i welded the strut brace together today and it fits like a glove :)

I've now done two coats of primer and the ill do top coat in about to hours :)

With the battery tray, coud'nt you weld the bolts to the underside of the tray?? that way the battery would sit fully into it :-)

i could try but they are hard to get on with a welder and one of them is inside the chassis leg!

i could try but they are hard to get on with a welder and one of them is inside the chassis leg!

Not the nuts, weld the heads of the bolts to the underside of the tray

The tray is made out of alli

The tray is made out of alli

Ok then, back to plan A

some pics of my strut brace now painted

etch primed

I've painted it satin back was gonna get it powder coated with some of my other bit but just thought id just paint it now as its nice new clean metal

found some vw snowflake alloys got them cheap and not in bad condition will be power coated in a different single colour:)

also got some g60 greens off stinkypete

and a set of core plugs for the block

parts list is getting there now still need to get my gaz coilovers but i need to work out the spring rates and dont really need them until the respray is done.

have also cleaned up the steering rack as it was horrid and its now a rolling shell again, things i need to do before respray:

.drill hole for front strut brace

.prep surface rust areas

.prep and under seal the underside and wheel arches and spray black

.make my our pipe for the one that alway rots off behind the osr door card (for the pipe that prevents airlocks in the tank when its full)

I'm sure there are a few more, but cant remember of the top of my head but will try to get as much as i can of that list done over the long weekend!

have a few more thing coming thro the post soon like poly engine mounts and some febi bits off peteg40

also i have a few places in mind for where I'm getting my parts powder coated but if anyone can recommend someone good near basingstoke would be much appreciated :)

Edited 23 May, 201313 yr by RyanC

Wow this is awesome! Nice garage too!

is exactly what i want to do to my g40, just dont have a garage to do it :(

nice fabricating skills too mate :)

taylor

thanks man i just need to start getting on with it now, instead of buying bits that i don't need atm haha

I'm not very good at updating this... But I will try sort it out, but this has now happened :)

Edited 8 September, 201411 yr by RyanC

Update on whats been done so far..

My daily bready got hit by a lorry on the way to work so i had to sort that out witch slowed things down for a long time, i ended up breaking that as the shell was dead and ended up buying a 9n3 1.4 d for getting me to work and save money on fuel to put more into the g40 :)

alot has been done to the car sorry my updates have be none existent i will try update as much as i can from now on :/

i have now decided that I'm am going turbo and lots of bits have been bought in the last year here is a list of some of the good bits:)

31mm, larger exhaust valves

cat cams vernier pulley

schrick turbo cam

rothe motorsport turbo mani

KO3 turbo

forge actuator

cg motorsport clutch stage 2

alli rad

pec rods and 77mm wossner pistons

gearbox rebuild kit all new bearing and seals for when i fit the LSD

PPP exhaust system

ford rs turbo front seats

max rpm ajustable top mounts.

i have nearly everything now to put the car together witch is good will get most pics as I'm putting stuff back on :)

i will update bit by bit so its not one long post.

Alot more to come :)

Edited 8 September, 201411 yr by RyanC

so before the car got resprayed there was alot of body prep to get done thanks to Taylor for his help with it!!

so i stitch welded the hole engine bay and the rear turrets witch made a huge difference to the area around the top part of the bulkhead.

this is a pic before i seal sealed the welds

i aslo did the vw repair for the inner arches to streathen the chassis legs as one was cracked.

aslo found one small hole in the floor so i cut all the rust out and welded a plate in.

all the weld sealed, all rust patches under the car and inner arches were cleaned back to bare metal then coats of POR 15 then re sealed then the hole under side stope chipped including the lower sill and inner arches

also cleaned and resealed the bottom or the doors.

battery tray seals and stone chipped

under the boot floor with a new rear exhaust hanger :)

Edited 7 September, 201411 yr by RyanC

After all the prep was done it was off for the respray :)

Edited 7 September, 201411 yr by RyanC

Great project.

Loving the work thats going into this, everything'll be brand new when it's done!

Where did you get your gearbox rebuild kit?

thanks guys! gearbox bearing and seal kit is off ebay mate, skf and timken bearings and gen seals :)

so after quite a long wait i got my shell back from the body shop in the time it was at the body shop my daily mk2 bready got hit up the back by a lorry witch wrote it off :( so that stoped work for a bit, i now have a 9n3 1.4 tdi and a daily so all my spare money is going on my g40 :)

Here are some pics of it getting sprayed, full respray including in the boot as well all car park dents removed.

garage tidied ready for it to come back

then collected my shell got it home back on axle stands :)

re stone chipped the inner arches and a few bit here and there that i missed

also got some really expensive cavity wax to use with my gun with a strew attachment and waxed all the cavity's, like chassis legs in the sills everywhere lol

rear legs

Edited 29 May, 201511 yr by RyanC

had a long chat with a machine shop about my engine and mostly about knife edging on the crank

and i ended up getting rid of all the casting marks on the webs and smoothing off the corners to make it more aerodynamic

and then the will knife edge balance it on he sides if you get me, so they will knife the sides until it is fully balanced

before

after!!

then got all my engine bits ready to take to the machine shop.

list of stuff that I'm getting done:

Crank:

balance with fly, clutch plate and pulleys

knife edge

regrind for .25 larger bearings

Block:

reface

77mm rebored

Head:

skim

reface of exhaust seal surface as it was real bumpy

exhaust valve seat cut to 31mm for BVH

valve guides removed and full gas flow and port match off inlet and exhaust manis

not got any pics of the block work but will put some up when i rebuild it.

sorry about all the pics :P

a lot more updated still to come trying to catch up then ill update as i go along :)

here are the balance figures before and after.

crank before, way out ha

and after, all knife edged and reground :)

The flywheel is done on it own after too.

Considering this is the lightened and balanced fly when i got it, it was quite far out too.

before

after

Sweet build thread, looking really good!

More updates

few more things i found that i forgot i had :P

boot and b- pillar decals and heko wind deflectors

magnacore kv85 ht leads

metal head gasket, block and head sealing kit

poly rear axle bushes and engine mounts and some new febi drive flanges

sfs coolant hoses

With my TCA's on a g40 they are rose jointed on the inner as some of you know, so i have some g40 tca's but the outer ball joints are worn and have play, it is nearly impossible to get hold of a new set. and if you find some they don't go cheap.

So i had a good idea!

looking at the rose joints they looked like they would press out as a hole peace, so i pressed them out of the worn tca's

so i got a standard tca and pressed the bush out to compare the inner part of the standard tca the g40 one

so as you can see the standard one has a lot smaller hole and is tapered inwards so i bought two need good quality standard tca's

sent them to my local machine shop and ask the to bore out the inner tca bush hole to a press fit to the rose joints

and then just pressed the g40 rose joints back in :) job done two new g40 tca's, rose joints re-greased so they last longer and refitted the dust covers just need to fit the solid nylon outer bushes

got my boot back so fitted the boot strut brackets after cleaning them up and painting them was gonna get them powder coated but wanted to get the boot on and working

also cleaned up the struts and sealed the hinges to the body with proper body sealer

also fitted my aerial got rid of the g40 one and fitted and 6n2 aerial with a better type of amplifer so should get a good signal also runs down a single wire instead of two wires

then fitted the boot wiring after checking the wires and re-wrapping it with proper fabric loom tape

also fitted fabric waterproof tape the boot aperture and door apertures like they do from factory (just helps stop water getting between the gaps) before fitting the lining and aperture seals

Edited 29 May, 201511 yr by RyanC