This will be my second polo and as usual an impulse buy just in time for christmas

first thread and donor of the G engine can be broswed at leisure here: http://www.polog40.co.uk/forum/index.php?topic=10583.0

So here goes:

My day has started very positively (considering it began at 6 am) I have bought a mk2 polo with a GT engine

and although the body work is a tad shonky it goes like stink. Conversion was done by a chap in south wales i believe and its done to a very good standard.

I didnt take this one but this is what the bay looks like

So its in for MOT today as it needs one and then i will be taking it for a spin around the Yorkshire wolds/dales.

Alonside this new arrival i am building the engine from the block up.

Got the rebored block and polished crank back

And finally it begins

My iphone is slowly failing and dying. So i apologise for the poor quality images

Any hoo got the bog brush and contact cleaner out

As well as cleaning all the bearing and thrust washer

And then bolted and torqued the lot up.

Tonights job is popping the 3 pistons in (one is without an oil ring as i managed to snap it popping it on) Got a 7-10 day wait for a set.

And i reassembled the head with the new cam (PSD) and dizzy. Gave it all a good clean first

Last night was spent putting 3 of the 4 pistons in the block. got a fair wait till the piston ring set turns up. but plenty of other jobs in the meantime

And this morning went for a spin in a freshly mot'd and taxed motor (big shout out to Cayne for sorting me the headlights and indicator stalk that got it through the MOT)

So i bet my mate i would have this finished and drive it into uni by the end of the year, i may be losing a fiver.

But i have put some hours in this week after the piston ring fiasco

Oil pump and chain, poured some oil in to prime it

Had all the gaskets bar this one, so being northern i wasnt going to spend money on buying the whole set, cheeky bit of gasket paper instead

Oil started coming out of the filter hole so a mini oil filter is on for the time being, thread doesn't feel quite right so will change when i pop the oil in

Mad painting skills, good job i put newspaper down, one messy pup

And a metal head-gasket and precision tightening later and i have a head attached

Hopefully i will get an hour or two in before the weekend and get the timing belt cover on and the engine timed up

Thor lives... and is going to have boost. :) great stuff

It's a bloody nippy motor with just the GT in it. Part of me doesn't want to replace it with the G..... But it's 1341 and with a full blend charger

Yeah it really is. I drove it round rockingham and it was rather epic. Also it was pretty much the same pace as my then 1.4 16v round Mallory. Mine just had a little bit more in the high rev range.

sore this polo when it was cumbria for prt of its life was very bloody quick id be really interested in buying the cam and tappets from the gt if u take it out ? :) great build though loving that new engine great work keep it up :)

sore this polo when it was cumbria for prt of its life was very bloody quick id be really interested in buying the cam and tappets from the gt if u take it out ? :) great build though loving that new engine great work keep it up :)

Not breaking it yet, but will let you know if I do, cheers though lad, getting there slowly

Edited 15 December, 201411 yr by physicsfool

So then i timed the motor up and popped the cam cover back on,

And slowly its starting to look like an engine again.

I stole various parts off the GT motor like the starter motor and its wiring harness as well as injector jackets

And a touch more..

And then the Christmas holiday arrived, which meant whole days on the car, missus had an assignment deadline which worked well for me

So here is the GT engine which sadly i ended up breaking.

But it will make way for the G so i believe its a worthy cause

Dragged it into the workshop to take the engine out, G watching from afar.....

After a morning of sweating and dealing with driveshaft bolts

Both engines out and so i set about breaking the GT for parts

......And then on christmas day i dropped my phone. which buggered it proper. Being the holidays i had to wait a week for the next screen... However i couldnt stop working so voila....Engine in car now

With most of the engine loom in.... I chopped the central bonnet catch support out to make way for the intercooler which fits rather well, but had to make slight adjustments to the radiator so that it now sits in fresh holes.

With the rad fitted

And the cowling, I chose to use this one as it still fits and should have better draw as well as shielding the radiator from the exhaust manifold

It all fits...just

Need to finish off the cooling system pipework, figure out where the last few clips on the engine loom go and mount the oil cooler as well as fitting the last part of the boost system...

Edited 12 January, 201511 yr by physicsfool

Good effort. I like this project.

Theres something about a mk2 with a G40 that really appeals to me.

Is it all plumbed in? I see you've managed to avoid cutting the slam panel.

Thanks chaps,

Yeah I hope it all comes together and starts.

Still missing the TB to boost pipe with co pot to intercooler pipework. Got the intercooler design and route from Freddy77's mk2 G conversion.

So progress has been good, putting in mornings and evenings to get her done as i am finally moving out of my parents house and into a flat.

Front end view with trial fit oil cooler. snug but not many options

And as i cut the bonnet latch support pillar out i have to pop some bonnet pins in, holes for bonnet rubbers looked to be cock on

As the bonnet is double layered i had to make a nick in one of the existing slits to drop the inner support plate through

All fits a treat

Now i came across some interesting soldering while checking the bumper indicators. My OCD went wild so had to re do it

and ...

with a cheeky bit of heat shrink for good measure.

Just before i got the proper oil cooler position, but clears the charger nicely and a bit of slack in the pipes to accommodate engine movement

Grille back on

and my freshly soldered indicators in the bumper and reattached

With the engine and loom looking so clean i couldn't let the washers hoses let it down

So knocked up a new set in black (stealth)

And after a final engine check tomorrow i will be starting it up. With the freshly charged battery

Will drop the plugs out and disconnect the hall sender so that i can build some oil pressure up and then get it all timed up wth the blue temp unplugged.

Lets hope its a good start to the weekend

Awesome!

Great progress. I like this a lot :)

Hmmmmmmm.... Had a loom related issue

and ....

and i reckon this is the connector that caused the issue

Chap has been really good about taking it back and replacing it, bad news is that its taken the coil and some of the internal loom with it

But he has refunded the dolla to replace all of the parts.

So tomorrow night i am going to start replacing the interior loom and putting the new coil on

So, here goes sorting my electrical issues.

Firstly i wanted to replace the interior loom as it got damaged. and sort the fuel pump wiring out at the same time.

And as i used a mk2f loom i realised i was going to have a few rear light and indicator/ignition plug issues. So got cracked on and changed the ignition barrels over and casings as you can see the bottom screw hole is a few mm over so wouldnt fit the mk2f indicator stalk. Also the door locks are on their way out so this gave me a chance to replace all the locks and use only one key. Plus this loom is wired up to an immobiliser.

And after a bit of tweeking it all fits a treat

But had to replace the handbrake sensor and little bits like that as the mk2f loom has different connectors to the previous mk2 interior loom, this has also allowed me to use my G clocks

and by the fuse box

So i just need to sort the rear lights but i have all the relevant bits of loom so shouldnt be too difficult.

Now this is where the frustration started, received the refurb loom that caused the electrical issue last time. But wasnt happy with the finish

Missing grommets

He didnt replace the heat damaged wire on this loom

and forgot the protective outer here

So i have decided to ask for a refund and stick with a 20 year old factory jobbie. Another delay but i am getting used to them

So having replaced the internal loom, i got hold of markG40T after he mentioned he has fuel lines off a clean mk2f.

so swapped him some seats and racing seatbelts and got the fuel lines and genesis interior

Seats

rears, and even door cards and seatbelts

Dash back in with the Clocks thats go with this engine

and wheel

Light was starting to go

and the buttons dont look quite right, but will do for now

Finally sorting the loom and rewrapping. Soooooo much insulation tape

and i cleaned up the fuel lines... all falling into place for this weekend

Day finally came to install the fuel lines, i was going to live with the current set up but decided last minute to appease the ocd and sort the fuel lines out.

The old girl showing us what she is made of, i popped some axle stands in before doing work. Safety first

Fresh filter and some zip ties

Then i measured up the fuel pump bracket to the back chassis and popped some rivet nuts in

After drilling a hole in the boot for the fuel pump wire and routing the breather and fuel lines over the tank i screwed it all into place

Now to fit the final piece of loom and get her started. But the next 2 weekends will be spent drinking continental larger and reducing my coefficient of friction. So will put that on hold for a little while longer, also hoping to hear back from York city council about a garage soon, which will make storage and tinkering a lot easier