Author Topic: G40 Turbo trackday car  (Read 3662 times)

Offline hobbes

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G40 Turbo trackday car
« on: September 27, 2011, 10:03:36 pm »

This is the buildthread for me and three mates' Polo G40 that we're making into a trackday car. The car was originally a Coupe CL but was converted to a G40 in the late 90s or early 2000s. I got the car 3 years ago and i had to fly to northern Norway and drive over 700 miles to get it home. (the G40 was never sold here in Norway, and i guess theres something between 10 and 20 cars in the country atm.) Back then, the car looked shit, it looked like it just came back from pimp my ride and featured a large stereo, cd-changer, pink bucketseats, two-tone paint and a ridicolous frontbumper. Since then it has been rotting outside my house as i got a brand new scirocco as my daily drive. But thats going to change now, we're planning on having the car ready for the first VW Audi Club Norwegen trackday in may next year.
The engine will be turboconverted and we already got a Rothe Motorsport manifold, K03 turbo, downpipe and a GT cam. The body will be widened in the arches, the windows will be swapped for makrolon ones and a rollcage, fuelcell, bucketseats and other stuff necessary to get the FIA license will be installed aswell. The interior has been ribbed for everything as weight will be a key factor. The asphaltmats and the rest of the sound dampening and insulation has been removed and we're looking at installing the cage next week.

Lets start of with a pic of the car, back in its glorydays when it was a "showstopper":

There's no doubt that drastic changes had to be done to this car.

This is a sketch i made of how the car will look when we're finished:

Større versjon her

Over to specifications and parts list.

1272cc G40 motor OK
Rothe Motorsport manifold OK
KKK K03 turbo  OK
Custom downpipe OK
Ported intake
Ported throttlebody
250cc injectors
GT cam OK
GT 4-speed box OK
Walbro 255lph fuelpump
19l fuelcell
Custom 2.5" exhaust with sidepipe
Metal headgasket
Large frontmounted intercooler
13row oilcooler with thermostat
PPP re-map
Greenfilter OK

Chassis and suspension:
PPP Stage 2 subframe with g-laderseite bushings
TA Technix coilovers
New bushings and bearings
BBS Mahle 14x6 ET13 OK

Black paint
Custom fiberglass "Integrale" spoiler
Custom fiberglass "integrale" evo/cup mirrors
Makrolon (lexan) windows OK
Custom diffusor
Original frontbumper
Mattig cupspoiler
OMP main power switch
Mono windscreen wiper OK
Yellow tinted frontlights
Clean grill
Widened arches

OMP rollcage OK
OMP Corsica wheel OK
OMP bucketseats
Sabelt 6point belts
Ribbed interior, sound isolation removed OK
Flocked dashboard with kevlar plates and gauges

Items marked with OK means that we already got them, or that they are purchased.

Some pictures:

Removing the asphaltmats


Widened wheel arch vs original


To be continued.
Appreciate comments, feedback and experiences with G40 trackdaycars, racecars, turboconvertion etc.

Offline Yoof

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Re: G40 Turbo trackday car
« Reply #1 on: September 29, 2011, 09:45:48 pm »
Looks like a good start- are you planning on racing it? Or just trackdays?

Offline hobbes

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Re: G40 Turbo trackday car
« Reply #2 on: September 29, 2011, 10:42:59 pm »
Just for trackdays for start, but we're specing it for the norwegian GT3 requirements (FIA rollcage, seats, 6pt belts, fuelcell, power to weight and so on). That way, we will have the opportunity later on, if we decide on racing it!

Offline breadman

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Re: G40 Turbo trackday car
« Reply #3 on: October 01, 2011, 12:35:28 pm »
Sounds like an excellent project. 'Gotta be said it did look shite when you got it though!
I've heard that the 3F/GT cam isn't very suitable with a K03 turbo? Yoof will be able to confirm this I'm sure.
Good luck with it mate, keep us posted.

Offline hobbes

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Re: G40 Turbo trackday car
« Reply #4 on: October 02, 2011, 06:25:28 pm »
I have no idea, im not in charge of the engine bit :) The GT cam came with the K03 turbokit.. Im not sure wether we're gonna use it yet..

Some new and old parts:

Offline hobbes

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Re: G40 Turbo trackday car
« Reply #5 on: October 10, 2011, 09:28:24 pm »
Small update.

Speedo before:


The steering wheel cleaned up

OMP Corsica

Makrolon windows arrived today :)

« Last Edit: October 11, 2011, 10:35:16 pm by hobbes »

Offline hobbes

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Re: G40 Turbo trackday car
« Reply #6 on: October 13, 2011, 09:37:10 pm »
Been working on the dashboard today, we're going to use the dash from a mk2 rather than the mk2f because its alot more tidy and it weighs 3kg less. I got some kevlar plates from ebay which i have been modifying to fit!

The plate was not long enough to cover the whole panel so had to use two.. Ended up like this:

All done

Installing gauges

Intercooler arrived today, oilcooler with sandwichplate and alu piping and hoses for the IC arrived yesterday!

Offline hobbes

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Re: G40 Turbo trackday car
« Reply #7 on: December 23, 2011, 04:20:49 am »

BBS Mahle 13x6 ET13:


Offline DMWG40

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Re: G40 Turbo trackday car
« Reply #8 on: March 21, 2012, 11:18:11 am »
Looks like a good project keep up the hard work