Author Topic: GSBellews 92 G40 2001 - 2010  (Read 5018 times)

Offline GSBellew

  • Members
  • *****
  • Posts: 112
GSBellews 92 G40 2001 - 2010
« on: April 03, 2010, 11:57:24 pm »
Its about time I posted up a few pictures of my G40 which has become a long term project.

I bought it on Sunday the 9th of September 2001 after spending a long time looking for one in the UK I happened to hear of one for sale just a few miles from home in the same town as me and the best bit was it was an original Irish registered one, one of only 2 original Irish G40's according to VW Ireland.

Here it was just after I bought it, parked beside my 94 boulevard coupe which it replaced (I have actually just been given that 94 one back too!)

It was virtually standard when I bought it, with the exception of a sebring back box and a slight drop on Eibach springs & Koni adjustable shocks.







I drove it as a daily driver for the next few years cleaning bits and pieces as I went, I had the charger rebuilt in early 02 to Stage 4 spec and changed the exhaust to a more subtle single tailpipe. Besides that I just drove and enjoyed the odd trackday here and there.











Its moment of fame in the Club GTI Rabbit magazine  ;D






It stayed pretty much as it was until 2007 when I decided to finally change the wheels:










Offline GSBellew

  • Members
  • *****
  • Posts: 112
Re: GSBellews 92 G40 2001 - 2010
« Reply #1 on: April 04, 2010, 12:10:13 am »
My original fan was always noisy and it eventually started to sieze, so I swapped it for a Corrado 16v one that I had in the Garage.

Old Polo one:



and The Corrado one fitted:





I had to use the entire shroud from the Corrado fan, it needed minor modification to fit it, but was easy enough to do.

Parked up in the workshop while I went on holidays, you have a glimpse of my day job in the background  ;)





I took it to one more show in 07 before retiring it to do all the bits I'd been putting off.






Offline GSBellew

  • Members
  • *****
  • Posts: 112
Re: GSBellews 92 G40 2001 - 2010
« Reply #2 on: April 04, 2010, 12:26:01 am »
I gave up on cleaning up the original petrol tank and bought a replacement one:



Removed the axle to clean it up:



Brake pressure regulator removed:



One rusty bracket:



All cleaned up:



Then coated in Dinitrol 448 Water based stonechip:





I then repaired any sections of damaged stonechip:



and went OCD on the new petrol tank  ::)

Dents filled, seam sealed, primed, stonechipped and then given a few coats of Satin Black







Fitted to the repainted floor:



I gave the fuel pump / filter bracket the same sort of treatment:



New suspension  ;)




Offline GSBellew

  • Members
  • *****
  • Posts: 112
Re: GSBellews 92 G40 2001 - 2010
« Reply #3 on: April 04, 2010, 12:56:06 am »
I rebuilt the back axle with new wheel cylinders, bolts and handbrake cables:









New brake pressure regulator and new solid lines:





More new bits:



Axle on and brakes back together:





Nearly two years after being put into the garage!



Then back in for the front  :D









I gave up taking photo's at this point as I had a day left to finish it mechanically, install the interior and get it running for the trip to the other end of Ireland for the last show of the Summer, which I was determined to make.......

It took myself and my very understanding wife until 3:40 am the next morning to get it built up, cleaned and ready to go, but we made it, exactly two years after I started it.





It only made it out a few times before going back to its dehumidified garage, before coming back out this week for the summer:



Sebrings are only on as temporary wheels  ;)

More (better) pictures when I get a chance to get it out in good weather.

Offline Puncharado

  • Members
  • *****
  • Posts: 446
  • Back on the road in 2010! No, 2011! Maybe.
Re: GSBellews 92 G40 2001 - 2010
« Reply #4 on: April 04, 2010, 01:57:47 am »
I'm liking this mate, looking real good!

Offline breadman

  • Members
  • *****
  • Posts: 636
  • mk2 breadvan 1341 turbo sleeper (currently snoring
Re: GSBellews 92 G40 2001 - 2010
« Reply #5 on: April 04, 2010, 09:12:49 pm »
That's a stunning rebuild of the underbody, fantastic work mate. 8)
What sort of mileage has the car covered and do you have more plans for it?
Cheers,
Richard.

Offline GSBellew

  • Members
  • *****
  • Posts: 112
Re: GSBellews 92 G40 2001 - 2010
« Reply #6 on: April 04, 2010, 10:57:15 pm »
Thanks, I'm still not happy with lots of little bits and pieces to be honest, but at least I know its solid underneath and will be good for another few years yet  :)

Its done just over 126k miles.

Future plans would see the engine and gearbox coming out to be cleaned up and to give me space to clean the engine bay properly, an overdue charger rebuild and maybe another new exhaust as I am not really happy with how the one that's on it is sitting at the minute, it hangs too low in the centre and is too close to the petrol tank. So I either need to find a nice stainless system or refit the old original exhaust but with a new standard backbox.

Offline GSBellew

  • Members
  • *****
  • Posts: 112
Re: GSBellews 92 G40 2001 - 2010
« Reply #7 on: September 12, 2015, 12:58:40 am »
Well it's been a long time, but I'm still about & so is my G40, just over 14 years since I bought it.

Was in Mondello Park on the FIA graded international track today, good fun but I had it set up all wrong for the wet weather we ended up having.



https://youtu.be/loxkEITAByA

Offline GSBellew

  • Members
  • *****
  • Posts: 112
Re: GSBellews 92 G40 2001 - 2010
« Reply #8 on: September 15, 2015, 11:43:53 pm »
















Offline JoeH

  • Members
  • *****
  • Posts: 213
Re: GSBellews 92 G40 2001 - 2010
« Reply #9 on: September 16, 2015, 08:56:15 pm »
What Mileage has it done now?
Have you done anything to the engine?
It looks mint though, nice to see photo's of it

Offline GSBellew

  • Members
  • *****
  • Posts: 112
Re: GSBellews 92 G40 2001 - 2010
« Reply #10 on: October 09, 2015, 11:57:43 pm »
It's on circa 129k now, it got neglected due to college & young children.

It's not really had any engine work to speak off, stage 4 charger, de restricted
air box & a K&N panel filter.

Needs a charger rebuild now so that will happen over the winter, then I hope
to get a lot more mileage on it next year.