Author Topic: mk2 g40 conversion  (Read 2866 times)

Offline Freddy77

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mk2 g40 conversion
« on: May 15, 2014, 08:51:03 pm »
so long over due I thought I should post the progress of the mk2 polo I bought off scotti

the car its self Is a mk2 coupe originally with little 1 litre had been converted (badly) to a charged
engine,

lowered all round on ta teknics shocks and springs on banded baby g60 steels

standard interior apart from a wolfsburg steering wheel
lots of work for me to do

this was the day after i bought it and aftera good wax polish not to shabby really



I removed the engine that was fitted a standard g40 lump with a jabba ported charger
as you will see below the engine bay was not the tidiest so I gave it a lick of paint

so with my engine in now it was time to make my ginger mark on the polo, I had done standardbay so some thing a bit different was on the cards



« Last Edit: May 15, 2014, 10:20:24 pm by Freddy77 »

Offline Freddy77

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Re: New project
« Reply #1 on: May 15, 2014, 08:59:15 pm »
heres a couple of photos of the old bay compared to the new,
I fitted the engine out of my lhd g which was a low mile one
and my charger as the  ocd one needs a good clear out where
it looks like they have gone crazy with kluber,
washing machine pipe work wasnt exactly working for the car
jabba cone is going and the ginger stamp on the engine is starting
to appear, just in the process of trying to fit an intercooler, due to a lack of space
its a lot harder than first thought,











Offline Freddy77

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Re: New project
« Reply #2 on: May 15, 2014, 09:04:44 pm »
interior looking a bit shabby, needed my gauges and probably get rid of that wheel,
not a big fan

looks really good once waxed and clayed

carbon fibre show plates, seemed rude not to

Offline JoeH

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Re: mk2 g40 conversion
« Reply #3 on: May 15, 2014, 10:34:26 pm »
Yess, looks like quality work, I remember speaking to VWS in Exeter (who had it in their garage for ages) who said it was a poor conversion.
Poor location for intercooler, poor cutting of engine bay panels. They said they struggled to get it running. And when they took it for a drive, they couldn't get any power down due to poor suspension... couldn't hit any bump.

Anyway I dunno if any of the above is/was your opinion too.

Is it still got 1 litre exhaust too?

Looks like its got a quality owner, exciting thread!

Offline Freddy77

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Re: mk2 g40 conversion
« Reply #4 on: May 15, 2014, 11:08:45 pm »
Glad to hear your a fan.
It does still have a pea shooter exhaust, when its running it
will have a custom system made for it.

Intercooler location was useless. Along with awful boost pipes.
I think whoever did the conversion didnt understand the concept
of boost

its still too low but can afford to sort as yet, stil got loads
To fit,
Needed g40 brakes so im using my old ones with new disks and pads
with braided hoses,
needs a 5spd arb which is in the powdercoaters and I have polybushed tcs's
which should all help with arb blocks, decent tyres is anothe of its issues

I had to dress the badly cut slam panel as they has cut too far, dont mind a bit of filing
once the engine is at a state that everything is in and fitting well I will remove the charger
and neaten it up there,

hopefully running shouldn't be an issue as im using my own loom ecu engine and box so
any issues it has will become obvious very quickly
just intercoolers im struggling with and need to source a small compact one simlar to standard size
but with straight end fittings

Offline Etches

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Re: mk2 g40 conversion
« Reply #5 on: May 16, 2014, 06:46:28 am »
Looks reallly cool man :)

Offline dubstar

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Re: mk2 g40 conversion
« Reply #6 on: May 16, 2014, 07:29:25 am »
Yeah I'm a fan too.  8)

Offline Jester

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Re: mk2 g40 conversion
« Reply #7 on: May 16, 2014, 07:48:51 pm »
Always thought this looked good when i'd seen it before. Glad it's in good hand's now

Offline breadman

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Re: mk2 g40 conversion
« Reply #8 on: May 17, 2014, 10:45:09 pm »
Always thought this looked good when i'd seen it before. Glad it's in good hand's now

I'll second that.
Properly sorted this will be a stunning car.
Keep us posted.

Offline Freddy77

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Re: mk2 g40 conversion
« Reply #9 on: May 18, 2014, 12:54:57 pm »
Well I want it ready sooner rather than later
however I have got my lhd one to finish stripping to scrap and then I can pull the mk2 out of the garage
and get it up on stands to finish the suspension stuff,
I have everythig needed to do it as I had a full g40 donor

Will keep the pictures coming

Offline Freddy77

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Re: mk2 g40 conversion
« Reply #10 on: June 11, 2014, 08:00:09 pm »
so I thought I would post an update on my mk2 as mines been completly out shone by the beautiful by the dark grey one
so ive been having some intercooler fun the last month or so, had to try and fit one in the small space between
the radiator and the grille because It is the biggest void at the front of the car, I thought mounting it where
the standard mk2 on would go would not get enough air flow and due to the height would get easily damaged



this was how I wanted to run the original mk2 boost pipe




heres the gap I had to fill, looks tighter than it is, ignore the boot pipe going the wrong way
I was contemplating going the full race fmic in front of the grill, silly idea





so I tried many different ideas  bought a toyo sports small intercooler, didnt comprend size and it was massive,
seen them fitted to mk2f cars and never realised how big they are, so I was contemplating using a standard one with revised end fittings as there easy to remove, didnt work so I bought this extra small one from tx auto sport which with a slight cut in the slam panel fitted like a glove






so this weekend with the wifes permission slip signed I was allowed to venture into the garage and go full chat on the rebuild, happy with how well the new intercooler braced the front panel, however I have now lost the ability to latch the bonnet so it will be going on flush fit lock pins, not a complete picture here but not far from, looks ace out in the sun, just need some more subtle orange touches,


not the clearest photo but heres how the intercooler setup looks fitted, its not 100% neat however is fit for purpose,
was not able to use the mk2 solid pipe in the end so used the 2f one instead, had to extent the inlet to boost pipe to help it fit, but this seems to look fine, just need a new header tank as mines minging,







so I built the engine complete, added the grille with a cheeky superchaged badge,
can just see the cooler through the grill so looks nice and subtle



Offline Freddy77

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Re: mk2 g40 conversion
« Reply #11 on: June 11, 2014, 08:08:54 pm »

also had a few more goodies picked up from the powder coaters ealier, arb from my old polo, gear box mount, front gerbox mount and the big washer and gladerseite (PPP) ARB  block plates
got a weekend ahead of me involiving fitting these beaties and fitting vwii caplipers
brembo disks, ebc pads, polybushed tca's and some braided hoses










Offline Freddy77

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Re: mk2 g40 conversion
« Reply #12 on: June 13, 2014, 03:10:33 pm »
So its starts and runs however a suspectpool of oil led me to do a bit of investigation,
Typical g lader and its unpredictable oil seals, bear in mind its done 3k miles
and only moved from one car to another. It now is just the best oil pump ever,
The annoyance is having to clean out my boost pipes again, I have a spate charger
which I hope to hell is a servicable one, it was on the car when I bought it, so fingers crossed
It will work

in more positive news I have managed to solve a gear selector problem
and now got some orange vac and washer pipe just to add a bit more ginger to the car

Offline 1982mk1

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Re: mk2 g40 conversion
« Reply #13 on: June 19, 2014, 08:33:15 pm »
This is tidy mate! Shame about the charger though!
Good luck getting her all sorted and on the road :)