Author Topic: Josh's G40 Turbo  (Read 4834 times)

Offline josé

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Josh's G40 Turbo
« on: September 01, 2012, 02:03:55 pm »
Hello everyone after nearly two years in the making i have nearly finished my G40 turbo project after re-shelling my original g40,

I bought the car as a rolling shell some of you may recognize the registration number, Soon after i got it i replaced the front wings as these were  knackered and looked a mess where somebody had hacked the lip with a grinder, I had some solid doors with no rot anywhere that i fitted and treated the car to a re-spray, unfortunately i can't find the pictures at the moment so will upload these when i find them, Once the re-spray was completed i re-shelled my old G40 J218 KFE into this car my reason for doing this was due very bad rot around the car (Drivers Floor pan, inner and outer sills, Rear valance, and boot floor) and also the drivers side chassis leg had seen better days. The paintwork was also looking tired and ideally wanted a re-spray to get the car back to former glory so when this shell came up which is solid with no rot or welding required i transferred all the bits over.

The spec is as follows:
Engine and gearbox
Standard bottom end and head with Newman 268/268 'turbo spec' cam
GT inlet manifold
51mm Throttle body with 6psi pressure switch in place of WOT switch.
G60 250cc injectors
Front mount intercooler
Mocal oil cooler
KKK K03 turbo
Rothe Manifold
PSD downpipe mated to a PPP exhaust system.
Rebuilt ATV with gripper LSD
Engine currently running No boost until its mapped.

Suspension
KW springs and shocks unknown spring rates, with new top mounts, wheel bearings, and G-laderseite TCA bushes
G-laderseite rear beam bushes.
PPP stage 3 subframe

Wheels and brakes
14" BBS RA refurbished with Audi 256mm Calipers

Interior
Standard unfaded interior with Stack Wideband Lambda sensor, boost gauge and oil pressure gauge.

Exterior
Standard with late spec rear lights and clear indicators and side repeaters.

Things left to do:
Sort an annoying misfire.
Re-fit the arch and sill trim blacken the bumpers and a general tidy up of a few things i'm not happy with. Get it re-mapped with PPP with uprated map sensor and 310cc injectors and then give it a good thrash. ;D

So here's a few pics just after its MOT last week,
 
any comments and feedback is much appreciated.
« Last Edit: September 27, 2014, 09:37:31 pm by josé »

Offline josé

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Re: Josh's G40 Turbo Project
« Reply #1 on: September 15, 2012, 07:09:10 pm »
Here's a pic of the car when i was fitting the arch and sill kit

The first wash since the car was painted.


Just after with all trim blackened.






I used some Mcguires tyre shine for the bumpers trim to get it back to black and shiny, What does everyone else use??

Thing left to do are remove the exhaust and chop the downpipe because the exhaust is vibrating against the rear valance and makes a right noise.
Remove some overspray from the rear window.
Fit CD player under the dash.

« Last Edit: September 16, 2012, 02:34:28 pm by josé »

Offline Jester

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Re: Josh's G40 Turbo Project
« Reply #2 on: September 16, 2012, 07:30:48 pm »
Hello!..I like this, very smart and shiny!
Nice to see it's kept fairly standard looking externally, looking really cool now the arch kit & trim is back on, do you think you'll return to the 'vw' badge grill?

Offline g40will

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Re: Josh's G40 Turbo Project
« Reply #3 on: September 16, 2012, 10:04:43 pm »
very nice looking g :)) i use peanut oil for my trim comes up lovely i get mine from morrisons about £2/1l 

Offline Jester

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Re: Josh's G40 Turbo Project
« Reply #4 on: September 17, 2012, 08:20:49 am »
very nice looking g :)) i use peanut oil for my trim comes up lovely i get mine from morrisons about £2/1l 

I used to use boiled oil with a sponge but over time it made the bumpers all weird and sticky almost, I've been using this for a while;

Offline josé

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Re: Josh's G40 Turbo Project
« Reply #5 on: September 17, 2012, 07:45:24 pm »
cool i might look into getting some of that stuff, I was thinking of getting a vw badge grill one becasue all but one clip is broken on the grill at the moment, but i think the one at the minute gives the little car a meaner looking front end as if to say i can still give you a run for your money.  :)

I do like your G though Jester especially with the orange indicators and subtle window tints.

Josh

Offline diggersg40

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Re: Josh's G40 Turbo Project
« Reply #6 on: May 12, 2013, 10:27:43 am »
wow my old g40 back on the road i do miss it

looks really nice mate

Offline breadman

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Re: Josh's G40 Turbo Project
« Reply #7 on: May 12, 2013, 06:47:54 pm »
That looks immaculate Josh, really like that.
Nice and subtle too, good work mate.

Offline Alex

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Re: Josh's G40 Turbo Project
« Reply #8 on: May 13, 2013, 12:25:28 am »
Stunning!

Offline josé

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Re: Josh's G40 Turbo Project
« Reply #9 on: May 14, 2013, 10:32:52 pm »
thanks guys

hope to update it with some more pictures of the engine bay and interior soon when i have time to upload them and a spec/change,

also hope to hit some shows with it this summer weather dependent.....

josh

Offline josé

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Re: Josh's G40 Turbo
« Reply #10 on: August 29, 2015, 09:34:11 am »
Update time!!!!

Since I first started this there have been a lot of the changes to my polo,
 Over the winter I took the engine out and beefed up the chassis leg gussets and stitch welded the engine bay and repainted,

The gripper LSD has gone and now have a quaife ATB diff fitted to a standard box much better and less snatchy than the gripper, also fitted a new CG paddle clutch while at it,

Badge less grille replaced with a standard one and Amber indicators fitted,

I have also dropped the spec of the car because a stage 3 subframe and coilovers were way overkill for the occasional road blast I do In the polo, I bought some GAZ coil overs but sold them and returned to the KW shocks and springs and a stage 2 subframe.

I also sold the Audi 256mm brakes and 14" BBS and returned to 13" with 239 brakes with DS2500 pads and drilled discs, I was sure on the colour of the wheels but I think they well with the car.

I have also replaced the front bumper and fitted a more 'stealthy' intercooler and alloy rad. I've probably missed a load of bits,

Anyway here are some recent pictures:-









 No intercooler hiding behind here  ;)








Nice unfaded rear bench!!

I will upload some more pictures soon once I have done a few little jobs on the old girl.

Josh