Author Topic: Daily G40- Windsor Blue L-Reg  (Read 13013 times)

Offline scotsjohn

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Re: Daily G40- Windsor Blue L-Reg
« Reply #15 on: September 14, 2012, 10:26:31 am »
Will you be keeping the PPS subframe in it Pete ? LOL.

Offline Andy

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Re: Daily G40- Windsor Blue L-Reg
« Reply #16 on: September 14, 2012, 12:02:38 pm »
Funny you mention that...

The race spec spesh gearbox mount supplied with it drops the engine at the back so much that the gear linkage operates in a different plane to the gear selector rod on the gearbox itself. Makes for a lovely shift! ::)

Offline Yoof

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Re: Daily G40- Windsor Blue L-Reg
« Reply #17 on: September 14, 2012, 12:32:20 pm »
Will you be keeping the PPS subframe in it Pete ? LOL.

LOL, nah, already sold that POS. The size of the holes at the front are quality, will get a pic next to one of ours.

Will put some ARB Blocks and new bushes on, I might put a stage 2 on it too, depends on time etc.

Engine is almost out of it now, got quite a few standard bits to go back on, but need a few biggies. Hoping to have it done over winter at a fairly relaxed pace, still got the red one to fix too!

Offline Justin14100

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Re: Daily G40- Windsor Blue L-Reg
« Reply #18 on: September 14, 2012, 02:29:39 pm »
The PPS subframe front bolt holes is probably about as bad as the original idea not having an anti-roll bar. The Germans laughed at it when they saw it...

Offline scotsjohn

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Re: Daily G40- Windsor Blue L-Reg
« Reply #19 on: September 14, 2012, 04:11:26 pm »
The bolt holes on mine took the 10mm bolts I fitted quite snugly, so I didn't have any issues with them.

Offline Yoof

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Re: Daily G40- Windsor Blue L-Reg
« Reply #20 on: October 09, 2012, 01:16:23 pm »
Have been busy buying a house recently, so have been trying to thin down my stock of various Polo related parts, spent a little time on the G40 last week, fitting nylon TCA bushes, ARB Blocks, and one of our stage 2 frames (installation guide to follow).

Will write up a guide to stage 2 fitting, in the meantime I leave you with pictures of what was on it, and what’s on it now...

What came off, quite frankly dangerous- new owner is welding fresh metal in on these thank god:







And its replacement, much better:









Took a few hours to fit (although I'v done a few now) and no drilling of any holes required, which means the repair work on the chassis was probably done for strength, not post accident damage, but I'll never know. All good now and ready for lots of road miles.

Whilst I had the TCAs out I decided to regrease and clean them, fairly simple job and should mean they last a little longer:

Take one crud filled TCA:



Clean and apply moly-coat grease:



Refit cleaned boot and clips:



Can see some of the chassis work here:



Welding looks acceptable, been stone chipped in the past so no signs of rusting, I'm going to spray it and leave, I'm happy with chassis strength now there's a decent subframe fitted.

Got some pistons on their way from Terry, so will be building a stock (ish) 1272cc motor for it, with a G40 lader on 65mm pulley once Pete's built it back up, and an ATV box, should be restored to its former glory and hopefully 130bhp or so.

Cheers

Pete

Offline DMWG40

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Re: Daily G40- Windsor Blue L-Reg
« Reply #21 on: October 17, 2012, 02:57:30 pm »
Nice motor, nice job on the work
  off the top of my head the only guy I knew who owned a L reg Windsor blue back in the days was a guy call shailan .

Offline Yoof

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Re: Daily G40- Windsor Blue L-Reg
« Reply #22 on: December 19, 2012, 02:27:27 pm »
Few more bits arrived for this now:

1272cc PY lump with a new CG Clutch (Thanks Gav!)
65mm Pulley
Stock Lader
ATV Gearbox

So should be able to restore it to its former glory (with a little better chassis and a touch more power)

Jobs to do:

Rebuild Supercharger over Christmas with Mr Mirfin
Swap ARB to one with decent threads (Cheers Sam)
New Cambelt, Waterpump and gasket set for the engine
Fit 13” Refurbished BBS with A539
Swap front bumper to stock one
Weld new flexi onto exhaust
Build engine up with fresh bits and painted up
Custom PPP map

Bits to source:

Stock Airbox – anyone got one?

Offline josé

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Re: Daily G40- Windsor Blue L-Reg
« Reply #23 on: December 19, 2012, 09:47:17 pm »
Think i've got a standard air box lying round somewhere, its been "de-restricted" where the charger pipe connects, all in good nick as far as i can remember.

josh

Offline Yoof

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Re: Daily G40- Windsor Blue L-Reg
« Reply #24 on: January 05, 2013, 04:45:53 pm »
Cheers Josh- can you PM me some payment details mate.

Been cracking on with this recentley, cleaning, painting, refurbishing bits and collecting parts, waiting for a top end gasket set to arrive, engine should be nice and fresh with a new cambelt and gaskets etc.

So, a few pics:

CG clutch release baring and clean gearbox (ATV):







CG Clutch (almost new):



Box bolted to engine so I can build it up before sticking it in.



Painting various bits with engine enamel- seems hardy stuff and looks great:





VHT on the exhaust manifold:



Refurbished Injectors ready to go:



REfurbished set of BBS from Pete- need a good clean but very straight  ;D



All for now, getting back towards an original smart (dare I say rare?) G40  :)

Offline Jester

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Re: Daily G40- Windsor Blue L-Reg
« Reply #25 on: January 05, 2013, 09:51:50 pm »
Awesome car, awesome thread, I love it when parts look super fresh  ::)

Offline erixtar1992

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Re: Daily G40- Windsor Blue L-Reg
« Reply #26 on: January 07, 2013, 07:31:26 pm »
looking nice this mr yoof. very nice colour indeed

Offline Yoof

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Re: Daily G40- Windsor Blue L-Reg
« Reply #27 on: January 08, 2013, 11:09:09 am »
Ordered today:

Cambelt
Waterpump
Dizzy gasket
Thermostat gasket
Cam seal
Inlet Gasket
Exhaust Gasket
Oil Filter
Fuel Filter
Air Filter
Oil (Synta Silver 10W40)
G12 Coolant
Gearbox Oil

Need to order a new set of plugs to go with the rest of the ignition system then that’s about everything which can be replaced done. Hopefully with a serviced charger it should be like new  ;D

More pics up at the weekend once it’s built back up, might aim to have it in the car by the end of Jan.

Offline MartinB

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Re: Daily G40- Windsor Blue L-Reg
« Reply #28 on: January 08, 2013, 01:24:02 pm »
Lovely :)

Offline Yoof

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Re: Daily G40- Windsor Blue L-Reg
« Reply #29 on: January 10, 2013, 08:19:51 pm »
Bit more done tonight before my fingers froze.

Few new bits:



Cam seal in:



New water pump and cleaned covers gone on, and then new cambelt all timed up:



Rocker and exhaust manifold back on:



Looks good- need to clean some overspray off a few bits, but getting there:



Hopefully by the weekend everything engine wise will be built up and ready to go, got to paint the engine mounts etc yet too.

Cheers

Pete