Author Topic: Matty's Polo G40  (Read 17044 times)

Offline Matty!

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Matty's Polo G40
« on: August 14, 2013, 10:46:55 am »
So...

I've been looking left right and centre for an old school VW of some sort, after boring my mates and my brother for around a year of a different car every week I thought I would just hold on out untill something crops up.

And it did!

So after battling crashes, road closures and potty stops it had endured a mammoth 6.5 hour trek home from Kent in the middle of the night. We arrived home without a hitch in my Supercharger Pocket rocket!


A 110k 1992 Genuine Polo G40

Spec is as followed:

Spec:

14" BBS RA's with 4 brand with Yokahoma A539's
GAZ dampening and height adjustable coilovers on the rear
Koni Springs and shocks on the front
258mm front disk conversion
Master cylinder


R1 Spec charger (rebuilt 4,000 miles ago)
Jabbasport induction kit
Alloy catch tank
Boost return mod (hence open hose)
De-cat
Stainless system from manifold back
Hidden polished stainless silencer
G60 Injectors
And I think its Cammed as its lumpy as hell on Idle.

161bhp - 800kg's


:D

This car goes! Its so good fun, when you plant the throttle it just takes off, and all that way you are laughing so hard because its only a little 1.3 8v! Makes the TT feel like a boat, but a stable boat atleast.

The car has to have had a full respray in its life, as there in not an ounce of rust on the thing and its immaculate inside & out.

I absolutely adore it, and hopefully will be keeping it for a long long while.
























Picture of it with the TT

Audi TT by Kurt Blythman, on Flickr



Since having this...

I've Been doing abit of research as I wanted to know if my car has an upgraded 51mm Throttle Body and GT inlet manifold, after inspection it does not have the GT inlet manifold so I booked the car into John at Bigfishtuning for a Dyno run just to see if the power its outputting was accurate before I start fiddling for maybe no reason.

the results:








So, I think I need to whip the inlet manifold off when my GT one arrives and see if this little bugger has said bits as this proves its running the power!

The car hunts for revs occasionally on Idle, could this be signs of the 51mm TB or Cams? Or neither as it has had an idle problem from day one according to all the service history.

Secondly I adjusted the dampening on the rear coilovers and now the car actually turns! Happy days, going to look into running GAZ coilovers on the front so atleast I have a matching set.

Cleaned under the arches yesterday to find no horror stories at all too! Its always a good feeling when you buy a car and realise there is no hidden secrets.

Anywho bought a few boring stuff to just neaten it up but over time this car will have the full treatment bringing it back to a full on immaculate G40.

Few pics with Scott-O's MK2


mk2 g401. by Matty!, on Flickr


MK2 Golf / Polo G40 by Matty!, on Flickr


mk2 Golf / Polo G40 by Matty!, on Flickr


Future plans:
Change front to coilovers - lower 5-10mm
Beg AAS to make a full manifold/exhaust for it
Check the cam and possibly buy a Schrick for it.
If it hasnt already Port the Inlet manifold and Head
Just generally neaten everything up untill its 100% immaculate.

Can anybody in the know look at my spec and look at my power output and possibly tell me what this car may have that the previous owner didn't list in the advert?


Thanks
Matty

Offline Matty!

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Re: Matty's Polo G40
« Reply #1 on: January 06, 2014, 09:48:51 pm »
Sooo, its all been happening, I thought I would post up a mid-build report :) Some of this is copied off vagcars so bare with me!

So after a lovley drive out:



This had to happen....


It... Was only a matter of time.



The charger was knocking its t*ts off on idle, but it would clear up as soon as you revved it, which to me sounded like something was rather amiss!

After some research I was heading in the direction of that the timing belt on the charger was delaminating, which is fairly common if it hasnt had the 11mm Belt upgrade, so got the charger off, opened it up and its fine and upgraded. b*llocks!

Looking at how to guides ect It looked easy enough to rebuild, so I looked for a rebuild kit  £190, then Scott-o alerted me to OnlyChargedDubs in manchester, few messages later the charger is now in his hands, for £300 and it comes back painted and fresh I wasnt going to groan!

And then he phones me... to tell me the charger is fine, what has actually gone is a bearing that isnt even in the rebuild kit because its so rare it fails in the top assembly, so now somewhere between Germany and here is my bearing for it! typical, yet im glad I didnt rebuild it now as I wouldnt have even had the contacts or the sense to look at that bearing.

Anyways it was a good excuse to buy these:

Bartek toothed belts, which may I add I bought on Sunday night and arrived here Wednesday morning at 10:00am with a text asking me if thats okay! unbelievable service especially when they are from germany.

Also bought some uprated engine polybush mounts as the ones on mine are rather squidgy:



Half way through fitting these, as every part that comes off this car either gets fully cleaned or sandblasted and painted, so things take twice as long when you do that.

Supercharger Mount:
Before


After



The grand plan this winter is to get the chassis fully up to top notch and dress the bay up.

Got hold of these beauties!
Adjustable top mounts:


I asked the guy I bought them from (breadman)  can he give me just a quick sketch of how they go together, expecting a daft little sketch and I got this!



Awesome sketch I must say.


So I've settled on my Chassis headache of which subframe to go for, Im going to go for the one that keeps the anti roll bars and went with the top mounts instead of rose jointed bottom arms, which are all pornographic yes, but good for a car that might go on track twice a year? probably not. So opted for the less hardcore version but in turn it should drive better on the roads it will be getting used on.


So anyways, got FAR too many things I need to save and order for this over winter, lets hope it can be done for March next year, but hopefully this car should be a huge step above what it is now by next year, Im just going to keep working on it when I can peel myself away from the Pub, GTA, work, dog, bike, GF, ect! Plus I have just got the use of a Milling machine, so watch this space!


Next update:
Quick picture of the wheels :)


I had these refurbed along with a few other components by Grover at RS Alloys in hartlepool! Top job I must say, the colour is audi hyper silver.

However 2 days after I put the deposit down on some EXTREMLEY special wheels! But watch this space, I wont post pics untill I have them in my hands!

The car is still on axle stands awaiting a handful of tastey suspension/misc parts. 







Offline Matty!

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Re: Matty's Polo G40
« Reply #2 on: January 06, 2014, 09:50:23 pm »
Soooooo, Been busy beavering away when I can, mainly when the weather has been god awful!

Not really anything flash as an update but bits and bobs that all help.

Started off with a standard G40 Rocker, now my car has had the return bypassed so the horrible inlet/outlet aint needed anymore, so I thought I would give it a bash at getting it blanked.

Start


After it being milled

polo g40 build by Matty!, on Flickr

The alu welded

polo g40 build by Matty!, on Flickr


After a quick whip over with a flapper wheel

polo g40 build by Matty!, on Flickr

Then after a hour or so of flapperwheeling!


polo g40 build by Matty!, on Flickr


polo g40 build by Matty!, on Flickr


So then I primered it and painted it Plastikote satin red...

polo g40 build by Matty!, on Flickr

When when dried looked more a lovley shade of Pink!!

So, I decided on VHT Crackle Red... which we on great, let it dry annddddd, it looks garbage, I put far too much paint on the top and not along the sides, the sides look awesome, the top is wrinklier than a 100 year old aborigines ball sack!

So I've sanded it back and painted again, fingers crossed it looks okay this time, havn't checked yet. 


I've painted and polybushed the TCA's and brake shields...

polo g40 build by Matty!, on Flickr


polo g40 build by Matty!, on Flickr

For any that are in the know I found out these actually arnt G40 items, these are normal TCA's however after abit of research if you polybush the TCA's its exactly the same as the G40 Rose jointed items which are £200!!!

Mounted up the Weichers Strut brace

polo g40 build by Matty!, on Flickr

I've had Grover Powder coat me ARB, Performance Subframe and soon to be strut brace as the finish on the strut brace I am not happy with so for £10 its a no brainer!



I have bought some extremely rare BBS wheels for this, but I wont post pictures ECT untill I have them here with me, as at the moment me and the previous owner dont want to risk loosing them at the courier in this busy time, but I will post them up when I get them.

Anywho, Im on with undersealing the arches and painting the calipers at the moment, got to send my struts off to KW for my coilovers which I am going to send off when the bank hols ect have ended.


So yeah, the list keeps getting bigger and bigger, but with the pressure of having to get it out the garage for my dads car it means im having to really pull my finger out!



So after having to do this for the second time!!


I finally got a result with the wrinkle finish!



Offline Matty!

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Re: Matty's Polo G40
« Reply #3 on: January 06, 2014, 09:50:36 pm »
So me and my Dad got cracked on with the PPP Subframe/Gearbox mount.

It came in black so I sent it to RS Alloys in Hartlepool for Powdercoating along with my ARB.


polo g40 subframe by Matty!, on Flickr

Fitting consisted of dropping the exhaust downpipe, removing the gear linkage and removing the arb, which all came off according to plan, for a 20 year old car it is in fine condition underneath!

Got the subframe hooked over and mounted the gearbox mount, this stops the pivoting movement on the gearbox by attaching to some of the existing bolt holes in the side of the gearbox, this along with the polybush mounts should make it feel very direct.

So on with the subframe, we got the rear mounted up in place, attached the gearlinkage to find... it wouldnt select 2 or 4th this was diagnosed to the ball on the gear linkage fouling the subframe, so we had to skim that down... should affect the gear change at all as all touching surfaces weren't needed to be touched.

Placed the arb in place, aligned, and bolted up! Sounds simple and easy, it isnt, its awkward and the tolerances are super close.

Anywho Ill let the pics do the talking:

Note: Still yet to finish off painting calipers




polo g40 subframe by Matty!, on Flickr


polo g40 subframe by Matty!, on Flickr

Gearbox mount/subframe:

polo g40 subframe by Matty!, on Flickr


polo g40 subframe by Matty!, on Flickr

This along with the AAS exhaust is gonna make the underside of the car look better than above!

Offline breadman

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Re: Matty's Polo G40
« Reply #4 on: January 06, 2014, 10:19:40 pm »
Hey Matty, that's coming along very nicely. I do like to see a job being done properly not just thrown together.
Can you remember to send me the suspension top hats that we spoke about? Would really help me out.
Cheers mate,
Richard.

Offline Matty!

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Re: Matty's Polo G40
« Reply #5 on: January 06, 2014, 10:34:47 pm »
Yeah man! I PM'd you like 5 mins ago :D

Offline breadman

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Re: Matty's Polo G40
« Reply #6 on: January 06, 2014, 11:21:53 pm »
Yeah man! I PM'd you like 5 mins ago :D


I didn't get a pm mate, maybe try again?

Offline physicsfool

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Re: Matty's Polo G40
« Reply #7 on: January 07, 2014, 01:46:15 pm »
Really nice work

Offline Matty!

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Re: Matty's Polo G40
« Reply #8 on: January 07, 2014, 06:48:48 pm »
Cheers :)

Anywho my wheels arrived today!
RS240 Which are 14" BBS RS's these are Uber uber rare, I've never seen a set in the flesh untill now.



BBS RS 240 by Matty!, on Flickr


BBS RS 240 by Matty!, on Flickr


BBS RS 240 by Matty!, on Flickr

Offline Jester

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Re: Matty's Polo G40
« Reply #9 on: January 07, 2014, 10:00:20 pm »
where did you manage to find a set of them  :o

Offline JoeH

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Re: Matty's Polo G40
« Reply #10 on: January 08, 2014, 11:32:36 pm »
NICE work
Have you poly bushed the outer end of the TCA, its just I would defo Nylon bush it, PPP sell them, much harder and won' tear...

You gonna LSD/Quaife it, with that much power?

Offline JoeH

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Re: Matty's Polo G40
« Reply #11 on: January 08, 2014, 11:34:58 pm »
Also, will you fit the little ARB block ring clamps? looks like you got the ARB that won't let your fit one on next to each block...
be interested to hear a solution

Offline Lionheart

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Re: Matty's Polo G40
« Reply #12 on: January 10, 2014, 11:52:50 pm »
Hi Matty, is that a stage two sub frame? And why did you need to drop the down pipe? Great project and thank you for putting the thread up.

Offline Matty!

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Re: Matty's Polo G40
« Reply #13 on: January 12, 2014, 07:28:58 pm »
Hey guys

I polybushed the inners, and the outers were already polybushed, I feel nylon would be abit of a rough ride for a road car especially coupled with the salzmann top mounts as ive heard they compromise on ride, I want it abit of a happy medium as im fortunate to have to epic roads on my doorstep, same as to why I went for stage 2 over 3, I dont think the benefits would benefit qhat I will be predominantly using the car for.

Thats not to say it will definitely be doing some track days this year!

I will eventually LSD it, but just one step at a time, dont want to do everything at once or I will have nothing to look forward too haha! Its probably on the limit at the moment but adds to the challenge of driving it, hopefully all this stiffening/ new setup should bring a little more confidence in the car, but depending on my situation next year I may look into a G60 or G45 setup but its not proirity, half cage is pencilled in for next winter! :D

I just hadn't fitted the clamps there, there on now, in satin black, look lovley!

Lion - had to drop the exhaust to get the rear of the frame over it :) if your planning on fitting one it will make sense when you come to it.

Bolted the rear strut brace in today too, probably the easiest mod I've ever done!

« Last Edit: January 12, 2014, 07:36:08 pm by Matty! »

Offline Matty!

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Re: Matty's Polo G40
« Reply #14 on: April 07, 2014, 09:16:12 pm »
UPDATE:


Been cracking on with this as and when.

First up, Front Bumper:

When I bought the car it had some mesh where the foglights were meant to go, and I always intended to get some foglights for the car, untill I realised how rare and expensive they are... I nearly spat my drink out when I saw how much they go for!

So I was browsing PVW bored as you do at work and found a MK3 golf that had brake vents installed, so I thought yeah Ill do that instead but make it a cold air feed.

Bit of measuring and headaches later I had some thing that would work, but when I placed them up to the car they were fouling the chassis... so had to rethink the ducts and eventually got them to fit nicely, happy days!

Also retro-fitted a new 6n front splitter to make the car look a tad more aggressive.


Polo G40 KW by Matty!, on Flickr


Polo G40 KW by Matty!, on Flickr


Polo G40 KW by Matty!, on Flickr


Polo G40 KW by Matty!, on Flickr


Polo G40 KW by Matty!, on Flickr



These arrived from KW this week... After the palava of loosing one strut 'during transit' and having to buy a second set...


Polo G40 KW by Matty!, on Flickr


Polo G40 KW by Matty!, on Flickr

Together will all the chassis components - Adjustable top mounts, Strut braces and V1's

I had the strut braces re powdercoated at RS-Alloys as the finish from wiechers was so weak it was chipping just looking at it.


Polo G40 KW by Matty!, on Flickr

Should be a beauty with all these chassis mods on!

Also got a Ferrari wheel 502bb wheel!


Polo G40 KW by Matty!, on Flickr

In which I have leather restored to freshen the 30 years worth of grubby mits to bring the old girl back up.


Got it all back together, the car had been stood for 6 months, and boom first flick of the key and it started! to a horrific noise... took me and my dad about 6 hours to work out what the hell was knocking we knew it was around the alternator but not sure what was after driving it it turned out to be the alternator pulley clipping the chassis due to the chassis being so stiff when the engine moved the toothed belt pulley was clipping it!

anywho modified the pulley and got the alternator refurbished whilst it was off and were all good! handles epically now!

Heres some pictorsss

Ferrari wheel on


Carpetted the rear turrets




Rear KW's on


Fronts




D-day


Its probably slightly lower now but heres what it looked like straight off the jacks











After a nice hoon over the moors:










Verdict:

The car drives completely differently now, before I had to really manipulate the steering to get it to hold a corner at pace, since all the chassis mods I've found I am still learning the car especially with the limit becoming several levels beyond what it was before, I find I hardly have to move the steering now its so direct and flicky, looking forward to a few more sunny mornings/evenings!



This week the car is booked at AAS for a fully custom race exhaust, I consider these one of the best exhaust builders in the country so it should be interesting and definitely sound epic!

Heres what my lupo sounded like after there work...

https://www.youtube.com/watch?v=y-eiW5rxjjs