I'm in the process of converting my Mk2 coupe S to G40 power:

I haven't really started yet, been buying tools + am ordering exhaust and lowering kit etc.

Anyway in the meantime I'd thought I'd do a nice easy job, swap the original G40 BBS alloys onto the Mk2, how hard can that be?

First problem: loosening the wheel nuts on the G40, one wouldn't come off, so borrowed a proper 4 spoke wheel brace, still wouldn't budge, even jumping on it. But after a long soak in WD40, and a torque wrench managed to free these off o.k.

Then to loosen the nuts on the Mk2 - dead easy - these were barely more than finger tight!

But then couldn't get the NSF wheel off the G, corroded onto the hub, again no amount of hammering + pulling would get it off, so went to machine mart + picked up a set of pullers (only £17 very pleased with these). Puller worked a treat, got the wheel off very nicely.

Finally swapped the wheels over, was tightening the nuts on the Mk2, and one sheared right off! I wasn't even putting any real force on it. (this was just during a pre-tighten).

I bought a set of extractors, but once started drilling the old nut, starting with a pilot hole, realised it wasn't really going to happen. On recommendation, took the car to a tyre place (I was going to put new rubber on anyway), they said if I remove the hub, might be able to get some mole grips on the back of the remaining nut.

So I think the best thing to do is to swap the hubs + discs + calipers with the G40 ones, (obviously the G40 one were going to go on at some point anyway) but not sure how to do this, Mr. Haynes isn't too clear on this - is there a guide on this site? couldn't see one in the FAQ.

Also are the wheel nuts same on Mk3 as the Mk2? the G40 ones are black, but silver on the Mk2.

Any help greatly appreciated.

I'm not sure if I'm understanding your correctly but do you mean can you put the mk3 struts straight onto your mk2? If so, yes, that should be fine. Should also mean you don't need to pull the bolt out of the old hub. Should just be a case of undoing the top mount, removing the tie rods, undoing the arb and popping out the bottom ball joint. You have to strip the brakes down first though. Obviously you'll need to swap the mk2 caliper for the G40 one. Should just be straight swap as far as I'm aware.

The wheels bolts should be the same between mk2 and 3. My 81 Derby shares the same bolts with my 01 Lupo. All the cars still probably have the same wheel bolts

Get new hubs from GSF, new front wheel bearings from VW, take the G40 struts off, take them to a garage and get then to press the new hubs/bearings in the g40 struts, build the lowering kit up on these and put it on with the G40 brakes. Replace the top mounts, bushes, etc at the same time, and you'll have a nice fresh suspension setup.

Thanks for your help guys.

@Heartagram - Didn't realise it meant swapping the whole strut assembly, tho that does make sense, thanks for the tip.

@PhilJ - why do I need new hubs + bearings? Actually I do need a new wheel bearing on that wheel on the G, but how did you know? Psychic like me?

It's all starting to make some sense now, I can work out a plan of attack! Looks like I'm getting the bus to work for a week or two though...

@PhilJ - why do I need new hubs + bearings? Actually I do need a new wheel bearing on that wheel on the G, but how did you know? Psychic like me?

It' always worth replacing wheel bearings, much better to be safe then sorry so might as well do it while the thing's apart.

Are you replacing the rar brakes and bearings as well? There might be a group buy on everything you need for this coming up. (drums, shoes, bearings, rear brake piston thingy, all nuts, seals, springs and locking pin)

Yep you guys all making perfect sense. Don't know about the rears (same on the G as the S right?) they seem fine, nice short handbrake, no noises, so probably not, though I'll inspect them first then decide. Any idea yet on the price on that buy?