Just finished painting the charger elbow, mount, larger collar (prototype) and T-piece mount. I'v also started on my new door cards to match my Corrado interior! Yes you heard - a complete Corrado interior in a G40 Front seats go straight in, the rear bench is going to need a bit more work! :)

Charger back in along with all the new painted bits - fitted my G60 injectors and SMS chip. And changed the alloys over to the Passat GT ones! Going to strip the interior tomorrow and trial fit the Corrado interior!

Right after 3 days hard work I've finally managed to download the pics of the work i've done!

here is how the engine bay started on Friday morning:-

freshly serviced charger - along with the charger, T-piece, elbow & bracket painted with high temp black paint

Also refitted my G60 injectors & sns chip - just got my spare rocker cover to paint with the same matt black high temp paint and polish the "VW" roundel.

Custom door cards started - begun with spare set of CL door cards and stripped them of their material so i'm just left with the fibre board backing.

After the first coat of filler primer and a rub down - 2 coats to go!

Corrado rear bench in - first trial fit!

Corrado front seats

Removed the rear bench until I can get some brackets made up and the seat scrubs modified

Fitted my new pressed metal number plates - along with the Passat GT alloys and new tyres

New German badge!

Needs a good wash, but i'm getting there slowly!

Hope you like it - I have loads more work to do on her! The door cards are going to be sprayed Black below the loine and metalic grey above the line!

Most peopel would have given up with it by now but you keep trucking on!

Good stuff Andy

I love my G40! even when its knackered It still makes me feel good when i get to work on it!

The rear bench is going to be a nightmare to fit so i'm thinking about selling the Corrado interior - and fitting some mk2 Golf Recaro's instead!

I've also got a complete spare G40 interior kicking about in the garage too - and a complete G40 engine just incase it does something horrible to me!

I'll manage to get it to the Polo Show this year!

I've been to all the shows and i've only shown up in 1 polo! and that was back in 2003 - then the Audi 100 in 2004 - then the mk3 golf shed in 2005 - then the GTD last years. Hope to bring the G40 + 50% down!

Just a quick update with how things with the G40 are going!

For some reason my boost gauge never seems to rise higher than 1/2 a bar of boost even on a 65mm pulley. So done a few checks and found the charger to elbow seal (the big one) was split, so i replaced it. and a few of the jubilee clamps were loose. So I tightened them all up. The car does feel alot faster through the revs, but the boost gauge still tops at 1/2 a bar - looks like a new boost gauge can go on the shopping list!

I've also done its 3000 mile oil and filter change. Since having the exhaust oil seal done i've had no oil lose problems!

I've also started to clean things up under the bonnet a bit! I had a spare rocker cover which i had painted white and it was WAY too bright so I tried its opposit! VW Diamond Black Pearlescent!

Before:-

After:- (a bit of paint and a hell of a good clean under the bonnet!)

Plus i gave the whole car a huge wash and polish! The first time in ages! Car looks SO good at the moment!

I've been slowly making a list of things that I want to sort out and things which need work and things which I just want to change!

New induction kit as its still using a std airbox and a crappy filter!

Fix the rattly tappets and fit a performance cam

new tyres for Tresers

fit new thermostat housing and thermostat - also replace the black and blue temp sensors

replace dizzy cap and rotor arm

FMIC

Toothies or something similar

replace rattly front shocks with something a bit better!

I'm finally back to enjoying driving my G40! :)

You still running the standard intercooler?

I was only getting about .5bar boost, traced it to the bottom plastic cap on the intercooler! must have cought it on a cerb or something.

deffinatly worth a check... You'll need to take it off the car to check it properly.

Wayne

Yeah i'm still running the std intercooler. I'll maybe take it off and have a look at it!

Had a good run to kamakazi929's place down in Salt Coat today - 160 mile round trip! had some fun with a Lexus Gs450H on the way there and a Porsche Boxster on the way home - well it would have been rude not to!

I've repaired a couple of annoying little bits on the G40 - the accelerator pedal was very loose due to a bent bracket on the bulk head so i straightened that and adjusted the throttle cable circlip and the cable holder was twisted. Now I get 0.75 BAR!

Stopped of on one of the back road for a few pics of the G40 too

Just got to repolish the Tresers and wait for my new 185/45/15's to show up!

u got a rear tail light out ant u ,

looking good when its clean, am considerin colour codeing my bumpers but not sure yet. interiour looks sooooo nice

Its not out - its just really dull for some reason!

Small update!

Right this year i'm determined to get to the Polo Show in the G40!

Fitted my foglights today and sorted myself out with a loom!

Had the new tyres fitted onto the Tresers (195/45/15 Toyo's) and fitted them onto the car this afternoon.

I've checked over all the normal service items, everything seemed fine other than a weap from the thermostat housing. so unbolted it and checked the o-ring which was fine, but the actual housing had crack away on the inside of the housing - So need to order a new one tomorrow! and an o-ring or 2!

Pics to follow as soon as I can get the car moved and get some pics of it!

be good to see the half aswell at the show :) . I had to do the housing the other week, dont do what i did and round off the bolt, Spent half the afternoon with a drill :(

Just a few quick updates seen as the g40 is now back in use!

New VAG distributor - £130!!

Foglights fitted

LED marker lights in the indicators and the foglights!

new alloys

Its running a little off at the moment - keeps coughing and missing firing when you get up the rev range!

Things to do:-

new thermostat (looks like this one is stuck open!)

New Coil (Possibly faulty?? or on the way out??)

New Earth straps on charger and from the coilpack to the chassis

Oil Change, Filter (3000 mile service)

New Plugs - W6DPO's from a you are Quattro!

New discs and pads

Refurb new alloys - White centres with polished dish and 195/45/14 tyres

Things I'd like!

PPP Crossmember

Schrick cam & new followers (to shut them up)

Rolling road session to check the timing and give me a power run

Electric windows kit

Wind-deflectors for the doors

central locking

boot popper

false floor in the boot

fix the hole in the battery tray

Well looks like another expensive year ahead! i hope not to see it at the next Polo Show (like the 3 before it!)

Good day - bad day!!

Thought seen as it was nice and dry and quite warm I would change to oil and filter on the G40. Along with changing the thermostat to sort out the lack of heat!

Everything went well, didnt take long to do. Asked Ross if he would have a look at my gearbox as it started sticking in gear and being difficult to change out of gear. So started by draining the oil, which looked like runny shite! But the stud which goes in the the top hole woundnt come out - but after hammering, battering and trying to get it out with an airgun. Finally got it out and nice new oil in.

However - I noticed the paint was flaking off my rocker cover so though i'd get it off stip it down and repaint it a bit better. So I put my other rocker cover on it, but for some reason the centre stud wouldnt tighten up then it jammed and sheered! Typical! Good job I have a spare G40 engine that I can steal a cam follower off to sort mine while I get it drilled and remove the broken stud!

Doh!

Another small update!

During a fast run up the motorway home a few nights ago - I stripped ANOTHER belt of all its teeth! So it was sat on my parents driveway for a week while the new belt showed up.

Also when I went out in it last weekend to collect JimmyB from the airport we got stuck in traffic and my clutch started to show the strain! The a couple of days later I was trying to accelerate up hill in 5th and all I got was clutch slip! So the car is now sitting in Ross's garage with no gearbox - awaitng refit of a new clutch when we get round to it!

Going to sort out its leaking battery tray next!

I have those alloys on my genisis but in grey!!!

BBS 14", 4x100 6.5j ???

What they off???

looks stunning, I'm impressed!

Thats it. I want rado seats too!!

Bin that towbar! Stick it on the barge instead! The Golf I mean.

I want the trailer.... looks so damn cool and it's actually really practical if you have an extra car lying about lol. Think when I get myself another shell to build a high spec mk3 I will be using my current mk3 as the base for a trailer conversion!!

I have those alloys on my genisis but in grey!!!

BBS 14", 4x100 6.5j ???

What they off???

Nope! 1983 Compromotive CXN'S! 6x14 try finding a set!

Looks like you well deserved to get to the show!

I'm loving the trailer too. You still got it as iirc, you were selling it a while ago.

Trailer doesnt actually belong to me - its 13KpoloGT's - its just it was always photographed on my car first!

does look good tho. I had an idea of making a trailer as sleeping quarters for when i go to shows but worked out there just aint enough room! Would save putting up a tent in the dark!