Author Topic: Trials and tribulations of a cheap G40  (Read 26642 times)

Offline physicsfool

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Trials and tribulations of a cheap G40
« on: December 22, 2013, 03:36:29 pm »
Hi All

So here is quick update of the last 8 months of G40 ownership:

Was on the look out for a mk2f polo after my last vehicle didn't fulfill certain criteria.


I bought this G40, having viewed it 4 hours previous, not a shred of service history and taking it for a test drive. No idea why anyone would put a supercharger on a 1.3 8v but it drove nicely and bloody quick.


After a good wash and bucket of T cut and some bumper spray. looking pretty flash.


But clean engine bay and no apparent abuse to any part of the engine


Now, I am still young and hopelessly optimistic, but when i thought i could run this car cheaply, that was my first and greatest mistake. Especially as i am not a mechanic, my hands are soft and only good for writing reports on my ergonomic keyboard.

24th birthday i got a Haynes manual, single greatest tool...... And then it all kicked off


but it was summer so long days and warm weekends


the culprit


but i made a good friend in the process.... his head work skills (waaaaahhey) are top notch


Plus the charger was pissing oil, so one top Yorkshire bloke later (pete) i had a fresh set of seals and a refurbished charger.


Usual top scroll bearing issues.............Hammer time


New belt and water pump....... never paying a mechanic to do one of these again is a good feeling


rebuild was a success and after a few timing issues she roared into life


Bought a £50 ATV with a smashed set of planetary gears


After a refurb and oil popped it on, runs mint but the release bearing has gone. Should havent swapped it out and not been a pikey about it


feel good small jobs..


..nice results


So here i am now, stripped the plastic arches to reveal bad wings. Popped some solid red doors on, not the best look though



Rust is pretty prevalent


So an window out spray is in order


frustratingly quite a bit of water still seems to be getting into the driver side foot well, i think the battery tray weld needs a touch up


The lake of water


So that's the plan, strip it down and paint it up.
« Last Edit: December 22, 2013, 04:00:14 pm by physicsfool »

Offline vee-dub90

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Re: Trials and tribulations of a cheap G40
« Reply #1 on: December 24, 2013, 01:40:57 am »
Looks like a good project you have there!

Offline physicsfool

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Re: Trials and tribulations of a cheap G40
« Reply #2 on: December 24, 2013, 02:42:31 pm »
    Ay, getting it RR'd soon so i have a good starting point. I dont want to do anything too destructive.. but....

    To do:
    • Lighten the flywheel
    • Chap that did the head work also ports, so fancy having a proper look into that
    • Do all the bottom end seals

    But this is mainly to repaint and freshen up

Offline z3i

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Re: Trials and tribulations of a cheap G40
« Reply #3 on: December 24, 2013, 05:01:51 pm »
Nice! I like it, keeps us updated :)

Offline dubstar

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Re: Trials and tribulations of a cheap G40
« Reply #4 on: December 29, 2013, 06:04:54 pm »
Good man for getting your hands dirty and finding out what life's about. Nice one chap.

Offline physicsfool

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Re: Trials and tribulations of a cheap G40
« Reply #5 on: January 16, 2014, 11:10:13 pm »
Got the rolling road on Saturday so in preparation I tightened the v-belts


And swapped the intercooler for one without a small stone chip hole on the front (left-stone chip)
« Last Edit: January 24, 2014, 09:43:51 pm by physicsfool »

Offline physicsfool

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Re: Trials and tribulations of a cheap G40
« Reply #6 on: January 19, 2014, 09:10:32 pm »
Rolling road on Saturday. This is how it's done in the north.


Generic rolling road photo


Results were good 106 at the wheel. Reckoned around 130 at the flywheel. Torque was good and peaked at 127.


Sooo time to rebuild the engine as I need a project. Daily is a 1.9tdi A4.


Been tagging the wiring loom so I don't forget where each belongs. Plus plastic bags to hold the bundles. There is a bit of damage to various wires. So thinking I may replace some sections
 

Got hold of an engine hoist so thought I would get it all done in one weekend


Then once free, got to stripping it down. Much easier second time round


Finally 24 hours after the rolling road...


So been a cracking polo related weekend. Got a cylinder head off here. Hoping to get a bit of porting and flow figures.


And just wondering if this is a standard exhaust?
« Last Edit: March 30, 2014, 07:01:42 pm by physicsfool »

Offline physicsfool

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Re: Trials and tribulations of a cheap G40
« Reply #7 on: January 21, 2014, 01:26:29 pm »
Cheeky 2 hour session this morning before uni, the bonus of studentom. Got hold of this weapon. With a fully charged battery it made quick work of the bottom crank bolt and flywheel bolts as well as the drive-shaft bolts. I have a feeling a lot more energy would have been expended otherwise. Plus i picked up a engine stand which i will attach the engine to later this evening.


Offline physicsfool

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Re: Trials and tribulations of a cheap G40
« Reply #8 on: January 21, 2014, 01:28:09 pm »
I apologies for the photo quality, turns out apple are pikey's that develop incompatible software

Offline Etches

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Re: Trials and tribulations of a cheap G40
« Reply #9 on: January 21, 2014, 05:32:34 pm »
Glad you tightened those belts Martin has your battery light gone off now?? Didn't realise you were breaking her down again after the rolling road haha! That looks like a standard exhaust to me fella, gimmie a shout if you want that modified one of mine it's yours for mega cheap  ;) will just need a decent backbox chucking on. Also gimmie a shout if youve got any q's when building the girl back up (seals n that)

Offline PeteG40

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Re: Trials and tribulations of a cheap G40
« Reply #10 on: January 21, 2014, 06:39:37 pm »
Looks like yr doing a decent job.

If u need any parts let me know! !!

Offline physicsfool

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Re: Trials and tribulations of a cheap G40
« Reply #11 on: January 21, 2014, 07:50:09 pm »
Battery light is still there, will be trying the new alternator.
Yeah count me in for the exhaust lad. When do I need to pick it up by?

Pete, list of parts from your horde is growing, just need my funding to kick in and I will be paying a visit!

Offline physicsfool

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Re: Trials and tribulations of a cheap G40
« Reply #12 on: January 25, 2014, 03:16:22 pm »
So I have whipped the entirety of the engine bay loom out. And spent the week measuring cutting and determining current capacities. Just need to order some up and cut to size and hopefully I will have a spanking new loom.
This is how it all started:


Now I have spent the day breaking the cylinder head off, valves and plugs are pretty black. Over fuelling is my guess!?


And finally p*ssing around trying to be arty!




Offline z3i

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Re: Trials and tribulations of a cheap G40
« Reply #13 on: January 26, 2014, 08:19:50 am »
awesome!!
im getting a workshop with a booth in the sumer (going halves with a mate :))
if you havnt sorted the paint out by then we could work something out if you want me to spray it? only problem is its in stevenage. but could do a pro job for like half what a bodyshop would charge! :D
Taylor

Offline Etches

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Re: Trials and tribulations of a cheap G40
« Reply #14 on: January 26, 2014, 08:24:55 am »
I'll be tempted after the show season Taylor! Great work with the loom Martin, you keeping all the old connectors then? Valves look like they are overfuelling as much as mine , factor in a wideband dude when your putting it all together  ;D