Author Topic: Trials and tribulations of a cheap G40  (Read 31150 times)

Offline Jester

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Re: Trials and tribulations of a cheap G40
« Reply #150 on: May 04, 2016, 07:48:52 pm »
Nice update martin, new flat looks very posh.. much better garage then your previous one.

I hope I'm still invited for it's first run? :)

Offline Rich_Royal

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Re: Trials and tribulations of a cheap G40
« Reply #151 on: May 08, 2016, 08:11:22 am »
New garage looks ace mate, what have you done to the passat?  ;D

Offline physicsfool

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Re: Trials and tribulations of a cheap G40
« Reply #152 on: May 10, 2016, 11:51:28 am »
Yeah its nice having a space I can work on the car when its wet outside. Nowt yet, just egr delete and cleaned up the boost pipes and inlet mani. Sorted a few niggles like the drivers door not opening on fob. More of a workhorse, so maintence costs but wont be lowering or putting 19"s on. But got a trip up to the isle of Skye in a few weeks

Also got my mate to put a fresh gearbox in, as the diff bearing had gone



And a cheeky clean this weekend

Offline physicsfool

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Re: Trials and tribulations of a cheap G40
« Reply #153 on: May 17, 2016, 10:27:37 am »
After a tip off from Pete Mirfman I went for a frontera intercooler. And popped the charger and rad back in



And just need to get a few mounting brackets for the intercooler and order a few reducer elbows as the inlets look to be 2"


But getting there slowly, hoping another few sessions and i should be able to test the engine.
« Last Edit: July 06, 2016, 10:21:43 am by physicsfool »

Offline physicsfool

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Re: Trials and tribulations of a cheap G40
« Reply #154 on: July 06, 2016, 10:19:58 am »
Bit more progress

Managed to suss an oil cooler position with thanks to everyones suggestions, it sits really snugly and only requires a few zip ties to keep it in place. All trial an error at this stage


Modified the bumper bar to allow a bit more flow to the intercooler, (intercooler is off a frontera and fits a treat, heads up to Pete Mirfin for the suggestion)


And test fit with the grille, fits behind a treat


And finally the bumper test, which i am happy with, just need a bit of tidying up now


Just refilling the gearbox oil and coolant and i should have a car that moves under its own steam again. which is totes exciting
« Last Edit: July 06, 2016, 10:22:20 am by physicsfool »

Offline Yoof

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Re: Trials and tribulations of a cheap G40
« Reply #155 on: July 06, 2016, 11:32:16 am »
Word of warning - braided lines will (and do) rub through anything, so make sure you clip it securely up  ;)

Do like a red G  8)

Offline physicsfool

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Re: Trials and tribulations of a cheap G40
« Reply #156 on: July 06, 2016, 11:45:11 am »
Cheers, will keep an eye on them. They get pretty warm as well so will make sure nothing gets damaged

Chip turned up today, thanks again for sorting it

Offline Sknight92

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Re: Trials and tribulations of a cheap G40
« Reply #157 on: July 06, 2016, 11:41:03 pm »
Hey man,
Did you have to get different hoses for the intercooler?
I'll definitely check out the frontera for a cooler!

Offline physicsfool

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Re: Trials and tribulations of a cheap G40
« Reply #158 on: July 07, 2016, 11:48:11 am »
Hey man,
Did you have to get different hoses for the intercooler?
I'll definitely check out the frontera for a cooler!

I needed a reducer 51 mm (Intercooler) to 57 mm (rest of the system), used 90 degree jobbies and a stainless 45 degree piece from the hard plastic (co pot) boost pipe down to the intercooler on the pass side. Was all straight forward, and as the outlets on the intercooler face backwards it saves using another 90 bend

Offline Sknight92

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Re: Trials and tribulations of a cheap G40
« Reply #159 on: July 08, 2016, 10:34:05 am »
Sweet, thanks man I'll check that out!
My G is causing me so much pain - currently getting forged by a friend who works at Mclarren (Yup, thee mcclaren, he's on the f1 now)
But still so much to do, praying I have it back before the summer ends. Yours is looking sweet man,
Definitely wish I had another colour other than grey!!
Keep up the good work!

Offline Rich_Royal

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Re: Trials and tribulations of a cheap G40
« Reply #160 on: July 10, 2016, 09:21:20 am »
Damn Martin this is turning out to be a bit of a beast.

Offline physicsfool

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Re: Trials and tribulations of a cheap G40
« Reply #161 on: September 19, 2016, 01:27:35 pm »
Just a quick update: Had a cracking Sunday weather wise, thought the G needed a small nudge towards its MOT, sorted insurance now so just a matter of getting it mechanically sound.

Well I have finished most of the motor issues, just sorting seat belts and making sure the indicators work and the like. Oh and my windscreen washers are back to front so i need to swap the pipes over on the motor.


need to sort the outer trim, but thats way down the list


And before i take it for an MOT i will give it a good clean and make sure its looking its best


But I took it for a drive (down a private road) and brought the smiles right back, that has helped with motivation

I have also bought another project (missus still doesnt know about it). Will update on that when i start working on it

Offline GR40

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Re: Trials and tribulations of a cheap G40
« Reply #162 on: September 19, 2016, 03:56:54 pm »
Or swap the 2 cables, that will work too!  ;D

Offline physicsfool

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Re: Trials and tribulations of a cheap G40
« Reply #163 on: January 05, 2017, 02:51:10 pm »
So finally some exciting news, got it MOT'd which means it no longer needs to spend all its time in a garage. Had a few internal loom issues while prepping it, and maybe a touch of smoke. Also emissions were way out so finally diagnosed as a dead lambda. But gave it a quick Italian tune before its MOT and the old girl does drive really nicely, stage 3 sub frame means handling is spot on.



Want to do a bit of touching up and pop the rear seats back in as well as a good clean.

Emissions failure culprit


So with the better weather will hopefully come more regular updates. Winter is always tough for motivation. Plus I have a thesis to write and a grown up job to find

Offline Jester

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Re: Trials and tribulations of a cheap G40
« Reply #164 on: January 07, 2017, 11:52:46 am »
Yes Martin! congrats. Hope you had a good new year and it's nice to see you finished it.

We should arrange a meet up when the weather improves  8)