Yoof's Turbo

[Yoof]

FAG 

Been alright in the past 

[erixtar1992]

dude this is very impressive fabrication work. welding looks neat too. come along way since i last saw the car.

can i ask where you got the arches for the yellow derby?

[Yoof]

I didn't buy them, but WL or KWL Motorsport 

[erixtar1992]

ah top man! il do a google

[cheys03]

Magnificent, Pete!
That's one hell of a lot of welding! Not to mention the fabrication

[Yoof]

Cheers mate- more updates to come this week. 12 weeks to go!

[Yoof]

So, a few minor updates, I've mostly been busy ordering parts and trying to keep everything on the boil. Run into some difficulties fitting the rear coolant pipe, and the thermostat housing.

Solved that by turning the 'stat housing through 180' and welding a bend in the coolant pipe- will probably have to add a de-gas line to the stat housing in the future.



And the up-side down 'stat:



With that kind of done, I could get on with installing the cooling pack, as nothing can be left alone on this car, I wanted to tweak things slightly, continuous improvement and all that (also known as compulsive meddling).

So, few bits to consider for front end minor re-hash:

- Get rid of old bumper bar, most G40 owners with big intercoolers have hacked these to death, and they serve no purpose in a crash
- Make the front bumper easily removable (was on two 10mm bolts) for easy loading on the trailer
- Move the IC closer to the bumper, allowing ducting and a more efficient air path
- Move radiator forward allowing more space for alternative downpipe routing if required
- Make it all look race spec etc.

First up, sack the old bits off, and make some new end plates from 5mm sheet:





I'll make these slightly smaller and slighter in due course, then get a piece of CDS cut to length and bent:



Plug #1 : http://www.tube-bender.co.uk/

Tom who runs Tube Bender was a very nice chap, and affordable, also had the bonus of being a few miles away  

After that I fitted the intercooler up, and tweaked its position:



The slight angle allows it to sit nicely against the bumper, speaking of the bumper this was then hacked to bits, holes drilled for catches, and bits cut out to shape around the IC:





And the semi-finished product:





Shut lines nee a slight tweak, but it slides on and off like a good 'un, so next bits are welding top tabs on for the IC and radiator supports, then boost hoses and coolant pipe routing.

I've also been busy with drive shaft manufacture and have chosen Elite in Stoke to make them: http://www.eliteracingtransmissions.com/ not cheap, but I don't want to buy twice.

Also had several e-mail exchanges with Gordon from Ringspann, who was very helpful - unfortunately bespoke cables are far too expensive, so I've used these guys: http://www.cable-tec.co.uk/ to alter some standard Mk4 Golf cables to length, I'll post results when done.

Cheers

Pete

[dubstar]

We use cable-tec for stuff at work, decent guys. You wont have a problem there. I should of mentioned them - didn't think.

It's looking awesome Pete - Standard.

[xandyx]

i think that biatch is asking for some ITB'S!!!

[Yoof]

So, finished off the bumper bar and lower radiator/IC support bar.

First up, top mounts for the radiator:





Then bottom mounts:





Now the rad and IC have a fairly consistent air gap between them, I've moved them much further forward to previously, hopefully the bumper aperture will direct more air over them both.

Finished (less paint) bars:







And with the bumper fitted up - note top radiator supports ensure a good fit against them slam panel:



Cables on their way, and some clutch bits from TPS, all for now!

Cheers

Pete

[Yoof]

So, been busy recently- the engine bay welding is now complete, and my to-do list is slightly shorter:

Coolant Pipes
Fit & make sump
Fit crank pulley end plate
Fit turbo
Downpipe Modification
Rear Wheel Stud
Brake line Tabs weld on
Vactan / Chassis leg rust protection
Oil Cooler Brackets (oil filter)
Starter Motor Wiring
Earth Cable
New Adapter Plate
Oil Pump Welding
Alternator Mounting
Repair Rear Exhaust Hanger

Now I've got gear shift cables that work I mocked everything up and adjusted accordingly. Very easy to setup compared to the Polo rod linkage, one of the selector ends fouled my engine mount slightly, so I modified that:





I then gave the bumper bar and intercooler/radiator bar a lick of paint:







After that it was time to move my attention to the OSF chassis leg, the crank pulley requires more clearance, and I need to rear mount the alternator and run the belt here. Removing the front ARB bracket wasn't an option as I wanted to maintain original suspension pickup locations. So, out with the grinder:



Usual drill, cut away what isn't required, plate with 3mm steel and stick it together with some weld. I may gusset up the chassis leg still, undecided yet.



Then back to the NSF leg, made clearance holes and welded studs in for the coil mount:



Few more bits were done after this, but left it looking fairly complete:





So, chuck the frame back on and push it outside for a wash:







And after that a few tweaks to the position of the bumper bar:



The bumper is sitting better than it ever did stock:



All for now, cheers

Pete

[scully]

I think that the lack of reactions is just because people are speechless. 

[GR40]

This is so much work! So many things to fabricate to the point that people can't relate. Sure it's amazing and probably the best way to go about it if you are in for reliability and performance but it has gone to the point where the front end is no longer a G40. And since this car has gone to that point to become that good, people are being turned off by the fact it takes so much work and effort to take it to that stage. We all love the G40 and we all want 200+hp but if this is what it takes, well it's just too much! I know this is for track use only but I bet you could fit the PY engine with the 1,8t gearbox on a newer VW chassis without that much work and have a nice track car. Just saying!

[runforrestrun]

As far as I am concerned, it's porn.

[Etches]

Those chassis legs are absolute works of art. So So good!