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Oil cooler aold
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Chassis & Braking / Re: Rear disc conversion
« Last post by sleag40 on Yesterday at 04:35:37 pm »
I used mk2 Golf ones for mine, need to cut them down though. Still on there over 10 years later!
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Chassis & Braking / Re: Rear disc conversion
« Last post by Richvw18 on Yesterday at 04:02:59 pm »
anyone??
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Chassis & Braking / Rear disc conversion
« Last post by Richvw18 on Yesterday at 08:54:33 am »
Morning everyone.

Im in the middle of doing a rear disc conversion on the G and wondered what handbrake cables I need? I've got the aluminium spacer for the cables on mine but there too short..? 
Do i need polo 6n2 gti ones or not? Cheers
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Chassis & Braking / Re: Standard suspension springs
« Last post by AxA on January 14, 2018, 02:46:24 pm »
Excellent and detailed information, many thanks Nick.
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Chassis & Braking / Re: Standard suspension springs
« Last post by G40supercharged on January 14, 2018, 12:54:24 pm »
Hi Neil,

Front springs are 871411105 951 with (3) paint markings yellow orange orange
Rear springs are 871511115A 951 with (2) paint markings brown white
(Taken from VW parts list)

I confirmed the above colour codes on my 1991 H reg G40 which is completely standard and has never had the springs replaced. There only seems to have been one set of standard springs for G40 anyway; I think they were about 10mm lower than other Polo models. I'm surprised VW heritage needed to ask as the paint details are included on the VW parts database. There are various versions online if you do a search for 'VW ETKA'. G40 variants are listed as model PY. 

Regards,
Nick
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Ongoing Projects / Re: Yoof's Turbo
« Last post by Yoof on January 14, 2018, 08:45:32 am »
Progress is slow, but it's progress all the same!

I've been making good the bulkhead after cutting large holes for the steering rack. The stock bulkhead was looking crusty, and I decided rather than repair, to replace the lower section entirely.

Untitled by Peter Strange, on Flickr

Obviously involved cardboard, cutting, grinding, welding, all the usual ingredients!

Untitled by Peter Strange, on Flickr

Couple if fiddly bits around the rack passing through the bulkhead, I was hoping to use the Corsa gasket here, but it's too big unfortunately, so a crush foam ring will have to do.

Untitled by Peter Strange, on Flickr

Big hole

Untitled by Peter Strange, on Flickr

No hole

Untitled by Peter Strange, on Flickr

Rack fitted

Untitled by Peter Strange, on Flickr

Welding on the engine side is nice and easy, welding the interior side is a back breaker, especially with a full cage in the way! Amost knocked myself out on the dash bar more than once...

Some Bilt Hamber no rust applied inside and out:

Untitled by Peter Strange, on Flickr

Untitled by Peter Strange, on Flickr

With that complete, I needed to make a heatshield, same process as I'd used for the exhaust tunnel. I made it in two parts due to the size and shape of my material.

Untitled by Peter Strange, on Flickr

Camera doesn't pick it up very well, but there's a large amount of manipulation involved to make it a good fit, can't say I'm 100% happy with it, but it's functional.

I then used 3M reflective tape over the surface, the reason for this is the standard heatshield material allows fluid to be collected and pool. It also is difficult to wipe clean without removing it. By taping the surface hopefully fluid won't pool and it's far easier to wipe down, both reducing the risk of a thermal event (I hope!). Unsure if this has had any detrimental effect to the thermal performance of it.

Untitled by Peter Strange, on Flickr

So, one rack with heat-shielding complete:

Untitled by Peter Strange, on Flickr

Cheers,

Pete
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Ongoing Projects / Re: Yoof's Turbo
« Last post by Yoof on January 14, 2018, 08:45:07 am »
Awesome work as ever!

Are you going to go 4wd at some point? In for a penny and all that! ;) :P

Cheers! 4wd probably not, I'm intending to use it for track days- power management (and driver skill) are key to make big power FWD work effectively. BTCC is a good example of different circuits playing to the strengths of rwd and fwd.

A VR6 Turbo in a 4wd Golf II does excite me though!
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Chassis & Braking / Standard suspension springs
« Last post by AxA on January 13, 2018, 01:12:23 pm »
Hello,

Looking for a set of new standard springs as part of restoration. VW heritage are providing a cost but have asked for the paint code located on the original springs. I do not have the originals so as far as a paint code its a dead end. Can anyone help or point to another source to purchase standard springs?

Many thanks
Neil
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