Got a few PMs so I am just going to start from the beginning and go from there.

After some convincing I managed to get Ben to sell me his G40.

Spec List

• Polo G40
• 1341cc
• JE Forged Pistons
• PSD Eaton Kit
• Cosworth Intercooler
• Mocal Oil Cooler
• Jabba Sport 31mm Ported & Polished Big Valve Head
• 300cc Injectors
• 4 Branch Manifold
• Stainless 2" De-cat Exhaust
• Paddle Clutch

Pics from Day1

The intercooler always bugged me. So I decided to have a little play about and see what I could achieve.

All the boost hoses were kinked, stretched or too long, meaning the intercooler sat really badly. Here is a pic of how it 'naturally' sits without any brackets etc. As you can see it sticks out far too much.

Realised the intercooler was fitted really badly as the radiator was in the way. Making the boost hoses kink.

Whoever originally set up the car decided that the PSD Radiator Bracket, that was fitted, wasn't a good enough way to support the rad. I put the rad on the bracket and made another bracket to stop the rad leaning forward.

Played with the hoses abit so I could move the intercooler back. Now the hoses don't kink and the intercooler sits perfectly square to the car. Hardly noticeable but makes me happy.

Moved the oil cooler to the cross member and cut out a small section of the numberplate. Now you can barely notice the intercooler. Also fitted a stock grille as they look nicer

Fitted some matching rears that I had knocking about

Once I got hold of the car I looked around and was quite shocked to find loose bolts, mis-matching nuts/bolts etc.

Since the car was off the road for the summer I decided to systematically strip the car and see whats what.

First off was the heat shield and air-filer. Filter needed a clean and the intake was bodged as the PSD Eaton intake never materialised during the production of the original kit.

Wanted to clean the edges and remake the tube as the angle makes it impossible to connect to the Eaton.

Taped it up to get some straight edges, filed it down and then stole some seals off an Impreza to make the edges look nicer.

A more detailed look about the bay found the charger belt was rubbing on the cambelt cover, a few choice moves with a file and I a have avoided some serious headache in the future.

Began to refurb a rear axel. Everything got stripped. Lick of paint and its fine. Just waiting for some rear disks to come up for sale at a reasonable price.

Next on the agender was the anchors. Decided to strip them down, file down some of the glazing on the pads, bleed the brakes and give them a wash. Generally please how they turned out but I think I am going to overhaul them and give them some paint since until I get some 4-pots sorted

While I was bleeding the brakes the rear cylinder managed to snap. Pair of them fitted

Really haven't updated this blog in ages as I have been too busy with my GT mk2 but here goes....

60/40 H&R Kit Went on along with a Subframe and G-laderseite bushes

Began getting all the sound deadning etc off the floors so the floor can get prep'd for paint

Can also see the test stages of moving my battery to the rear

Snow halted play so I went into the garage. Cleaned all my tools in some OCD rage then decided to crack open my broken GT box out of bordem.

Forgive my lack of technical terminology

Drain the oil

Take the flangitas off

Split it in 2

Took the diff out

Got to here and snapped my 20p circlip pliers. Managed to get the clips off but I cant seem to dismantle the box any more. Any pointers?

Edited 20 March, 201115 yr by GiorgioGT

woooooooooooooooooooow

never seen inside of a GT box, infact most gearbox's thats mad....which cog does what? lol

what condition are the gears in, can u see and chunks missing?

had a few doors knocking about so i thought I would put them on a diet just to see if the weight saved was worth the effort.

had an assistant all day so everything was photographed.

Take it out

The bit I chopped out weighs about 2grams so its really not worth the hassle. Could always have the side impact bar out and get the hole saw on it but I really don't see the point. Much easier ways to save the weight

woooooooooooooooooooow

never seen inside of a GT box, infact most gearbox's thats mad....which cog does what? lol

what condition are the gears in, can u see and chunks missing?

god knows what each cog does. I just took it apart. Feel free to come and collect and continue the fascinating dismantling of the box.

ha proper good job on door,

angle grinder ftw!

you need a puller to get the bearings off to go further i think

Yeah, I struggled as my pulley puller was a bit too big for the task - but good enough to dismantle a couple of gearboxes so far.

i dont get side impact bars on mk3s, my gt had them, then i found another mk3 (a fox i think) with out them. Is it just older or lower spec cars that dont have them?

Abit more going on in G40 land. Tried my hand at welding today. Far from perfect but they will do until I get another shell

Windows out, headlining out. Then I re-routed the main wiring sleeve for the rear of the car so it goes on the outside of the turret, rather than around it on the inside. The I found a meat cleaver. . Not sure which one of the owner had that hidden down the side of the rear quarter

Ground down some paint on the turrets so I could get some nice welds going down.

Did my first bit of welding. Wasn't too shabby if I must say so myself

Cleaned up the welds abit with a grinder but by this time I gave up take photos

Began to flat off the paint so I can lay down some primer tomorrow hopefully

Looking good. I always thought your G40 was white tho? Looks darker in them pics!

so you having the inside totally stripped out then? why u welding the rear turrets up (you running cup car suspension or somthing along those lines)

so you having the inside totally stripped out then? why u welding the rear turrets up (you running cup car suspension or somthing along those lines)

Already running H&R kit. No plans to change it as yet but see how it holds up under testing. Welding is just to increase the torsional rigidity of the car.

Kam my GT is white, which is now home to my old G40 engine. My brother now has this.

The GT engine is now located in my Loon.

probs will going along the same lines next year with mine, still got to fit the safety devices cage, gut the car etc etc

(somthing to keep me busy lol)

lookin good tho anymore pics of the whole car.

the cable you have routed around the other side of the turret where does it end as i would like to so this to mine, does it just finsh where the taillight is or is it further into the boot?

where are you planning on putting the battery?

What are you planning on using the car for fast road or track or just fun? is it gonna be stripped out?

Really liking what you have done here.

Thanks Greg

the cable you have routed around the other side of the turret where does it end as i would like to so this to mine, does it just finsh where the taillight is or is it further into the boot?

where are you planning on putting the battery?

What are you planning on using the car for fast road or track or just fun? is it gonna be stripped out?

Really liking what you have done here.

Thanks Greg

battery is currently lying in the passenger foot well but the battery will end up on the bottom of the back seat. Alot of people mount it as far back as possible which I feel is wrong. It just moves weight past the wheels which just increases the pendulum effect on the car. Car will be fully track prepared. Will be used on as many track days as I can afford. Will still be my daily driver until I can afford to completely take it off the road and be a trailor queen to tracks.

Is going to be totally stripped. Only things left in are going to be heaters and half a dashboard. Not going overkill on weigh reduction as the car already has plenty power. Not even been mapped yet

i opened this thread thinking you had posted up in the wrong section and it was of an actual mini oh well and haha a bloody meat cleavre! HAHA! rad the log book see which one sounds most suspicious

That's probably a murder weapon you've found hidden there...

Bloody hell, Giorgio bought the car off me and I am def not a meat cleaver murderer!!!

Oh well at least it adds to the weight reduction!!!

Bloody hell, Giorgio bought the car off me and I am def not a meat cleaver murderer!!!

Oh well at least it adds to the weight reduction!!!

was going to PM you about my discovery. PS - sorry about killing your car

Today was spent masking up and sanding - o the fun i had

Also messed about with the loon and ended up buyin a new lambda and Blue temp to try and solve my shit fuel economy

Edited 10 April, 200818 yr by GiorgioGT

This is what I'm going to be doing in the next few days hopefully to my mk2 i have just baught . I hope the floor pan isnt too bad like yours . It will be a ball ache to get all the dirt / sound deadening off i asume .

It will be a ball ache to get all the dirt / sound deadening off i asume .

2 Days with a chisel The bulk head can be heated and peeled off though.

Somewhere during the chiseling your going to go through the floor. Dont worry there are 2 small holes from factory in the rear foot wells. I had a mini stroke when i went through

Sounds harsh but what i was expecting really. going to have fun time doing that then ..

Swung by dave_h's house last night, top guy. Picked up this bad boy

Need to add a rear diagonal and a harness bar. But its nothing to cry about at the moment.

Excuse the crap pictures, built in the hallway at uni

nice. powder coat it?