1991 Mk3 Polo G40
Discussion
Thought I'd whack up a thread for this beasty, not my first rodeo into old VW's
Since I sold my first polo, kinda fancied getting back into a polo and successive other old dub projects had failed to scratch the itch (Purple VR6 Corrado that never worked and a Tornado Pink Mk2 Scirocco with a GTi Engineering RE2000 8V conversion)
Also having done the VR6 thing, felt it was time to do the supercharged thing too
All the way back in February I fuelled up the A5 and went for a trek up the M1 to see a man about a dog/geniune G40 that he was selling that had a tasty specification.
After a long catch up and potter out in it, we came to a deal and I drove back a wrote up the advert for the RE2000 (which took a few months to sell!)
Finally got sorted for the weekend before All Types VW Show (13th May) settled in for a long train ride up to Leeds
So two trains and two and bit hours later, got to the car
And a sort out of stuff and gave it a quick clean
Quick run down of spec
Stainless exhaust
HnR Cup suspension with uprated ARB and rose jointed track arms (not sure on that, I've lost the advert and doing this by memory!
Stage two charger (with a stage four to be rebuilt )
EBC discs and pads
65 mm pulley
Boost gauge
Rest is standard G/mk3 stuff
So started off on my home, however car had other ideas, a gearbox issue that neither of us spotted or could've predicted reared its head, lost drive at 70mph on the M1 near Rotterham, managed to coast it off the carriageway at J33 and ended up having to be recovered home.
Saf being the awesome mega sound dude that he is sorted me another gearbox out and I organised collection of my car by my mates VW garage to get it swapped over
In meantime, the car sat on my drive looking sorry for itself so got new plates and holders on
Also at the same time refurbished the snowflakes I had left over from the scirocco with a Volvo dark grey and slapped on some 195/45/14 Falkens as old 185/60/14 Conti's don't cut it on a G
Whilst it was at the garage, it had some good company
However we found the replacement box (CEG code) didn't like 5th and kept jumping out (also needed to replace the linkage as I'd broken the ball at the bottom of the stick in order to get it out of gear so could roll for recovery!)
So trip to Shropshire for the linkage and a run up to Tibshelf to meet someone halfway for another box (8P this time) and we got it in and back up and running
(With an appearance by my dad's new Ateca and my mum's Fabia )
So after lots of brapping about all weekend, set about sorting the matte bonnet that had green coming through
And all was well....or so I thought
Took it to work on Monday morning couple weeks ago, I work 26 miles from home and go M5/M42 and about 7 miles away it started doing odd things and having no power, up until it died on me in the rush hour traffic
Queue calling the RAC who said its the alternator, charged me up and followed me to work, however a chat with a few people we agreed it wasn't and set about checking the charge circuit, then found this:
Left in works secure carpark over night, got lift home and back the next morning but with new strap, tools and battery charger, borrowed electricity off work and got it back in and now seems to be sweet, just goes to show, never take what RAC/recovery say to you as rite!
That was until I cut out again on me, this time thankfully just as I pulled onto my drive. After lots of conflab and head scratching and new plugs, couldn't figure out why it wouldn't start, I loaded up my daily A5 to get to Polo Social. Upon the arrival of the Scottish contingent, Steven said to me 'we're going back to yours tomorrow to get the G', never argue with a Scotsman!
So we loaded up in two cars, me and Chris in the Audi and Steven & Ross in Steven's G-Turbo, we got 20 miles and Steven's clutch cable broke, queue all piling in a 2 door coupe to go to local garage to try a repair/order another. Ended up ordering another cable which would take 3 hours to arrive so we did the jag back to Brum from the other side of Nottingham.
We set to work on the G, took the fuel pipe off the rail and cranked it to find not much coming through, so Steven had a look at the pump and we put another 5 litres in to give it the best chance, 3 cranks and 1 failed start it started, sender to gauge appears to be a bit off as it reads 1/4 when its nowhere near! (filled up with 40 litres, did 250 miles of driving and it still reads a 1/4, I think not!)
Queue going four up in a G40 (with a video that Steven took ending up on Club Polo's Instagram thanks to an admin!) with a diversion round traffic and stop to adjust the timing, then back to garage for clutch cable, return to fix Steven's car then return to Polo Social (left at 11am, back for 6pm)
Saturday afternoon at Polo Social saw a few people descend on it to sort out a few niggles and to refit the front bumper (needs a pair of bumpers really) and codes read and removed by my mate Gaz on Sunday
After the show finished decided to give it its first proper clean in my ownership and it came out pretty well (still need to sort out the bonnet!) and lined up with my friends' Steven and Scott's cars for the A-polo-clypse photo below (courtesy of Ceri Jones)
So that brings us up to date, still lots to do and maybe improve on (there's no stereo or speakers!) but all in good time, just going to enjoy it for now
Since I sold my first polo, kinda fancied getting back into a polo and successive other old dub projects had failed to scratch the itch (Purple VR6 Corrado that never worked and a Tornado Pink Mk2 Scirocco with a GTi Engineering RE2000 8V conversion)
Also having done the VR6 thing, felt it was time to do the supercharged thing too
All the way back in February I fuelled up the A5 and went for a trek up the M1 to see a man about a dog/geniune G40 that he was selling that had a tasty specification.
After a long catch up and potter out in it, we came to a deal and I drove back a wrote up the advert for the RE2000 (which took a few months to sell!)
Finally got sorted for the weekend before All Types VW Show (13th May) settled in for a long train ride up to Leeds
So two trains and two and bit hours later, got to the car
And a sort out of stuff and gave it a quick clean
Quick run down of spec
Stainless exhaust
HnR Cup suspension with uprated ARB and rose jointed track arms (not sure on that, I've lost the advert and doing this by memory!
Stage two charger (with a stage four to be rebuilt )
EBC discs and pads
65 mm pulley
Boost gauge
Rest is standard G/mk3 stuff
So started off on my home, however car had other ideas, a gearbox issue that neither of us spotted or could've predicted reared its head, lost drive at 70mph on the M1 near Rotterham, managed to coast it off the carriageway at J33 and ended up having to be recovered home.
Saf being the awesome mega sound dude that he is sorted me another gearbox out and I organised collection of my car by my mates VW garage to get it swapped over
In meantime, the car sat on my drive looking sorry for itself so got new plates and holders on
Also at the same time refurbished the snowflakes I had left over from the scirocco with a Volvo dark grey and slapped on some 195/45/14 Falkens as old 185/60/14 Conti's don't cut it on a G
Whilst it was at the garage, it had some good company
However we found the replacement box (CEG code) didn't like 5th and kept jumping out (also needed to replace the linkage as I'd broken the ball at the bottom of the stick in order to get it out of gear so could roll for recovery!)
So trip to Shropshire for the linkage and a run up to Tibshelf to meet someone halfway for another box (8P this time) and we got it in and back up and running
(With an appearance by my dad's new Ateca and my mum's Fabia )
So after lots of brapping about all weekend, set about sorting the matte bonnet that had green coming through
And all was well....or so I thought
Took it to work on Monday morning couple weeks ago, I work 26 miles from home and go M5/M42 and about 7 miles away it started doing odd things and having no power, up until it died on me in the rush hour traffic
Queue calling the RAC who said its the alternator, charged me up and followed me to work, however a chat with a few people we agreed it wasn't and set about checking the charge circuit, then found this:
Left in works secure carpark over night, got lift home and back the next morning but with new strap, tools and battery charger, borrowed electricity off work and got it back in and now seems to be sweet, just goes to show, never take what RAC/recovery say to you as rite!
That was until I cut out again on me, this time thankfully just as I pulled onto my drive. After lots of conflab and head scratching and new plugs, couldn't figure out why it wouldn't start, I loaded up my daily A5 to get to Polo Social. Upon the arrival of the Scottish contingent, Steven said to me 'we're going back to yours tomorrow to get the G', never argue with a Scotsman!
So we loaded up in two cars, me and Chris in the Audi and Steven & Ross in Steven's G-Turbo, we got 20 miles and Steven's clutch cable broke, queue all piling in a 2 door coupe to go to local garage to try a repair/order another. Ended up ordering another cable which would take 3 hours to arrive so we did the jag back to Brum from the other side of Nottingham.
We set to work on the G, took the fuel pipe off the rail and cranked it to find not much coming through, so Steven had a look at the pump and we put another 5 litres in to give it the best chance, 3 cranks and 1 failed start it started, sender to gauge appears to be a bit off as it reads 1/4 when its nowhere near! (filled up with 40 litres, did 250 miles of driving and it still reads a 1/4, I think not!)
Queue going four up in a G40 (with a video that Steven took ending up on Club Polo's Instagram thanks to an admin!) with a diversion round traffic and stop to adjust the timing, then back to garage for clutch cable, return to fix Steven's car then return to Polo Social (left at 11am, back for 6pm)
Saturday afternoon at Polo Social saw a few people descend on it to sort out a few niggles and to refit the front bumper (needs a pair of bumpers really) and codes read and removed by my mate Gaz on Sunday
After the show finished decided to give it its first proper clean in my ownership and it came out pretty well (still need to sort out the bonnet!) and lined up with my friends' Steven and Scott's cars for the A-polo-clypse photo below (courtesy of Ceri Jones)
So that brings us up to date, still lots to do and maybe improve on (there's no stereo or speakers!) but all in good time, just going to enjoy it for now
Gotta love the reliability (or lack of) of a G40. I had one for about 5 years when I was younger and as a general rule something would go wrong with it at least once a month! That was after me rebuilding the majority of it too.
Can't beat them for putting a stupid grin on your face though!
This was mine
Can't beat them for putting a stupid grin on your face though!
This was mine
Well it played up quite a bit between now and initial post, alternator finally gave up on the way back from VW Action in September so it stayed on the drive until we moved at the end of October where it now has a garage to live in, charged up the battery the night before then drove the 5 miles and parked it where it still is now!
Parts acquired to go through and change
Quieter exhaust (closer to standard diameter, 1.75 to 2" rather than 2.5")
Alternator
Front Wings/Bonnet (in black and better condition than current items)
B pillar decals
Bumpers (front one hangers are damaged on the one side and the rear has been cut)
Have borrowed the wifes Skoda estate quite a bit recently!
So Saturday saw a partial strip down, got the asbo exhaust off and then set about changing the bonnet and passenger wing (the passenger one is the worst condition with a big dent and rusting on the bottom where it mounts to the car)
Got all the easy bolts off and then got defeated by the three on the A pillar that happen to be covered in body sealant (got two off in the end)
So currently sat like this until it warms up a bit!
Parts acquired to go through and change
Quieter exhaust (closer to standard diameter, 1.75 to 2" rather than 2.5")
Alternator
Front Wings/Bonnet (in black and better condition than current items)
B pillar decals
Bumpers (front one hangers are damaged on the one side and the rear has been cut)
Have borrowed the wifes Skoda estate quite a bit recently!
So Saturday saw a partial strip down, got the asbo exhaust off and then set about changing the bonnet and passenger wing (the passenger one is the worst condition with a big dent and rusting on the bottom where it mounts to the car)
Got all the easy bolts off and then got defeated by the three on the A pillar that happen to be covered in body sealant (got two off in the end)
So currently sat like this until it warms up a bit!
Currently looking like this
Picking up some bumpers this weekend and perhaps fitting the new exhaust
Picked up some TIM/VDO gauges with senders this weekend so many play with that as well plus decide on which way to go with my other purchase:
Before anyone says owt, I know its on the wrong side, I just grabbed one to look at fitment and for a photo
Picking up some bumpers this weekend and perhaps fitting the new exhaust
Picked up some TIM/VDO gauges with senders this weekend so many play with that as well plus decide on which way to go with my other purchase:
Before anyone says owt, I know its on the wrong side, I just grabbed one to look at fitment and for a photo
I had a G40 back in the late 90's - absolutely loved it - There was quite a big group of us in 'Club G40' having regular stands at GTI International and other VW shows of the era, rolling road shootouts in Performance VW etc. Always remember going to a show somewhere off the M23, and around 15x G40's in convoy chancing upon a middle lane hogger that wouldn't move over so he ended up having all these G40's flying past him on both sides - great days
Thanks guys
Quick trip on the weekend up to Shropshire yielded some better bumpers for the G
Need a cleanup and the rear restriping but got the bits to be able to do that, the front has slight scuff damage but I'll take a bumper with two intact side mounts and a small amount of damage over a droopy one
Also grabbed this when I went and got the bumpers
Heat shield for cone made to fit a G40, just need to decide on what filter to run on it now, will leave the standard airbox on for now though
Quick trip on the weekend up to Shropshire yielded some better bumpers for the G
Need a cleanup and the rear restriping but got the bits to be able to do that, the front has slight scuff damage but I'll take a bumper with two intact side mounts and a small amount of damage over a droopy one
Also grabbed this when I went and got the bumpers
Heat shield for cone made to fit a G40, just need to decide on what filter to run on it now, will leave the standard airbox on for now though
Always loved the Polo G40 but have yet to be in a position when space/money/one being for sale have all occurred at the same time. I had a Polo GT and 1.3 SPI an helped my little brother build (at the time) one of the higher spec'd modified ones in the country- he practically lived on Club Polo and Polo3
This 1.3GT with about 115hp + RSL Cults (I think there are only a handful of the staggered sets in the UK.)and a lot of suspension/brake/steering mods -
Are you able to shed some more light on the rose jointed front end that your car has??
i have one of these on my mk2 bready.
Combined with upper/lower strut braces, upgraded rear anti roll bar + polo G40 axle (flipped) an upper brace. It's about as sturdy as you can make a Polo before you install a full cage.
This 1.3GT with about 115hp + RSL Cults (I think there are only a handful of the staggered sets in the UK.)and a lot of suspension/brake/steering mods -
Are you able to shed some more light on the rose jointed front end that your car has??
i have one of these on my mk2 bready.
Combined with upper/lower strut braces, upgraded rear anti roll bar + polo G40 axle (flipped) an upper brace. It's about as sturdy as you can make a Polo before you install a full cage.
aka_kerrly said:
Always loved the Polo G40 but have yet to be in a position when space/money/one being for sale have all occurred at the same time. I had a Polo GT and 1.3 SPI an helped my little brother build (at the time) one of the higher spec'd modified ones in the country- he practically lived on Club Polo and Polo3
This 1.3GT with about 115hp + RSL Cults (I think there are only a handful of the staggered sets in the UK.)and a lot of suspension/brake/steering mods -
Are you able to shed some more light on the rose jointed front end that your car has??
i have one of these on my mk2 bready.
Combined with upper/lower strut braces, upgraded rear anti roll bar + polo G40 axle (flipped) an upper brace. It's about as sturdy as you can make a Polo before you install a full cage.
As far as am aware, they're standard G40 items (G40 rose jointed TCA's/G40 rose jointed steering arms) and many people with mk3's upgrade to them, teaming with PPP subframe on the infamous Gleidersite bushesThis 1.3GT with about 115hp + RSL Cults (I think there are only a handful of the staggered sets in the UK.)and a lot of suspension/brake/steering mods -
Are you able to shed some more light on the rose jointed front end that your car has??
i have one of these on my mk2 bready.
Combined with upper/lower strut braces, upgraded rear anti roll bar + polo G40 axle (flipped) an upper brace. It's about as sturdy as you can make a Polo before you install a full cage.
I think I vaguely remember your brother, I'm long in the CP tooth (since 2006) and remember him only as 'Ginge'
Love these, have always had a soft spot for them since I had a 1.0 mk3 back in the day as my first car. would have another one but the reason I got rid of it was because I didn't fit in it would have loved a G40 will keep my eye on this thread as I'm interested to see the progression
would have loved a G40 will keep my eye on this thread as I'm interested to see the progression 
Small update, got round to cleaning the bumpers and re-instating the red stripe on the rear bumper before refitting (and shearing a head off a bolt luckily only one of the minor ones on the underside)
Still need to figure out swapping the alternator, may just swap the voltage regulator or get my mate's garage to do it before the MOT
luckily only one of the minor ones on the underside)Still need to figure out swapping the alternator, may just swap the voltage regulator or get my mate's garage to do it before the MOT
jonvw84 said:
I think I vaguely remember your brother, I'm long in the CP tooth (since 2006) and remember him only as 'Ginge'
That would be him, Mr Ginge I think is his screen name with a silly Garfield gif. I don't tend to get on club polo so much now, haven't done anything worth updating the several year old thread on the Polo Bready 1.6 16v. I've know Saf for a few years now an traded many ol Vw bits (even some TSW Venoms that i bought from him when i had a MK2 Astra GTE) and we would party at Edition 38.
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