So had a week of work due to gashing my arm open pretty bad. Went up to my unit yesterday to get some snaps of some bits i need shifted. Thought i'd get some piccys of the money pit G40 conversion..

Basically bought this as a Genesis with a G40 engine in it.. a rather knackered engine at that. Rest of the car was stock with cut springs being about the only mod! Drove it for a bit, ran like shit and was frighteneing to say the least

Left it on the drive for about 2 years, until I got a unit last summer. Then I decided i'd rip it apart and re-build it properly. Although, not go mad on this one and get it built (i told myself ).

Ended up buying a proper G40 which got used for a while until mot came up, at which point for various reasons the decision was made to sack it and use it for parts. So thats been sat around for about a year.. until now, it's donating the useful bits that are missing to the money pit.

Poor G40..

Spec is as follows..

Shell: Solid L reg Genesis shell (with tin sunroof, unfortunately)

Engine: PY bottom end, rebuilt with new big-end shells, piston rings, all new gaskets, seals and bolts. PY headgasket and headbolts (extortionate amount off vw). Low milage 3f head stripped, inspected and skimmed (cleanest engine iv ever seen inside and I only paid 80 quid for the whole lump!). All new PY valves from VW, new collets, Dbilas Springs, INA followers from the stealers, Catcams Camshaft and vernier pulley, new camshaft oil seal. Basically all the parts it needed genuine or better. Bosch W5 DPO plugs. Standard G40 blower, with probably a standard pulley to run it in. Also Poly engine mounts (group buy on here or G40 forum I forget).

Suspension: Started from scratch, powdercoated struts, new SKF bearings, new disc back plates (and powdercoated), budget Phil special shock kit (stolen from my mk2 until I can afford/be arsed to make propa-bo sus.) with lowering top caps, new gen top mounts, castle nuts, bump stops, insert retaining caps etc. G40 spec lower TCA's, stock powdercoated ARB and brackets, powerflex ARB bushes, new washers, nuts and bolts throughout. G40 rose jointed steering arms, damper still to go on. Powdercoated G40 beam and brackets, new bushes from vw and bolts throughout, cica 12mm stub axle spacers to go on (thankyou mgozzard).

Brakes: VWI carriers with VWII 239mm vented calipers, stripped and powdercoated pure orange, all new seals/dustboots, sliders/boots/plastics/bolts, had some new stainless pistons (Kitec), chose not to use em, wish I had now! EBC reds and HEL s/s bleed nipples.

Drum backplates at the coaters, will get all new cylinders, drums, shoes, bearings upon re-assembly. New solid lines throughout and Goodridge braided hoses with s/s fitments.

And thats about as far as iv got with it. Anyway, enough waffle, some pics..

Charger bracket I had powdercoated before realising it fouled the manifold, so robbed one off the other G, which has been hacked about and is now at the powdercoaters.

The bit i most proud of so far.. getting the oe clips back on under the inlet for the isv etc. I hate the look of jubilee clips, but they are soo much easier to use..

Porn in a box..

more shit waiting for it's day..

and got these off a mate, just need to make myself some subframes..

And just so the Golfie doesn't feel left out!

Took my box to the local garage to get a new selector rod bush and oil seal fitted as I'm feeling a bit weak atm so once thats done, needs paint and a clutch and I can get it in the car. Still got to order a stainless threaded insert for the lambda sensor and tig that in.

Will get some more pics up as things start to come together, may not be very regular mind

Edited 24 October, 201015 yr by randombadger69

awesome!

So fresh, love it.

That charger looks spanking

Oh dear, Dont let toby see that.

Just awsomeness.

looks superb - but please tell me your not going to use the rusty old bolts on some of the things??? i have a polished steering rack and a black powder coated one - please dont leave that bit out as its isnt much work and youl regret not doing it when you put the motor back in.

looks like it could be a show winning bay if you scrub that paint up shiney!

Good work

Youngprodigys

Cheers for all the comments guys Thought if I posted some pics it might encourage me to get some more work done!

looks superb - but please tell me your not going to use the rusty old bolts on some of the things??? i have a polished steering rack and a black powder coated one - please dont leave that bit out as its isnt much work and youl regret not doing it when you put the motor back in.

looks like it could be a show winning bay if you scrub that paint up shiney!

Good work

Youngprodigys

Don't worry, all new bolts, where possible, still need some for the steering arms. I have a box of OE chrome bolts, that I just can't bring myself to use. Can't be dealing with chroming on this one, it all snowballs out of control (with me) and gets too ocd!

I know what you mean with the steering rack, but it'll match the cylinder head if I leave it alone

Charger decision was a case of do I leave my NOS blower in a box for the next 10 years to appreciate in value a bit.. or actually use it and know that it's good for probably more miles than the engine. Was a no-brainer in the end. I know Phil refuses to use his

Anyone got a standard pulley btw? What are they 78mm? Mine got broken en-route from germany, due to shoddy packaging. And i can't find the piece that snapped off, so no chance of welding it back together

Very nice! :-)

Nice build

Looking good. It's almost insipred me to start putting mine back together!

Cheers peeps.

Stuck my neck out and ordered an 18x1.5mm stainless threaded insert for the lambda sensor. Then all I have to do is cut a lovely hole in my downipe and weld it in, pillar drill and TIG welder are on the wish list. Until then college tools it is.

Ohhh my god, I've gotta step up my game!

Stunning dude!

Oh and I've just sent a text to my mate about the pulley, as he has toothies on his now.

You just gotta promise that it will get powder-coated orange like the rest of the stuff

wow mate this is amazing work! really love the quality of work and attention to detail you are putting in must've taken a while to get everything renewed, the brakes + suspension are beautiful!

you must be a regular at the powder coaters?! is it expensive to get parts done? I usually just slap chassis paint on stuff :rolleyes:

these kind of threads are my favourite :)

Ohhh my god, I've gotta step up my game!

Stunning dude!

Haha, nice one!

Oh and I've just sent a text to my mate about the pulley, as he has toothies on his now.

You just gotta promise that it will get powder-coated orange like the rest of the stuff

Ooooh.. I was Thinking black on this one

But beggars can't be choosin!

wow mate this is amazing work! really love the quality of work and attention to detail you are putting in must've taken a while to get everything renewed, the brakes + suspension are beautiful!

you must be a regular at the powder coaters?! is it expensive to get parts done? I usually just slap chassis paint on stuff :rolleyes:

these kind of threads are my favourite :)

Cheers mate. this ones a bit of a case of chuck all the eggs in one polo shaped basket!

Iv been systematically robbing parts from my mk2 coupe project (Don't ask ) and riding my bike buying bits (Whoarding) over a few years now. The direction has swayed between various polo's but they were all mk2/2f, so all the running gear is fairly interchangable. I had a good shell, so thought i'd use that for a "guinea pig" and as it had a PY engine, things stayed that way..

I have been lucky enough to get aquainteced with local powdercoaters through work. They are good chaps and always sort out the little bits. Petrol dropping and collecting parts all adds up though!

Tonight.. I rid the engine bay of the horrible wiring loom. Continued labelling the loom from the green g40 and unplugging stuff. Looks like it could do with a few repairs, but so far a lot better than the shoddy loom in the conversion.

Wires suck.

Wires do indeed suck!

That much so, i just dashed my loom in and left it i haven't tidied them since lmao! Wait till the carbs are on then sort it, as theres less to sort then

I'll get Brett to PM you about the pulley or something. He text me saying he should still have it and doesn't need it.... so i guess its yours lol.

My golf was a bit like that when i swapped the lump a while back, still had the odd masking tape labels on it about a month later

Carbs should rid you of some wires.. that shit weighs! I was genuinely shocked when I picked up the loom and fuse box!

Maybe i should get back on my twin 40'd mk2..

Oh and yeah, pulley would be sound, i'll buy y'all some beers

Edited 23 October, 201015 yr by randombadger69

HOLY SHIT!! Only 3 words for this one bud: WORK.OF.ART

Yea agreed, wires do suck. Especially 2 x wiring looms in one engine bay.. I will tidy them... one day..... maybe.........!

Is there a build thread of your Mk2?

Becks fuelled as well I noticed :biggrin:

I was thinking about getting my mk2 running yesterday.. then remembered I robbed the hydro buckets, camshaft oil seal, exhaust manifold and probably more bits for the PY lump

Also I have serviced and replaced the gaskets/seals in one of my DHLA 40 carbs, when starting the other i noticed that the cast alloy top cap is damaged. It's where the spindle locates that supports the floats. Still haven't sorted this.. could do with a spare carb for parts.

Maybe one day i'll sort her out!

As for build threads.. one is plenty for now