Trials and tribulations of a cheap G40

[physicsfool]

Port & polished cylinder head, Schrick 268 cam, custom PPP ecu chip
Pipex cone filter, S/S 4-2-1 manifold and Longlife S/S exhaust system
Vauxhall Calibra ATE front calipers with 256mm vented discs & yellow stuff pads
G-laderseite Poly ARB blocks and TCA bushes
GMax suspension
Polo GT rear axle with ARB
Sparco Sprint bucket seat and Sabelt 4-point harnesses
Polo GT clocks
Stripped-out interior
Ronal 14x6 multi-spoke wheels with road tyres

[z3i]

Awesome!!!! get that g40 engine in there!

[Jester]

Yea get that g40 in it!

mk2 shell + g40 = awesome

[physicsfool]

My iphone is slowly failing and dying. So i apologise for the poor quality images

Any hoo got the bog brush and contact cleaner out


As well as cleaning all the bearing and thrust washer


And then bolted and torqued the lot up.


Tonights job is popping the 3 pistons in (one is without an oil ring as i managed to snap it popping it on) Got a 7-10 day wait for a set.

The mk2 is off for its re-test today as the headlights appear to have confused the MOT centre. Lets hope todays tester is a touch more competant

[physicsfool]

And i reassembled the head with the new cam and dizzy. Gave it all a good clean first

[physicsfool]

Last night was spent putting 3 of the 4 pistons in the block. got a fair wait till the piston ring set turns up. but plenty of other jobs in the meantime


And this morning went for a spin in a freshly mot'd and taxed motor

[physicsfool]

So i bet my mate i would have this finished and drive it into uni by the end of the year, i may be losing a fiver.

But i have put some hours in this week after the piston ring fiasco
Oil pump and chain, poured some oil in to prime it


Had all the gaskets bar this one, so being northern i wasnt going to spend money on buying the whole set, cheeky bit of gasket paper instead


Oil started coming out of the filter hole so a mini oil filter is on for the time being, thread doesn't feel quite right so will change when i pop the oil in


Mad painting skills, good job i put newspaper down, one messy pup


And a metal head-gasket and precision tightening later and i have a head attached


Hopefully i will get an hour or two in before the weekend and get the timing belt cover on and the engine timed up

[Jester]

Anymore updates on this Martin??

Hows the mk2 shell looking now?

[physicsfool]

I dropped my phone on Christmas Day, replacement screen should be with me tomorrow.

But the engine is in,

• exhaust is back together
• gear linkage is all set up
• charger is in place
• driveshafts all torqued up

Need to decide on an intercooler design and radiator position as it doesn't quite fit
And pop the wiring back in, so hopefully not too far off.

Pictures to follow shortly

[physicsfool]

So then i timed the motor up and popped the cam cover back on,


And slowly its starting to look like an engine again.


I stole various parts off the GT motor like the starter motor and its wiring harness as well as injector jackets


And a touch more..


And then the Christmas holiday arrived, which meant whole days on the car, missus had an assignment deadline which worked well for me

So here is the GT engine which sadly i ended up breaking.


But it will make way for the G so i believe its a worthy cause


Dragged it into the workshop to take the engine out, G watching from afar.....



After a morning of sweating and dealing with driveshaft bolts


Both engines out and so i set about breaking the GT for parts



......And then on christmas day i dropped my phone. which buggered it proper. Being the holidays i had to wait a week for the next screen... However i couldnt stop working so voila....Engine in car now


With most of the engine loom in.... I chopped the central bonnet catch support out to make way for the intercooler which fits rather well, but had to make slight adjustments to the radiator so that it now sits in fresh holes.


With the rad fitted


And the cowling, I chose to use this one as it still fits and should have better draw as well as shielding the radiator from the exhaust manifold




It all fits...just

Need to finish off the cooling system pipework, figure out where the last few clips on the engine loom go and mount the oil cooler as well as fitting the last part of the boost system...

[Jester]

This is going to be so sweet once done Martin, good job.

What sort of power you aiming for from this.

[Freddy77]

That intercooler setup looks very familiar......  Works spot on!

[Yoof]

Is this a new loom? You need to push home all the rubber grommets, otherwise they're not sealed and moisture will get in.

Rest looks spot on though 

[physicsfool]

No idea Matt, will get it on the same rolling road I used just before I took it all apart.

Yes it's a Freddy special. Yeah decent route and no real cutting to the shell!

Yeah Pete, he appears to have put to large ends in. So they won't push in any more! Will have to wait and see.

[Yoof]

They compress down a fair bit. But I'd send it back if they really don't push home, it's not much use otherwise.