So I decided to get rid of the Jetta after missing my old Polo so much, and I came across this G40..knowing it would need some attention but it ended up needing a little bit more..

So on my way home from getting the car the clutch decided to give up, then having a rummage around after taking the headunit out I noticed it needed some wiring as some moron decided to just cut a load of wires and twist and taped live battery cable which got taken off the battery cut off switch..

So as soon as I got it home I decided to rip out the dash and carpet to sort out a small waterleak and the wiring issues, now it's all sorted I decided to give the engine a good service, new belts, fluids, clutch and cable etc

Eventually I will be getting rid of the eaton set up and will be going down the turbo route with a 1341 bottom end even though the eaton does sound cool. So fairly soon I will be buying bit by bit ready for the turbo conversion

but heres some pictures..

This is how I had it, but I have sold the allycats, badgeless grille and bonnet bra

Decided to joey the headlights too

Then I bought a few bits some rare I guess..

Also decided to buy a Helix paddle clutch and some new yoko's

Bought some G-laderseite beam bushes too then painted the beam

Also then decided to fit braided brake hoses all round with new copper hard lines on the rear and front and also a disc conversion on the back using mk4 golf rear calipers, also spaced the rear wheels out 10mm with axle spacers

Quick snap shot of the bay before it was done

After mot'ing it and re taxing it, it's being used daily but I also have some more bits that need doing but it will get done.

few shots from being out and also a new addition of a G40 badge..

Edited 20 May, 201313 yr by vee-dub90

Two gorgeous cars :)

Nice little motor you've got there, the bay wants a bit of a clean but apart from that she's tidy

Cheers, I've cleaned the bay up a lot now, also got some fogs (which I will fit eventually) and also fitted my under bonnet sound proofing :)

Haven't got my fogs on as of yet as my boost hose's either side of the front mount are in the way, so i'll have to wait until I turbo it as i'll be running a different cooler.

but here's a picture of the fogs


And a picture of the underbonnet soundproofing on


I've got a list of a few oem parts that I am after but I will not say until I get hold of the parts and will update this as of when

Also managed to pick up an Ibiza Cupra R master cylinder which is 23mm where as the 16v gti one I have fitted is 22mm so I will put it on when I get chance.

I even managed to find a video of my car:

Edited 26 February, 201412 yr by vee-dub90

you will have to push quite hard on the pedal to get the same brake feel using the 23mm cylinder.

nice car, you wont regret going turbo!

you will have to push quite hard on the pedal to get the same brake feel using the 23mm cylinder.

nice car, you wont regret going turbo!

Really though? I would have thought it would loose some of the travel which is still there from the 22mm one. Also in my mates mk2 golf which i fitted one its got an awesome pedal feel to it with hardly any travel.

Yeah I really cannot wait to go turbo even though the noise with the eaton is pretty cool but its crap haha

you loose pedal travel, but the amount of pressure being created is less, and ultimately its brake line pressure which is key to making good solid brakes.

That is true. It works out that the m/c hasn't cost me anything so I will give it a bash when I get spare time

nice Alex :)

cant be alot of clearance between the aux belt pulleys and the chassis? only pro of using a psd kit I've found.

id still have my eaton had it not gone through belts like an american on a fast food diet

theres a huge difference between eaton and turbo like you wouldnt believe although id still love a standard g-lader lumo to fettle.

Yeah there's literally no room between anything I've even put the polyurethane engine mounts on as the old one's were dead and it kept making the battery light come on, so after I put the new ones on it stoped it, but now that problem is back, so as soon as i get my pair of solid engine mounts so I'll chuck one driverside one on and see what that is like haha.

To be fair the belt on it is pretty good but I'm just fed up of the bloody engine mount issue. But it will not be long and I will start buying bits to go k03

By the battery light coming on, i mean the alternator pulley was catching haha

i had the same kind of issue but a blip of the throttle and it cleared. i even had the belt guide on the alternator pulley come loose and rattle like a bastard! i was running toothed belts and there was alot of flex of the charger on the mount causing the belt to dig into the pulleys shredding them :( not good at £15 a pop.

should be able to do the turbo conversion cheapish enough.

i had the same kind of issue but a blip of the throttle and it cleared. i even had the belt guide on the alternator pulley come loose and rattle like a bastard! i was running toothed belts and there was alot of flex of the charger on the mount causing the belt to dig into the pulleys shredding them :( not good at £15 a pop.

should be able to do the turbo conversion cheapish enough.

That's not good lol.

Well I want to go all out in a way, like with new parts except the turbo as they are pretty costy

the odd K03 comes up cheap on ebay but cheaps not often good!

i brought two originally although ones now fooked (snapped shaft - goddamn backwards thread!) and id love a new one but £180 is the cheapest!

so youre aiming for the same spec as mine?

I think so as your spec makes sense haha. Except aquamist I don't get that

Basically cools the charge down a little more so you can run more boost pressure

such an awesome little car. i want one. swaps??

Basically cools the charge down a little more so you can run more boost pressure

I understand that, its just the plumbing of it

such an awesome little car. i want one. swaps??

Cheers Nick. Really?

Jon, i never had any belt issue with my kit at all, this was because i used feeler gauges to make up shim packs to bolt the charger in place so it ran true, as it ran true the belt never moved around and barely wore the anodising of the pulley- i even had to dress the pulley as it arrived damaged from PSD.

Did you not have any problems with the chassis leg on your set up kiz?

not that i can remember, the roll bar drop plate was modified so that it had more clearance, but no i didnt. theres photos of my old setup (when it was non metallic red) in my build thread. i did have an additional tensioner on it compared to your setup. the AWT kit never shat a belt either.

if you haven't don it already i recommend unbolting the charger and remove it, them undo the charger engine mount (obviously having a jack under the motor) and bolt back up again with it perfectly square to the engine block. i used engineers parallels and a level and got it as best as i could. then do the same on the charger once you have put it back on- use shims/washers to make sure the charger pulley is running parallel to the crank pulley. if there not straight it will screw the belt up.

The AWT kit has a really awful rear mount- this needs to be stronger and again attached without pulling the charger pulley out of true. in my final incarnation of this kit i got half waythrough making a new mount for the rear which used the hole through the charger further down ( the downside to this was the fact it would have to be fitted with no radiator installed. the rear mount is key to the belt wear/snap/ flapping about as under the load the charger deflects and no longer runs true = your belt wears out quicker than a giggalos.

and if the noise does get on your nerves to bad then you need to move the throttle to before the charger inlet (a lot of work)

Ahh right, well the roll bar drop plate has been ground back a fair bit and the belt so far hasnt shit itself but it doesnt run 100% true but I'm not bothered really as the belt still stays on under full boost. To be fair the noise doesn't do my head in haha.

the plumbing of the aquamist is easy - must be because i fitted it

basically from tank to pump, to check valve and then to injector which I've installed on boost pipe after intercooler. my kits a hybrid of bits n bobs I've brought, just need to check all the wiring.

Hmm, think i'll have to take a look on a few installs

Edited 4 August, 201213 yr by vee-dub90