keeping the thing on the road is hard enough never mind polishing too hehe, I'll get around to it mate, one day :-P
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Does look awesome though, how i want my bay.
Need to find a charger!
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Started on making things lighter, these are a pair of doors i got off Tez a couple of weeks ago, outside handle is now off an Audi A4.
(http://i134.photobucket.com/albums/q89/photo123_2007/Polo/IMG-20121117-00782.jpg)
(http://i134.photobucket.com/albums/q89/photo123_2007/Polo/IMG-20121117-00781.jpg)
The scruffy after thought of a window winder is only on the drivers side. I dont have a heater in the car so need to wind the window down to stop condensation. The back of the winder metal has some fibreglass angle iron and the front has a ''doorcard'' cover, as seen below:
(http://i134.photobucket.com/albums/q89/photo123_2007/Polo/IMG-20121115-00777.jpg)
This is a ''during'' pic of the wing:
(http://i134.photobucket.com/albums/q89/photo123_2007/Polo/IMG-20121115-00778.jpg)
Wings have no side reps, trimmed metal along the front where it bolts to the wing mount bit and the top edge has had the spreader plate moved and the metal under trimmed back between the bolts.
Finally a pic of a piece im working on, 25" across, sure you can all work out what it is :-)
(http://i134.photobucket.com/albums/q89/photo123_2007/Polo/IMG-20121120-00785.jpg)
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nice work benny, what are you using to push the holes through?
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Orite Ryan, its just hole sawed and then a homemade hole flare to roll the edge abit. Adds abit of strength back in from drilling a hole :-D
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Nice,, may be useful if i get a £999 challenge car off the ground 8) Ps cant find you on facebook at all. you have Pm on TMF
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No real update sorry to say but the car is now off the road for a substantial amount of months getting another rebuild, stiffening and interior/underside painting this time :-)
(http://i134.photobucket.com/albums/q89/photo123_2007/Polo/utf-8BSU1HLTIwMTIxMjE1LTAwODEzLmpwZw.jpg)
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bay looks fresh tbh, did you have to use much filler when removiing the scuttle?
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Naa, very light skim. Probably 1/6 of a bag of sugar kinda size, hardly anything. the flat bit that that scuttle is spot welded to from 1 side to another. Ive had decent practice with a grinder from various intricate bits in the past so i was able to grind through the majorit of spot welds, awkward ones got cut with a hacksaw or chisel then dressed with flap wheels.
Bought some more stuff too, nothing major just odds and sods to help with the build :-) :
(http://i134.photobucket.com/albums/q89/photo123_2007/Polo/utf-8BSU1HLTIwMTIxMjIzLVdBMDAzLmpwZw.jpg)
Shells new colour, opinions welcome ofcourse i have to say i love it :
(http://i134.photobucket.com/albums/q89/photo123_2007/Polo/utf-8BSU1HLTIwMTMwMTA3LTAwODQ0LmpwZw.jpg)
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nice work Ben. the lightening is top class, as always
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thats good new then. cheers
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Nice work dude!
Enjoying the Lawn Mower green bay and aluminium alloy fixings where appropriate. Spot a bit of bespoke AC TIG welding on the (mk1 Golf?) Thermo housing. Did the rad suffice?
Suprised you havn't located the Air intake in the o/s wheel arch. (Although if it floods like norfolk near you, probs wise!).
Andy
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Cheers lads.
Need to get on and do more yet Ryan, kinda planning out the fuel system at the minute so no body updates sorry.
Haha Andy the bays selvas green, supposed to be a rare VW colour and the body is going almond green :-P near enough mower green and creamy mower green lol.
Nice to see someone noticing the housing. Props to Arun (Phataz1) for that. A lot more alloy and custom stuff coming, just finding the time to get it all planned out really. Rads excellent too cheers, gna have to 2" lift it to match the engine whilst its off the road, kept getting air locks in the thermo housing with the engine being so high lol. Self inflicted fail right there!
If I'm honest I rushed to get the G setup done and get it on the road so I could feel the smiles wipe across my face. The plan is to build a alloy box behind the bumper (fog light hole) for the filter. I've made a blank for the carbon canister that has a joiner so filter on arch side and tother side the charger with silicone and alloy. Just time really mate.
How's that polo of yours doing mate, haven't seen any updates in a fair old while?
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Picture quality is really poor i know but gives everyone a idea of the overall colour scheme and things. Green, black and gold and polished stuff :-)
(http://i134.photobucket.com/albums/q89/photo123_2007/Polo/utf-8BSU1HLTIwMTMwMTExLTAwODUyLmpwZw.jpg)
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Loving the colour there dude, looks top class with the gold and black/carbon. Nice work on the lightweighting!
Alisons coming along, just had to have a week off work due to a knackered and unhappy mk1 golf. Now back to 1986 325i smiles for a wee while, which should encourage me to finish Alison ASAP (40 litres of unleaded gone in circa 150 miles) and my daily commute is 40 miles round trip :'(
I almost sold-out and went for finance on a bluemotion 1.2 polo/ora Work van, then reminded myself why I chose not to drive modern cars and the false economy of it, just for an easy (and boring) life. Im looking forward to being deafened on the way to work waiting for the engine to melt! ;D
Motor is all built up, just got a bit of welding left underneath and the horrible task of painting.. everywhere i turn atm it's all about paint! Feckin hate it!
Camera is fooked, hence the build-thread death!
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Bens whats happened to the build?