You better bloody run it in properly!

Once this is done.. and my rado has had it's top secret work carried out.... maybe we'll race for slips

not that I really want another polo..... :p

Awesome, I wish, wish , wish I knew where to even start with something like that!

duuude.

dont even start with that mk1.

but shes in kingston now and coming very damn close to finally coming back to life. minus the g40ness, not stoaked. I'm sure something else will come along an fuck it up for me though, haha.

hopefully itll have been worth the wait as much as this should be!

Good work, brings back the memories of building engines!!!!

& the satisfaction of knowing you did it yourself too!!!

Dave, get that mk1 going...

Been working on this the last couple weeks.

Pulled the old lump out.

Then went to pick up my head, just need the last couple bits putting on it...

1mm Bigger exhaust valves, gasflowed and rebuilt...

Then started back on the lump...

Put the crank seals and oil pump on..

Oil breather was a bit of a bastid to get in...

Sorted that, got on with the sump. Put the gasket and a bit of blue flange sealent on...

And on the sump went...

Copper greased near enough every bolt on the engine, should come apart eaasily again, hope it wont have to though!

Tightened it down..

Then got paranoid, and decided to take it off to check all the bolts in the engine.

Weighed the flywheel.. 4.04KGs IF anyone knows the weight of a standard g40 fly wheel that would be great.

looking really good this is, looking forward to seeing pics of the engine in the car :)

Took the lump home to finish it off...

Started to put it together. Then realised it needed a cambelt first

So sorted that and got the rest of the bits on.

Got the head on, torqued it up.

Put the tappets in...

Then left it for the day looking a little more complete...

Painted a few things...

Robbed the cam out of the old engine...

Put it in the new engine, with the new pulley, then put the belt on.

Put the rear water pipe on...

Then the inlet and fuel rail

Put the clutch release bearing on

Then went to put the flywheel and paddle clutch on, and my friction plate had magically disappeared from my garage, between the last time I saw it and when i went to put it on, the only people who had been in there was me, and 2 guys off here who came to buy some bits, which was a nice little setback.

So I had to wait for another one, and got this done today.

Then put the new dizzy, plugs, and gearbox on.

Gearbox lets the engines prettyness down. I had a nice low mileage painted box which spat a gear though the casing, didnt really have the time to paint this atm.

Vw sent me the wrong thermostat housing, and I'm waiting on some more stainless bolts to put the rest of it together (have replaced as many as I can with stainless bolts, need to pick up a few more. So may paint the box this weekend.

Got a new rack, arms, damper, coilies, and bottom arms to put on the suspension before the lump goes in.

Going to do the gearlinkage bush, and rear axle bushes as well when I get a chance.

Top work my man. Nice to see projects like this in detail and with lots of picys.

Have you got any estimate what BHP she'll be running once fully completed????

Good work, brings back the memories of building engines!!!!

& the satisfaction of knowing you did it yourself too!!!

not a true'r word spoken..........nice to see somboby getting there hands dirty and doing it themselfs

Edited 9 May, 200818 yr by bort

thats quite a project....good luck with the outcome

Blimey

wow, makes me want to buy a G lump n rebuild it haha

wow bet that wasnt cheap I'm planning on doing that to an abd engine before i turbo it and put it in my mk2, once iv finished the current abd transplant

Great stuff, good to see such a thorough job.

I changed my sump on the car, Never again. Theres like no clearance under the driveshaft, drove me insane.

Alright Phil,

Lovely job you're doing there, looks the real business.

What make of paddle clutch are you using and where did you get the headwork done? Did you supply the oversize exhaust valves or did they?

Keep us posted with the progress pics mate.

Cheers,

Richard.

Cheers for the comments.

Not sure on bhp yet, will have to see...

Clutch is a CG paddle, headwork was done by a friend who used to race G40s back in the day. Hoping it'll be in the car and running next weekend.

Hey Phil, awesome work so far! Bt get that gearbox clean :-)

Gearbox is in the process...

Took the gearbox back off the lump, degreased and wire brushed it.

Started on the rack as well, that clamp underneath the dash is a pain in the tits in a car with a roll cage.

Chucked on a 22mm master cylinder while I was down there, then put the rack back on..

Pulled the suspension and brakes off, found some lovely hanging standard bottom arms.

Fitted the new ones, left the anti roll bar as a subframes going on asap.

Got the new coilies out, went to put the salzmann top mounts on to find Gaz have used a different thread to the normal polo one. I've had and wanted the to use these coilies on something fresh for ages! Rather annoying. I had a set of cathedral clamps, but managed to loose one over the years...

So put the Fks back on for the moment so it can drive when the lumps in.

Fresh steering at least, does fell tioght like a tioger.

Then went and had some dinner, and blagged the girlfriend to help me paint the gearbox...

Will get that on tomorrow with any luck.

Is that bp garage in ewell? nice looking car.

this is a well inspiring project to see goinng on, cant wait for my engine to get under way

keep it up mate

adam

Brand new steering rack philious?

Was some BP on the way back from preston, not sure where tbh.

Yeah, new rack, arms, damper, and brackets.

Gearbox is painted and back on the engine with a new mount rubber...

New engine mount rubber, managed to find some random VW around the country that had this in stock.

New oil pressure sensors...

Front mount fitting later.

nice work dude, ganna be a real nice g when your dun.

impressive work phil it has to be said... loadsa pics kept me interested, a good read! real progress...

get it running! i cant wait for the next bit! this why i hate soaps...

How much are new racks + dampers out of interest?