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91
Ongoing Projects / Re: Hayesey's red G40 restoration - J142WLS
« Last post by Max on April 06, 2023, 09:19:01 pm »
Great to see a build thread again, making me want to do one too!

Look forward to seeing some more updates.
92
Ongoing Projects / Hayesey's red G40 restoration - J142WLS
« Last post by hayesey on April 04, 2023, 05:35:04 pm »
Back in 2020, I bought another G40. I got it from Nealpeal (a member on this forum) as it had been sat on his driveway for some time and he came to the conclusion that he wasn't going to use it, so wanted to sell it to someone who wouldn't just break it.

I already knew the car as once being owned by Mark Hunter in the early-to-mid 2000s, he's a long-time member of this group.

When I first bought it, I spent a fair bit of time re-commissioning it, getting it back on the road and MOTd. Things like replacing belts, ignition parts, filters, charger service etc... After that I used the car for a couple of years, taking it to shows in the summer, SORNing in winter, the occasional run out on a Sunday. But it has always been my intention to get it properly restored.

It's had various owners over the years, it's had modifications done to it in the past including some strange paintwork (someone painted the roof, boot, bonnet and c-pillars black) and some DIY paintwork back to red. So it really needs properly stripping down and sorting out.

Last year I got talking to another member on here, Steve (sleag40), on our ClubG40 stand at tatton park, he said that he could take this work on. He later showed me the astounding level of restoration work he'd done to a mk2 Cavalier and he knows G40s too owning a very nice L-reg one himself. It seemed perfect.

So a few weeks ago I agreed a plan with him and the work has begun. I want to document progress in this thread.

My goal isn't going to be a full-on concourse level car at the end but a very nicely sorted, standard spec, G40 which will last another 30 years hopefully!

Firstly, some old pictures of it.



This is a photo I took at (if I remember correctly) VW Action 2004. Mark Hunter owned it at the time. The red 6n parked next to it was my car at the time!



This is it again some time after Mark sold it, the less said the better........



Then when I first got it home in 2020, I had to trailer it as it hadn't been on the road for quite a few years at that point,

Next, some repair work don't by myself which were necessary to get it back on the road but I always saw as being temporary:





Charger went off to PeteG40 for servicing, amazingly it had never been touched, no porting or anything which is good for me as it's keeps it original spec! The charger wouldn't be the same as the car had originally as Nealpeal put his engine into this shell when he had the car.



It had it's first MOT in about ten years:



At this point, I just used it. Went to some shows etc...

Pretty much the first meetup to happen after lockdown, cars&coffee manchester (which was ridiculously busy and we had to get there very early to get it):



And then Tatton Park VW Show 2022:



Which brings us to a couple of weeks ago when I booked two days off work to get it ready to take to Steve for the part of the restoration he will be handling since bodywork and paint aren't my forte:











Not bad for two day's work I don't think!

Then, Sunday just gone, I got it back on the trailer and took it to Steve's unit where we got it up on his spit:



So the first job Steve will do is getting all the underseal off down to the e coat. Then he'll do any welding that's needed and reseal it all, then it'll be off for paint. But this will all take a few months.

I got my first update photo last night from Steve:



Yes there is a hole cut in the inner wing, that's from it having a wing vent fitted I suspect, in it's euro-look-gone-wrong days. It'll be getting welded up.

Meanwhile I will be rebuilding/refreshing the engine (there's nothing wrong with it just needs making look nice and will be doing all seals etc.. while it's on a stand) and getting all the other parts made to look like new or replaced. New nuts and bolts all round too. I wont be putting any manky bits back on to this once I get the shell back.
93
Exterior and Interior / Re: G40 seat and doorcard fabric
« Last post by Max on April 03, 2023, 01:41:58 pm »
Yep worth doing I think!
94
Exterior and Interior / Re: G40 seat and doorcard fabric
« Last post by hayesey on April 03, 2023, 09:44:05 am »
really? that's disappointing. Maybe I should ask too, if enough people ask then they might start to think there's enough demand
95
Exterior and Interior / Re: G40 seat and doorcard fabric
« Last post by Max on April 02, 2023, 06:05:40 pm »
A fairly short “nein” was the response!
96
Exterior and Interior / Re: G40 seat and doorcard fabric
« Last post by hayesey on March 29, 2023, 04:18:02 pm »
I'm interested in what they say
97
General Car Chat / Re: New to the forum and some questions
« Last post by hayesey on March 29, 2023, 02:28:10 pm »
are the photos before or after it's been repaired? looks quite clean there (dusty obviously ...).

To tell if the ECU is standard or not, open it up and look at the chip. Four torx head screws and then slide the board out, remove the metal clip from the RF shield and pull that off. Standard chip should have a silver sticker on it with a partcode. Otherwise, post a photo of what you find. Highly likely it's been changed if someone had gone to the lengths of changing the intercooler.

The injectors will have a part code on them, check against this table:

https://www.polog40.co.uk/article_injector_table.php

VWII calipers came on loads of VWs from 80s and 90s, pretty much anything with 239mm discs. MK2 golf etc... but the caliper carriers will be different, you can get away with using the VWI carriers, they'll fit but are different. Or find carriers from mk1 golf, mk1/2 scirocco etc... or from a polo where someone is upgrading brakes.

If you're going for modified though I'd get some 256mm discs and suitable calipers, off an audi of some sort, there'll be threads in the braking section on here somewhere, put some wanted ads up too, check facebook groups if you're on there (much more active than the forum nowadays sadly).
98
Exterior and Interior / Re: G40 seat and doorcard fabric
« Last post by Max on March 26, 2023, 08:50:37 pm »
I’ve just messaged them.
99
General Car Chat / Re: New to the forum and some questions
« Last post by e90330 on March 24, 2023, 10:08:01 am »
Hello again. A bit more info and few more questions on my G40 story. Car sat for 2 years in a garage, due to other life things like birth of my son, it all went to the background. But now, it came out again.
So, as I thought the G40 had some minor floor pan and sills rust, boy was I wrong. I found a bodyshop, far far away, who agreed to do the work. Local ones were or not interested, or quoted me astronomical prices. As I originate from that far, far away country and visit it frequently, I found a shop there. Ok, brought the G40 to the shop and a nightmare scenario was brought to me. Car is really in a bad shape, was poorly painted (guy was peeling off paint with his fingernail), lot's of rust in places I could not even see it. In any case, as the car was already there, I decided to do it properly. Car has been stripped, sandblasted, all rust repaired, and meanwhile it's been painted back to original color. Engine went to a mechanic for an overhaul. Some pics of the progress.

What I did see, is that the car has a bigger intercooler. How to tell if the ecu has been programmed? Only by reading it out? About the injectors, if there a way to tell if thery're from G40 or G60?
And a question about the looks of the engine: I saw online some engines where the bottom block is painted black, while the cyinderhead is silver. Is that how it was originally? Or was it originally just all in silver/chrome?

As for suspension, I decided to go with Bilstein B12 Pro kit, but it's almost impossible to find it. Would an other combination be similar. Eg Bilstein B6 with Eibach or other brand springs?
And again regarding the brakes: I saw posted above to look out for vw11 calipers. From what model do these originate? Will I need some custom brackets? Does it take same size brake disc?

Progress was slow till now as it's a side job for the bodyshop, but I'll update this thread when I have updates myself.


100
Photos and videos / Re: Hi, Here is my Royal Blue G40 J599 CWB
« Last post by JoeH on March 20, 2023, 10:54:34 pm »
Breakdown

Nothing serious - blue temp sender was saying temp was too cold, and therefore flooding engine with fuel.



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