This is where i got upto yesterday.

Had trouble getting the starter motor to work properly, thought id see if it actualy worked before shoving all the inlet on and shit, turned it over and it kept sparking like crazy. 1 hour of head scratching later turns out i didnt tighten the 13mm nut enough

gave all the water pipes that came with the new engine a good wash out, as the old coolant had crispyfied inside, and swaped the thermostat out for my working one.

Today: finished work early, so got 10 litres of oil so i can do a proper flush through, then run the engine for 300ish miles then change the oil agian just to be extra safe.

Ordered in the usual gaskets bar the top part of the throttle body, gunna have to get some gasket paper and make my own for that.

See if i can get it all done today, doubt it

Edited 18 June, 201214 yr by Matt G40

Time to get cracking!

Weather looking good, taken the van back and picked up my brother gazibo in case it rains.

Hopefully make a good charger out the two i have too (good internals and seals with a oil return that isnt threaded). No doubt its going to be blood sweat and tears all day

if you need to pop to mine one evening to look over the two chargers etc, let me know as your not far from me. i have a number of helicoil kits, depending on what's gone.

thats sweet mate, il take you up on that offer , I'm gunna chuck the charger with the oil seals that have gone on the G40 to get it running.

Then il probably get up to yours pete and see what you can do with the other charger. Its the bottom return on the charger thats threaded, the banjo will go finger tight thats about it, so it weeps oil, how much would you charge mate?

So far I've done:

Cleaned the altornater, as the charger leaked oil on top of it for a month and it was just pure black when i took it off, nice and shiney agian after a bit of elbow grease.

Got some wire wool on the exhuast manifold then sprayed it with some alum high temp paint, also doin the charger bracket to clean things up abit.

Inlet manifolds all bolted up with a new gasket.

So its just charger and alternator to go, plus little odds and ends. Woop Woop!

Edited 18 June, 201214 yr by Matt G40

good stuff mate! really hope u can make it to poloshow!

Good turnaround Matt, seen your chucking the charger with the knackered seals on. If it's the same one Ad had, id advise against, made a right mess of his sensors and stuff when he had it on his iirc.

Just post it to Pete or somebody who can get it fixed and wait a while.

thats sweet mate, il take you up on that offer , I'm gunna chuck the charger with the oil seals that have gone on the G40 to get it running.

Then il probably get up to yours pete and see what you can do with the other charger. Its the bottom return on the charger thats threaded, the banjo will go finger tight thats about it, so it weeps oil, how much would you charge mate?

So far I've done:

Cleaned the altornater, as the charger leaked oil on top of it for a month and it was just pure black when i took it off, nice and shiney agian after a bit of elbow grease.

Got some wire wool on the exhuast manifold then sprayed it with some alum high temp paint, also doin the charger bracket to clean things up abit.

Inlet manifolds all bolted up with a new gasket.

So its just charger and alternator to go, plus little odds and ends. Woop Woop!

just checked, i've got every other helicoil kit for every other thread on the charger but that one!! its m10x1!!! sorry!

Good turnaround Matt, seen your chucking the charger with the knackered seals on. If it's the same one Ad had, id advise against, made a right mess of his sensors and stuff when he had it on his iirc.

Just post it to Pete or somebody who can get it fixed and wait a while.

messed up what sensors and stuff?

i love you jay but your such an old man trapped in a beefy young boys body!

matt, get the charger on and then get over to pete, ill give you some charger casings you can take with and you should be able to make a good one with a non dethreaded oil feed

as its a return- it could just be drilled up to the next size and a new return line with a larger connector fitted (obviously requires a strip down)

they helicoil really easily, just i've not got that kit - only the feeds, mounting bolts and inlet sizes!

your weeping one might just be a single seal which is an easy fix.

just had a look and helicoil kits m10x1 are less than £10 so get one of those and if your careful with blu-tac down the hole you can very very carefully do a helicoil and clean it out. (drill, clean with cotton buds, drill clean, then tap, clean, tap, clean) you get the idea.

Shes alive!!!!! drove her about 20miles last night.

Few niggly problems like running a little rough, to be expected for a stood engine, starter motors not doing anything this morning, and the exhuast is blowing like mad. Other than that well happy

Pete: threw the old charger on (threaded one) and just removed the washers on the oil return as a temp fix, checked it actualy returns oil which it does and it doesnt leak at all Woop Woop!!!

Well actualy managing to put some miles on her now.

Bobbed up to safs unit to drop the engine crane off, managed to get a few things done:

Alternator decided to lose its top mounting bolt (the long one) a few days ago, must have forgot to tighten it properly 67p later i had a same spec bolt, fitted and shes all good, no more wonky alternator thats held up by prayers.

Replaced the drivers side steering arm, as some pikey garage welded the nut on after they threaded it, but they welded it so the arm wasnt tight on the strut if you get me? Pretty scary in wet weather to say the least!

Saf gave me a spare one he had and bolted that on and it drives much better, although it needs tracking up.

____

Left to do before I'm fully happy to use it as a daily agian:

Exhaust needs replacing manifold back realy, blowing its arse off.

Need wheels badly!!!!

Old engine for sale at £130 if anyone wants it? only this cheap untill the poloshow mind as i neeed money to go

http://www.clubpolo.co.uk/forum/index.php?...=287213&hl=

getting more welding gas on tuesday Matt, if you want us to have a go at your exhaust some time soon :)

Past week or so had just involed sorting the niggles out and such.

Last night The car just lost all boost, then i had a blowout, luckly it was only at 20mph, so nothing drastic....Parked her up as i was in a mood. Woke up next moring to see what occuring with the boost issue and it was just a hidden boost pipe had poped off thank god!

Today I made another attempt at the exhuast as the one previous wasnt exactly brilliant

Got a cat back stainless pipe of a lad on here for £25 and fitted a middle box to the end. Alot quieter now, bar a tingling noise in the empty cat box

Just picked up some steelies with caps for agian £25.

Fitted them then gave them a clean after i took the photo, Balling some staggerd whhheeels mate.. (4.5J F / 5.5J R)

Oh and finaly fitted my washer bottle after a week of driving

Next up is debadging the rear and fitting my POLO_CL badge if i can find it,

And Paint the middle part of the wheel trims black.

Edited 27 June, 201214 yr by Matt G40

Lets not forget a good clean and some back to black aswell!

Love this! Sleeper mode FTW!

Personall not into debadging g40's but dont snap it mate when you do it as they are worth big monies :)

Jake the g looks a bit shitty at the moment, so it doesn't really deserve the badge IMO , plus is will make it less desirable to rob if it looks like a CL.

Thanks slim :)

I'd like the 5.5s on the front but it will lt will look daft haha, plus trying to accelerate in the wet is fun

I was going to say, as it's set up at the moment you're getting the worst of both worlds.

Too little grip on the driven wheels, too much on the back.

So traction issues and slightly exaggerated understeer. The latter being the main reason I will never run staggered wheels on mine.

Quit fussing about looks and swap them over!

At the moment alex the G doesnt get driven hard enough to warant more grip. So I'm not fussed intil i get a decent set of 14" ras

Updatingzzz:

Sprayed my wheels trims up last night to make them look like gt items, for £6 all in you cant complian

Bish:

Bash:

Bosh:

They clould have come out better but i was pretty much blind yesterday as i had a massive hayfever attack.

Found a random clubpolo sticker lying about:

And a better pic of the new stianless exhuast:

Lastly I realised I have no intirior shot in this thread so heres one:

Edited 29 June, 201214 yr by Matt G40

You on the look out for wheels then dude? Looks pretty cool on the GT esque trims!

Keep the G40 badge on though!

Not at the moment max, il be struggling for the poloshow money wise :/

And the G badges are still on

Edited 29 June, 201214 yr by Matt G40

Il just leave this.....

Summary of whats happend over the weeks will be soon :)