UPDATE:

Ill start from the beginning, I took the car to AAS in Newcastle and dropped it off to get a 4-2-1 race system for the car, happy days, until they call me in the morning saying the jobs going to take too long so they have back healed the job... Awesome, especially after the 6 month waiting list. They said no one will take this on.

So I went around 10 minutes round the corner to a bloke who did do it! Took longer than expected but I wasn't in no rush but here we have it, a fully custom 4-2-1 Manifold - Decat with an outward rolled tip which is exactly what I wanted.

Ill let the pictures do the talking...

Untitled by Matty!, on Flickr

Untitled by Matty!, on Flickr

Untitled by Matty!, on Flickr

Manifold

Untitled by Matty!, on Flickr

Untitled by Matty!, on Flickr

Untitled by Matty!, on Flickr

Untitled by Matty!, on Flickr

So I'm really happy with it, Ill get a vid up soon.

Had the geometry setup for the Vagcars trackday @ Teesside Autodrome

VW Polo G40 by Kurt Blythman, on Flickr

Playing with the lift off oversteer :laugh:

VW Polo G40 by Kurt Blythman, on Flickr

VW Polo G40 by Kurt Blythman, on Flickr

Was really good fun on track, comparing it to the Audi it was so much more 'flicky' could do what you want it in and you could do it fairly predictable.

On one session I was literally loving the lift off oversteer it could achieve so was having a right good laugh!

Thats what this car is all about, having a laugh and a play! So chuffed with the KW's/Subframe/Exhaust mods!

Currently saving and amounting parts for a handful of reliability mods such as Oil Cooler and Alloy Radiator, Silicone Hoses ect, so thats next.

Hello mate,

Love the look of this car! great mods and nicely done.

Funny enough I spoke to AAS last week with regards to a manifold and he said he had a look at a G40 and said it would take too long. He said it would require taking the exhaust off loads and the charger etc etc, I kind of said how else do you make a manifold fit? very strange considering this is what he does! I bought a cheap manifold from MAXRPM which isn't the best but finding a manifold that doesn't require waiting for group buys etc is near impossible especially when I need something now. Anyway I asked AAS if they would modify the manifold I bought and he said not a chance! to me this guy was stuck up and only interested in exhaust building for easy fit cars!

Anyway he did weld my lambda sensor boss onto the manifold in the end. Glad you got sorted in the end.

Yeah I lost faith in AAS now.

Ported the charger outlet myself too, and also cleaned out that strainer at the bottom which looked to have not been cleaned out for a very long while, raised the boost by .15 bar too so shows how much it can hold the car back.

Anywho

Fitted my 14" BBS RS' on this weekend :)

Polo G40 by Matty!, on Flickr

Polo G40 by Matty!, on Flickr

Edited 23 June, 201412 yr by Matty!

Love it, your the only person apart from myself who have had to space the charger how u did also!

Can't wait to roll mine out of hibernation now reading this last page.

Bit of progress has happened on this...

I originally bought an Oil Cooler to start with, but after booking a Nurburgring trip it was time for the snowball effect to occur, so I set about focusing on reliability mods for the car.

Its temperature has always fluctuated in traffic from 90*- a nail biting 110* so I set about finiding solutions...

I first started with an APS Oil Cooler, Mocal Thermostatic Sandwhich Plate and braided lines, but then I couldnt resist a set of SFS Coolant hoses to neaten up the bay, then I found it really hard to resist an aluminium race rad.

During this time the clutch decided to start slipping like a b*stard so that was abit of unplanned splashing out but whilst it was in the pipeline its worth doing right I suppose.

Ill start with the radiator:

Here is the sexy rad...

Untitled by Matty!, on Flickr

Made some braces for the slimline cooling fan:

Untitled by Matty!, on Flickr

Then I went to the easy task of fitting this brass fan switch...

Untitled by Matty!, on Flickr

Turns out the Einstein who made the Radiator put a M20 X1.5 thread in, when the polo's is M22X1.5. As this radiator is used in the kit car world I thought I would nip to the motorfactors and se what they had, turns out no manufacturer makes an M20 X1.5 switch... so why the hell they did that I dont know. Anywho I called in a favour at Billingham Machines company which machined my fan switch to fit perfectly.

This was also wired up onto a manual override switch.

all fitted :)

Untitled by Matty!, on Flickr

Next up is the oil cooler, mounted in the passenge side of the bumper it fits so neatly and compact, plus the ducting that I fitted to the bumper months ago now aims straight at it and with a purpose!

Untitled by Matty!, on Flickr

Next was I may aswell get the flywheel lightened! so I searched all over the internet with no luck, I ended up asking Carl (S1MK179) if he had any bits... in which he totally had one!

Untitled by Matty!, on Flickr

And after a week at AMAC engineering...

Untitled by Matty!, on Flickr

Its now 4.1kg's! he managed to skim 1kg off the fly.

The standard clutch isn't much kop for the power the polo is running so a helix was the only option, I opted for the fast road as paddles are that hard to press they actually break the pedal box! plus it can handle about the same power anyways so win.

Untitled by Matty!, on Flickr

Untitled by Matty!, on Flickr

Andy at Northeast Auto Tech fitted this for one hell of an epic price!!

So the list of things done are:

Aluminium Rad

Slimline fan with manual overide

SFS Coolant hoses

Brand new Coolant Bottle

Thermostat

Blue Temp Sender

APS Oil Cooler

Mocal Thermostatic Sandwhich plate

Braided Lines

1/2" BSP Fittings

Lightened Flywheel

Helix Fast road clutch

Pressure Plate

Release bearing

Oil Change

Spark Plug change

Coolant Change

Filter clean

Back on the BBS RA's

Had a few teething problems too like a disturbed Oring caused th heater matrix to leak, and the fact I forgot to put the CO Pot in properly which resulted in it firing it out under boost along with its orings and clips!

But apart from that, I have spent a **** load of money and effort of me, craig, Josh Chris and Higgins for something no one will see in essence.

However it does run 7 degrees less on a run and doesn't over heat either! wooooo so looking forward to the Nurburgring on Thursday!

Untitled by Matty!, on Flickr

Untitled by Matty!, on Flickr

Polo G40 14" BBS RS by Matty!, on Flickr

Lets hope the 'ring is successful, if so, alot of mod's are coming this cars way!

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Well the Nurburgring was a success for all of us! Apart from Bens V12 BMW coming back a straight 6 but we will brush over that...

Car was flawless through its 1070mile eurotrip including several tunnel runs, some epic mountain road bashing, 4 laps of the Nurburgring and a 20 minute soaking wet session on the GP Circuit.

So pleased with how the car performed, and in the end with some instructing from Craig the little polo was setting some good strong pace round the Green hell, even surprising a few people

Heres some pictures anywho:

G40 Nurburgring by Matty!, on Flickr

G40 Nurburgring by Matty!, on Flickr

G40 Nurburgring by Matty!, on Flickr

G40 Nurburgring by Matty!, on Flickr

G40 Nurburgring by Matty!, on Flickr

Generic Ring Photo by Matty!, on Flickr

Cocem by Matty!, on Flickr

Nurburgring 2014 by Matty!, on Flickr

Now I am in debate whether to Bucket and Cage it or let it sit pretty as is and work towards getting a devoted track car of the BMW variety.

Edited 14 October, 201411 yr by Matty!

What do you mean by strainer that you cleaned to increase pressure?

How did the G compare to your mates cars, they look pretty cool.

It looks like a tea strainer in the inlet of the intercooler, I dont think it had been cleaned ever before hand and was thick with grease from the rebuild of the charger.

Faired extremley well, the 205gti is a MI16 With Webbers on and we are absolutely even on the straights, about level on the ring but his would have me on a tighter circuit due to it being setup for tarmac.

The MK2 is a 20vt KO3S setup with a LSD and all the doodaa's and managed to keep him at bay in the wet, however on the ring he would have the overall legs due to the power.

But all in all its a good setup on the Polo, especially for the ring as the KW's are towards the softer side of the spectrum which maks it more forgiving on the road/ring.

Love this!

Is an awesome build mate, proper nice car and looks to be good workmanship

Looks good mate really liking it, keep up with the work!

So as some of you may or may not know I've been busy on this car this winter (not all of it me)

Fitted a 51mm Ported Throttle Body and GT inlet manifold...

20141229_170640 by Matty!, on Flickr

Left - GT Manifold Right - G40 you can see the GT is larger. this was powder coated silver by mr Grover at RS Alloys

20141130_164941 by Matty!, on Flickr

I also fitted Corbeau sprint bucket seats...

20150106_181209 by Matty!, on Flickr

The we get to the really juicy bit.

I had the car booked in at Performance & Proctection in Skipton for a full 6 point roll cage, through dash jobby.

So the car was there a while as I said I wasnt in a rush...

And here are the results:

20150417_200023 by Matty!, on Flickr

20150417_195956 by Matty!, on Flickr

20150417_200013 by Matty!, on Flickr

20150417_195748 by Matty!, on Flickr

They have done a fantastic job, they make rollcages for all the big rally teams and manufacturers project cars so I knew I was in safe hands, the cage is not intrusive on getting in and out either, still allowing the sunroof to operate also.

It has really stiffened the car up also, feels fantastic to drive.

Still left to do:

Carpet it out with acoustic carpet to neaten it up.

Relocate the battery and use a Mitsubishi Evo 6 Battery behind passenger seat.

Relocate washer bottle with a washer bag somewhere.

Sun strip as the buckets are lower that standard seats.

get seatframes powder coated

Neaten everything up

More juicy bits:

I managed to get my hands on a Gripper LSD and ATV G40 gearbox

Wideband Guage

Oil Pressure Gauge

and polycarb windows which I am umming and arring about fitting at the moment.

VW Motorsport G40 bottoms arms with VWM Bushes

VW Motorsport Rear beam bushes

Got alot more still to go on the car, but I am glad to have it back so I can tinker!

looking good matty we have to meet up so and get the black beast to meet the red one

Impressive build thread. I really like way you've went about this build.

I loved the pictures of you and your friends cars in Germany. Just a bunch of friends in their nice cars having a laugh around some good roads and a wee trip to a world class racing circuit.

Impressive build thread. I really like way you've went about this build.

I loved the pictures of you and your friends cars in Germany. Just a bunch of friends in their nice cars having a laugh around some good roads and a wee trip to a world class racing circuit.

Thanks Doug!

Have you ever been? if not its really worth going, been quite a few times but that was the first time I took the G and really loved it, wasnt going to break any records however we werent going shy! But its just an all round good laugh of a holiday with like minded people.

I keep trying to find avenues to get weight out the car without sacrificing too much, however having a dirty cage in there is never going to help things!!

I've not been but I do love a good road trip. It's up there on the to-do list!

There's not an awful lot of places to lose weight in a polo so keep it as it is. It's a very well balanced polo in my eyes.

*Update*

So, been busy on this never ending project...

So far managed to pick up:

Gripper Diff LSD'd ATV Gearbox

Poly Carb windows

Oil Pressure Guage

Wideband

Oil Temp Guage

VW Motorsport Bottom Arms

FMIC - With Thermocouples

and a shed load of spares.

Anywho, been cracking on:

Fitted a FMIC which has thermocouples installed at either end of the intercooler to give a live readout of the inlet and outlet temperatures of the intercooler.

IMG_20150508_230344 by Matty Pollock, on Flickr

IMG_20150508_230422 by Matty Pollock, on Flickr

IMG_20150510_160055 by Matty Pollock, on Flickr

Also added a black tint film sunstrip, as once the buckets were in it really made the low sun a nightmare.

Here is the digital readout installed in the car:

IMG_20150523_185618 by Matty Pollock, on Flickr

Took it out for a good run yesterday with ChrisP to see what was what.

the ambient temperature was 20degrees, on average when driving normally around town ect at around 1700-2800 revs the inlet (Charger side) was around 31-33 degrees whilst the intercooler would keep a steady 21degrees.

Fast twisty road driving would raise the Inlet side to around 40-50 and the outlet holding around 25degrees.

On a really long mile straight stretch the max chager outlet temp I saw was 83degrees!! its amazing how fast it rockets up the temperatures whilst the outlet side was holding around 35 degrees! so as a whole it would cut the temperatures by half. Its a cool mod which proves that a front mount intercooler really does work, at some point I will experiment with water mist onto the cooler and see if that drops temps much more.

Shot of her at Teesside Autodrome

FB_IMG_1431429721115 by Matty Pollock, on Flickr

However upon inspection it looks like I have the dreaded pedal box crack :( so will have to get that sorted somehow, what do most do? Replace with a new one or is there a way of bracing them.

Edited 24 May, 201511 yr by Matty!

That's a good amount of work you've done. You can weld the pedal box and fit in bracing plates to help spread the load a bit. I seen pictures of one being done on somebody's build thread but I can't seem to find it.

Are you going to the Polo Social?

That's a good amount of work you've done. You can weld the pedal box and fit in bracing plates to help spread the load a bit. I seen pictures of one being done on somebody's build thread but I can't seem to find it.

Are you going to the Polo Social?

Sorry for delayed reply!!! Dont think so, not heard of polo social

Yeah I fabbed up a load of bracing plates making the cracked side almost 5mm thick!, I think the car will rot around the pedal box before that cracks again lol!!

Seems a crap design from factory, shame aftermarket pedal boxes seem a mare to fit.

Are you going to the Polo Social?

Sorry for delayed reply!!! Dont think so, not heard of polo social

Lol, it's all over the forum! It's an annual meet for the whole forum over the weekend of the 26th to the 28th of June at billing aquadrome.

Www.thepolosocial.co.UK

There's lots of cars there and it's a great laugh with lots of like minded people.

Well this could do with an update:

I went to a wet croft on October 30th:

Polo G40 Track Car Croft 4 by Matty Pollock, on Flickr

Polo G40 Track Car Croft 6 by Matty Pollock, on Flickr

Polo G40 Track Car Croft 7 by Matty Pollock, on Flickr

The car ran well, until mid morning the gearbox would intermittently select gears after around 20mins of use. I put this down to heat and the Gripper LSD together showing early signs of something.

But once it was home my dreads became a reality, the Diff either needs rebuilding or the gearbox does, as when I took it for another spin the gearbox gremlins reared there ugly head again... so it looks like a gearbox rebuild and diff rebuild is on the cards.

Anywho the more important part was that croft was Oct 30th and Cadwell was booked for November 6th! So Luckily I still had my old standard ATV gearbox, in which we had to fit on a night after work! Stressful times but we managed to get it running Wednesday Night for the 2.5 Hour trip down to Louth after work Thursday.

Cadwell Park:
DSC_3473 by Matty Pollock, on Flickr

DSC_3618 by Matty Pollock, on Flickr

DSC_3571 by Matty Pollock, on Flickr

DSC_3846 by Matty Pollock, on Flickr

DSC_3607 by Matty Pollock, on Flickr

The car held up perfectly all day! I will upload a video later however they don't look spectacular due to the fact it rained pretty much all day at Cadwell also!

So

Plans this winter are:
Fix a broken Box
Put my TH Mono's on
Neaten up the boost pipes to the intercooler

So not a lot but the Gearbox Rebuild isn't exactly cheap!

Love the oversteer shot!

Thanks! the photographer is Extremephotography who goes with Javelin and does some good stuff!

Shame my SJ Cam wasn't working with the 64gb memory card at Croft or we would have had some decent moments, however heres the only dry session at Cadwell which got red flagged.

https://www.youtube.com/watch?v=v6fcssjHoIM

Hi mate this car looks awesome now since the last time I saw this thread, thiers a sorg 02j gearbox conversion on eBay at the moment 😜

How much did the cage cost if you don't mind me asking it looks nice. I'm about too fit a stage 2 subframe too my carbed k03 turbocharged polo, so those pictures of yours will hopefully help 😄

Thanks! the photographer is Extremephotography who goes with Javelin and does some good stuff!

Shame my SJ Cam wasn't working with the 64gb memory card at Croft or we would have had some decent moments, however heres the only dry session at Cadwell which got red flagged.

https://www.youtube.com/watch?v=v6fcssjHoIM

How long have you been racing on tracks in cars? Your driving line looks bang on all the way through and catching the apex's nicely too. Some parts were I don't think I would have the beans to throw it in the corners at then speeds lol

Buxton - sounds awesome! I'll get the ATV's one more chance haha then I'll look into other options, I know PeteG40 is doing some real fancy conversion for the 02j

Yeah its a good fit! The PPP stuff really is good, my gearbox ball selector type thing slightly clipped it but all I did was file the rubber down which did the trick, other than that its exhaust downpipe off and then pretty straight forward!

Wow thanks Wizardman! I've been doing it on and off for about 3 years, that's my second time at Cadwell and first time in the Polo. Next I'm going to work on my speed as I've always felt I've been abit reserved on track, mainly because I don't want to risk binning it after all this effort.

The cage was around £1200 from Protection and Performance, sounds expensive but the reality is its a couple of hundred quid more than a safety devices but this cage still allows the sunroof to work and they fitted and powdercoated it! Weighs 840kg's with the cage and struggling to find areas to trim more weight that would make a difference.