Thought id share my G40 rust busting project with you all..

I bought this beast back in Nov 2010 and enjoyed the full 2 years with her gracing the rds..

Shes running an Eaton M45 supercharger,on red top injectors,,remapped ecu,,induction kit,4-2-1 and full stainless exhaust system..

Heres a few pics from when she was on the rd...

Look at this beasty engine

Then in September 2012 i locked her away in my unit ready for its restoration haha.

So August 2014 i decided to make a start on the G40,,reason i took it of the rd was i knew it had some rot in the back end of the car,which has turned out to be a total understatement,,i was shocked with what I've found so far..

I emptied as its been used for storage for the past few years..

Let the work commence so I've decided to start from the rear as i know theres some welding work to do...the polo leaked water into the boot for a while and has produced alot of surface rust,,In the spare wheel well I've found some rot.

Got the wire wheel out and cleaned around the infected area's..

I removed the wheel well,,i could have patched it up but the rot can just come back as quick,took me ages to drill all the spot welds once drilled out i started peeling it away and found that the metal brace that holds the wheel well to the rear seat floor section had rotted away..

My replacement wheel well,,just gotta strip it and drill out the spot welds again :tumbleweeds:

Time to start cleaning up the rest of the boot floor..found more rot <_<

In each corner theres more rot coming through,and after taking a lot underneath some of the chassis has gone to :( ,so I'm gonna have to re-weld some new chassis pieces in..il be investigating more tomorrow.

Edited 13 January, 201511 yr by p3kano

Found a nice hole that had rotted through in the rear chassis,right under the rear tow point bracket,so that section needs re-doing,might have to replace the full chassis leg as other parts dont look good either..

Then on the other side of the chassis,right under the rear arch there was another big hole :rolleyes:

so now I&#39;m going to have to remove the full back end of the g,,but i know the back end was all replaced before i bought it and all needs doing again,theres sections of the floor that need replacing,,ideally it needs a full new boot floor panel and a full rear chassis leg....does anyone know if you can still buy those.

Finally with the full rear panels off i can now inspect the chassis ends,the passenger rear doesnt look to bad well until i get the underseal off.

The drivers rear side is a bit of a mess.

Drilled out the few spot welds that hold the chassis in,,and the towing point section just broke away

Looks a bit of a mess under there gonna be a fair bit of work just to sort the rear end out..

So i had the daunting task of unpicking the full boot floor panel :huh: ,

Sourced a genuine boot floor panel

Floor section out

Looking a bit floorless now..

Chassis leg sections exposed now,,drivers side has gone in several places,but the passenger side isnt that bad there is some rust starting to eat through,,so both legs will be replaced..

The G has a few more hidden suprises for me to tackle now.

Rear drivers inner arch is rotting through,,theres been alot of patch ups in the past,so found that the breather pipe from the petrol tank has gone through,,around the petrol cap has gone as well :(

And some bright spark has jacked the polo up of its cill and crushed the cill section up and has caused rot through the floor to cill area,,il be replacing the full cill as well.

All the rot has spread in the past through the drivers side and has caused havoc,,the passengers side is in really good condition.

I&#39;ve pondered over the idea of re-shelling but id get more satisfaction doing the work myself then cheat and re-shell Blehhhhh.giffy

managed to get the floor out,,just gotta pick a few bits of now...

Finally got the engine out,,managed to have a good look around the engine bay and suprisingly isnt that bad

Found a bit of rot on the inner wing nothing major thou :rolleyes:

Got both sections of rear chassis stripped out and I&#39;ve finally managed to pick the floor out but still have a few more panels to drill out yet :(

Made a start on removing the inner wing lining to see what lurks behind :rolleyes:

Lining removed.

Cleaned a few areas to see how bad they was,,gonna need a few sections re-welding in.

Fuel tank breather pipe area.

Inner petrol flap area gone right through on both sides.

Now that i can get to the area's that need patching up i can make a start on some welding.

Cut this old patch out from the bottom rear arch.

Made my own arch repair section from some mk1 polo metal I&#39;ve got.

Another bit of rot cut out around the fuel tank breather and a new bit of polo metal welded back in :rolleyes:

Finished of and breather pipe fed back through,,I&#39;m gonna put a rubber grommit and seal it in to prevent water getting through..

Cleaned up the the other section i put in the other day needed a bit more welding as there was a gap where the sun roof drain pipe runs through..

:)

I&#39;ve decided that I&#39;m gonna smooth the engine bay so gotta fill the charcoal canister hole up,,so made myself a templet piece and welded it in...

Cut a piece from some mk1 polo metal

Then welded in and primed up,,just need smoothing off now..

Warning some pictures may cause shock haha but I&#39;ve got a thing about rot lol

Anyway a while back i removed the boot floor to reveal rot in the chassis legs,,in the main chassis leg at the jacking point it had rotted through..

Doesnt look bad from inside :rolleyes:

Then removed an old scabby patch up on the inner arch,this is what was lurking behind it :drugie:

I&#39;m suprised its not all caved in from jacking up

So I&#39;ve addressed the support panel out in the chassis leg,,I&#39;ve patched it up so once the floor is back on you'll never see it

Next was to sort the horric rot in the inner arch/chassis leg,,so fabricated myself a piece of metal and welded it all up.

Then cleaned all of it up and coated it in some red oxide.

So my next job is to sort out the hole that once was a rotten petrol filler panel.

Then me being me i hunted down some more rot but on the passenger inner rear arch into the chassis leg so that needs doing as well now..

So thats as far i am with it at the moment,,so still plenty to do haha.. :)

Excellent work mate! Most people would of given up and re-shelled it. Glad your taking your time and doing it all proper in one go.

Look forward to seeing more metalwork.

Wow nice work!

Thanks :)

It did cross my mind a few times that I&#39;ve bitten of more then i can chew haha but il see this project through to the end,,once I&#39;ve got all the welding sorted it plain sailing then

Hi Kano, Looks good ! Glad to see you more on here than Polo3 as it seems to have died off over the last few years. Is Rick Gee? still about on there and still go a G40? Glad to see you're doing a proper job :)

Hi Jake

I&#39;ve been trying to get on here a little more nowadays and thought id share my project with yer all..

Polo3 is still going,yer its a bit quiet at times but its still ticking over,,infact we've just started a fresh new polo3 forum as the old forum was a bit dated..

The G I&#39;ve got was Ricks old G,,he's still around as well and he's got a G hide away somewhere..

wow mate, thats a lot of bodywork, gonna be mint after all those panels!

what kind of power are you getting from the eaton?, and is is the Eaton conversion easy enough to do?

Hopefully bud it'll be rot free with some fresh new panels fitted..

I bought the G with the Eaton already on it,but its fairly easy to fit,,there more of a pain getting set up properly,,when i bought it the Guy said it was running about 160-170 bhp,,but it was running a standard g40 cam and its mapped for an eaton cam,,so it never really ran brilliant,,but I&#39;ve since bought an Eaton cam so I&#39;m hoping for alot more power...

Been doing a few bits to the G

Finally finished the drivers rear inner arch out,,fully seam sealed up.

Cleaned the inner wheel linning up and red oxided it and seam sealed it.

Test fit the wheel linning in place.

Sorted the other bit of rot out in the passenger side rear chassis.

I&#39;ve also started cleaning the inner chassis up and painting it ready for re-waxing.

Also started cleaning panels up cause my unit is freezing and surface rust is appering on everything,,so I&#39;m cleaning them up and red oxiding..

drivers side cill cleaned up and painted.

Now the floor panel,,this has took me hrs to clean but I&#39;m getting there with it..

:)

Got a few bits done over the weekend..

Finally got the boot floor panel cleaned up.

Then a few coats of red oxide.

Drivers rear wheel linning all welded into place.

Found a bit more rot hidden away deep inside the chassis behind the rear section of the drivers cill,,as I&#39;m replacing the full cill anyway i cut a section out so i could get to the infected area..

Little bit more patch work needed.