Etches G40 (2)

[higgo]

Bet your gutted but also glad you started the poking...... least now you can stop it before it gets worse. Love this car, makes me actually like my white mk3 as I can imagine its as cool as this (It really isnt!)

[JoeH]

I always tend to fill the sills full of some decent waxoil on any polo's i've had, as holes in sill gets em all eventually, imo.
Hope you get it done.

[Etches]

Cheers Higgo, I've only ever owned alpine white mk3s since 2007 haha!

Joe man, only problem with doing that is that if you put waxoil on the inside is that its flammable, dont really fancy another fire at least till next year haha!

Will get some pics up tnite how I get on, not welded before so its guna be some good practise haha!

[Etches]

Straight 5 hour stretch tnite!

Marked out danger zones



All the shit cut out



Metal cut



Managed to do two



My appreciation for welders has gone up ten fold, I practised for about half an hour pre welding on the car and managed to find the setting I preferred. Only managed to blow a few holes but sorted em, not pretty but its solid as fuck.

Will get ground back tomorrow undersealed , high build then painted. Should manage to get to bed normal time hopefully!

[Etches]

Yeah , I've not enjoyed this job haha. What a ballache!!

Sorted the final two, the small one was an absolute bastard. Ran out of gas which made it difficult!!



All cleaned and undersealed,

[Etches]

Got the MOT monday , flew through with minors for a little bit of crumpled sill from jacking up and an oil drip.



On the way home to sheff lost all boost, got a massive blow from the turbo manifold-turbo section. Guna whip that off to check , fingers crossed its just the gasket! Polo show next week so best be an easy fix.

[Etches]

Just spent the last half an hour to find this,







The old tubular - cast argument comes to mind lads!! Guna take it somewhere to get welded up properly. Bloody annoying!

[z3i]

Ah Dayum!! Message Phil J lol

[PeteG40]

when i saw the pics all i thought was 'flange' haha

[Andy]

Where did you get your oil drain line from please? Looks decent.

Make sure you mark up the exact orientation of the flange in relation to the manifold, don't want to find the downpipe etc. doesn't fit properly after you get it re-welded!

[Etches]

Just looked through 30 pages of Pm's Andy and couldnt find the chap off here who I bought em from! Do you run a gasket on the feed?

Fortunately there is a weld bead which shows the orientation but Ill Sharpie marker it to be sure!

Its lasted 6k miles so not very good at all, fortunately I've just nabbed those poly engine mounts so hopefully that stops the engine moving as much.

[z3i]

when i saw the pics all i thought was 'flange' haha

Such a child....

[Etches]

Managed to find some lad in Barrow to sort my manifold using a beast of a tig



He did a really good job welding from both sides!

[Etches]

Been a really rushed week as I'm going to the polo show on friday, sorted the manifold



All back together, had a difficulty bolting the turbo to the manifold as the welds had given less room for nuts when fully tight.



Happy I snapped these up last week, higher shore engine mount bushes and powder coated mounts



Hopefully these should minimise the engine rocking.

Also managed to put the driver sill trim back on



Might get round to chucking those mounts on and give it a wash before friday

[PeteG40]

Is drivers one in right looks upside down compared to others