my G40 project She runs YAY YAY new pics

ok so about a month of slow progress i have been "slotting" a g40 into my mk1 1.1 and this how im getting along from this


to this


i must admit its been a bit more "fun" than exspected i didnt want to cut into my chassis so i decided to make a creation from both golf and polo mount for the nearside mount ie the charge mount so this how it turned out


but there was another problem the belt was rubbing on the mount so added a
fan belt tensioner from a pug 406 diesel and should be fine but have had to order some new belts which im still waiting for.

done nearly all the wiring now apart from the dash wiring and the fuel pump wiring SHE TURNS OVER AND SPARKS.

next prob was what intercooler to use so i have decided on on a twin pass from a renault 5 but still waitin for it to arrive then will sort the intercooler pipe work.

So there you go any comments welcome :twisted:

haha nice1 wish I could just 'slot' a G40 into my 1.1    :twisted:

Keep us posted on how its going, maybe upload a video onto youtube of it tickin over n that? That would be good.

Cheeers

well spent a good days work on her today changed the fuel tank and put my exhaust on i am using a G40 4 branch with a gti1.6 OMP system seems to all fit good but there is a section about the same size as the flexy pipe which is missing to join the 2 together so does any know where i can get some big bore flexi???? need to be at least 1.75" bore any ideas?

look on ebay, pipewerx do them made to order, either weld or clamp on and pipewerx have an ebay outlet too, also plenty of other companies on there that sell the flexis for pittance

forgeman said

i didnt want to cut into my chassis so i decided to make a creation

Good man. I've got away without the flexi pipe by using the polybush rear mount and a bigblock bush on the gearbox mount. 3 years down the line and no exhaust issues. I also removed the front snubber. You've got a bit more torque to deal with than I have though.

ok done absolutly nothing today apart from collect a few bits and pieces and took some pics but camera ran out of batts after the first 3    so here they are as i have never put any pics of my car so here they are before and afters

before


at the moment


o yeah and i knew that the black board bonnet would be a good idea lol



all goin gd and i can see the light at the end of the tunnel

today was like christmas for me i got …. my renult5 intercooler which is near perfect fit a new VW 1300 beetle badge just thought it looked cool o yeh a ram air induction kit and i think thats bout it but should be enough to keep me going for a while :twisted:  :twisted:  :twisted:  :twisted:  :twisted:

o yeh just in case some of you pick up on it i have change my deadline lol

awesome, gonna b a beast once its done

im will be doing this to mine, after newyear

a few Q's

how easy is the wireing?

was going to get a whole car and take what bits out i needed

forgot that i had this thread running lol been working too much so not had much time to work on the car but got a few bits done fitted the rad and intercooler trying to get my head around the pipe work. i reunder sealed the whole car and spent all night tring to align my gear linkage but got it sorted  :twisted: nearly got all my bit now just a coulpe of odds and sods to get. and if every gos to plan a couple weeks o yeah the wiring wasn't to hard just make sure you have the polo manuel.
will get some more pics up soon.

Well today i thought i would try and start her and guess what she did YAY :twisted:  :twisted:  :twisted:  
But it highlighted a few probs for example the fuel system leaks like a sieve but new copper washers should sort that
Also the lack of and exhaust gasket was very apparent but aprt from them it was all good  :twisted:

well dun dude just kep it updated with more pic's
=D

i would love to do this conversion….

its gonna fly when its done dude…

ok have been sorting most of the problems out but im still waitng for my 8mm belts for my charger  
but here is some more pics to keep you lot happy

forgeman said

o yeah and i knew that the black board bonnet would be a good idea lol

That is pure class  8)

It's coming along nicely too - plus it's gonna be a bit of a sleeper being a 5 door.

Have you integrated the looms yet? I'd be interested to find out how easy / difficult that is for a G40…

Rich

done most of loom so all the engine electrics work but i need to do the dash ie the oil presure, temp sensor, and i think thats about but really its not that hard the hardest pat so far i eckon is tghe off side mount as i decided not to cut into my chassis as she is petty solid.

but yeah i have learnt alot as the most i had ever done to a car is regular services but had messed about with bikes before. the general aim behind her was a ratty sleeper :twisted:

tidyed moset things up today and thought i would take her for a quick spin   but was a bit dissapointed felt like a poorly running 1.1      but got the bonnet off again a realised that the golf throttle cable was too long so there for wasnt opening the thottle fully so there for the riculation valve was staying open so adjusted it and then i pooed my self  :twisted: she spins up in 1st 2nd a a little in 3rd :twisted:  :twisted: so im happy
also gutted the back and removed all my carpets will get some more pics when shes done and will be at ultimate dubs if all goes to plan :twisted:

well done getting all done

im still havent even fitted the engine in yet

what did you do on the gearbox side?

also fuel system what did you do to get the fuel up front?

ok well for the fuel i used a gti sytem pto the filter then on the end of that i just used a piece of 8mm bore braided pipe to go to the pressure reg
for the gearbox mount i had to make a combination of the top of the old mount and the bottom of the 5 speed
im interesed at how you get about the offside charger mount  i will post some pics up of my mounts and maybe a how 2 guide for a g40 and polo engines
im sure yeha will give his imput

I am cheating Im going turbo so I can use the standard mounts well except gearbox which Ill have to make something up from gti and g40 one I have sitting here.

Also did you have to change your tank? as ive got a few options avaliable for me