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Chassis & Braking / Rear disc conversion
« Last post by Richvw18 on January 15, 2018, 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
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.
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. 

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


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!
Chassis & Braking / Standard suspension springs
« Last post by AxA on January 13, 2018, 01:12:23 pm »

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
Wanted / Re: Wanted: g40 PPP subframe, coilovers, handing upgrades
« Last post by Irmr on January 13, 2018, 10:45:41 am »
Hi I have a full set of coil overs,front set are new and the rear set are used.They are in good condition and only done under a 1000 miles.Taken off. 1992 G40.
Cars for sale / Genuine G40 - K488 YRP *90K MILES*
« Last post by alexmac738 on January 10, 2018, 04:45:08 pm »
Posting here to see if there is any interest in my 1992 (K reg) Polo G40. *ORIGINAL 90K MILES*

MOT until 16/11/18

This is a clean example with the only bit of rust that I can spot on the tailgate under the glass.
The car has had a respray at some point in it's life and it's not amazing. The finish of the paint is okay, however it looks as though the prep work wasn't done to the highest standard as the paint is starting to come off around the edges of the driver's door and on the sunroof.
There is also a slight dent on the passenger's side wing.
Tailgate doesn't open from the outside, button doesn't seem to be connected to the latch itself. You are able to open it from the inside though.
The interior could do with some TLC, passenger seat and rear bench are original material but could do with a clean, stitching is also starting to come away on the rear bench but should be an easy fix if you're taking the material off to clean it anyway. Driver's seat is not the original, apparently the original seat broke and it was replaced with a standard polo seat but I have the material from the original if you would like to swap the material over. Door cards could also use some straightening.
The engine is all original as far as I can tell. Supercharger had a Stage 2 service by JabbaSport at 86k miles. Oil pump, pick up, crank seal and baffle plate all done around 4k miles ago. Timing belt kit also fitted around 4k miles ago.
New fuel tank was fitted around the same time along with the fuel pumps and filter.
Master cylinder replaced around June last year.
Discs and Pads replaced in December along with a caliper (all Pagid). Have new brake shoes, fitting kit and handbrake cables (all Pagid except fitting kit) for the rear brakes but haven't gotten round to doing it yet. (Need to order another handbrake cable due to only ordering one). Two advisories on current MOT were due to the handbrake and the rear registration plate being deteriorated (since been replaced).
Recently replaced the headlight switch and fog light switch.
Rear heated windscreen doesn't work for some reason... tried replacing the switch but still won't work.
Full stainless exhaust fitted last year and sounds good, not too loud at all.
The car has BBS RA's which are in very good condition, tyres are also good.

Looking at the MOT history, the car was off the road between 2008 and 2016 so it has only covered around 5,000 miles in 10 years which is very hard to find nowadays. I have been using the car as my daily since I got it in November and it runs well, it hasn't missed a beat apart from a stalling issue that has since been resolved.
Genuine reason for sale: I got rid of my MK2 Golf GTI 16V for this car and I miss it too much, also the car is too small for me as I am 6'3" so I need something slightly bigger.

The car is located in Preston, Lancashire and I'd be happy to facilitate viewings.
Looking for offers around £3800. Will consider swaps/px with cash my way.
I'd be more than happy to send pictures or answer any questions you may have. Please e-mail me at or ring me on 07483883415. I've tried posting pictures on here but it won't let me for some reason so please contact me for more info.
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