Polo G40 Turbo- Trackday Toy

Discussion in 'Members Gallery' started by Yoof, Nov 8, 2010.

  1. Yoof Forum Member

    Joined:
    Feb 20, 2005
    Likes Received:
    217
    Location:
    United Kingdom
    Hello All!

    I've been lurking on here for a few years now, and thought I best introduce myself as I'm going to be tagging along on the Trackday Tour 2011, aside from the occasional MSN chat with Eddie (toyotec) I don't really know anyone on here.

    So, this is the sotry of my car and its progression to how it is now.

    Started like this:

    [​IMG]

    90bhp Polo GT engine, and 80bhp worth of nitrous- was great fun at 18! [:D]

    This then lead to ITBs, megasquirt, and a few more bhp:

    [​IMG]

    After I drove the car like this for a year or so, I then drove my brother's G40 Turbo here:

    [video]http://youtube.googleapis.com/v/pABQ7ROwhY4?fs=1&hl=en_US[/video]

    ^ The Golf is the one making all the noise, Polo is silent :thumbup:

    Decided forced induction was the way to go- sold the ITBs and built a turbo motor up:

    [​IMG]

    Change of wheels:

    [​IMG]

    This engine setup has done everything I wanted it to, I enjoyed visiting Santa Pod (the car has over 130 runs under its belt).

    Best run of 2008:

    [video]http://www.youtube.com/v/Pg7KeWEUGZQ?fs=1&hl=en_US[/video]

    Some more modifications for 2009 saw this:

    [​IMG]
    [video]http://youtube.googleapis.com/v/VTLYBk3a2rY?fs=1&hl=en_US[/video]

    Against a 470bhp RS4:

    [video]http://www.youtube.com/v/clUseUvsBN4?fs=1&hl=en_US[/video]

    At this point I was getting interested in trackdays, I live close to Oulton Park so did a wet day there late in 2009 and was hooked.
     
    Last edited: Oct 30, 2012
  2. Yoof Forum Member

    Joined:
    Feb 20, 2005
    Likes Received:
    217
    Location:
    United Kingdom
    So I decided a car that could hit 110mph in 400m required a cage, especially a tin box polo. Hence this:

    [​IMG]

    [​IMG]

    [​IMG]

    [​IMG]

    And a few custom suspension components thrown into the mix:

    Top Mounts & G40 Cup Car Suspension (Sachs):

    [​IMG]

    [​IMG]

    Proper seats:

    [​IMG]

    I've got lots of pics which I won't bore you all with! The old engine made 223bhp and 210lbft with 25bhp of nitrous, so my aim for the new turbo setup is this, I'll put the nitrous back on when required :p

    [​IMG]

    See you around!

    Yoof
     
    Last edited: Nov 9, 2010
  3. Dan W

    Dan W CGTI Regional Host

    Joined:
    Jan 21, 2009
    Likes Received:
    114
    Location:
    Penryn, Cornwall
    I saw this at the pod last year, very rapid! sounded pretty awesome too, love it[:D]:thumbup:
     
  4. infinity

    infinity Forum Member

    Joined:
    Jan 20, 2004
    Likes Received:
    33
    Location:
    United Kingdom
    :thumbup:

    look forward to seeing it on track! loving the work so far
     
  5. scruffydubber Paid Member Paid Member

    Joined:
    Apr 28, 2004
    Likes Received:
    15
    Location:
    Dubhampton
    Great project, Hope to see it in action sometime.

    Whats the spec on the engine? And what turbo are you using?

    Thanks
     
  6. Yoof Forum Member

    Joined:
    Feb 20, 2005
    Likes Received:
    217
    Location:
    United Kingdom
    Cheers guys :)

    Engine is nothing special really, just attention paid to the setup and mapping, spec is as follows:

    1341cc (Accralite Pistons- 9.3:1 Compression)
    Big Valve Head (Oversized Exhaust 2mm) Ported & Polished
    Polo GT Inlet Manifold
    Larger 51mm Throttle Body
    Custom Intercooler/Boost Pipes & Pace Radiator
    Old Turbo was a K03 (running 22psi @ 203bhp)
    New Turbo is GT2554R (hopefully running 18psi at 220bhp ish)
    250kPa Map Sensor
    Custom Map (Still using Digifant)
    315cc/min Injectors
     
    Last edited: Oct 30, 2012
  7. Yoof Forum Member

    Joined:
    Feb 20, 2005
    Likes Received:
    217
    Location:
    United Kingdom
    Couple of more recent pics:

    [​IMG]

    Por-15 is great :thumbup:

    [​IMG]

    Even a brush gives an excellent finish:

    [​IMG]

    The welded circles are plates made after access holes for the welder have been made.

    infinity- The video you posted the other day of Donnington Park (2004?) that's me in the passenger seat of the G40 you went past on the grass :lol::thumbup:

    Pete
     
    Last edited: Nov 9, 2010
  8. Yoof Forum Member

    Joined:
    Feb 20, 2005
    Likes Received:
    217
    Location:
    United Kingdom
    So, thread is now back alive again- thanks :thumbup:

    To update from Nov two years ago:

    Flat floor made in the rear, complete with diffuser to stop the bumper acting like a 'cute:

    [​IMG]

    Some paint on the cage and engine bay:

    [​IMG]

    [​IMG]

    [​IMG]

    A little more interior going back in:

    [​IMG]

    Carpets cut around the cage, I'm not a fan of track cars with no carpet in, so for the 2kg it adds:

    [​IMG]

    Lots of little bits that take the time, stuff like making new door seals:

    [​IMG]

    Was lucky to get these before Performance Trim folded:

    [​IMG]

    More carefull cutting:

    [​IMG]

    Diffuser on:

    [​IMG]

    Fresh bits, adjustable TCA (camber) and new hubs with Bildon studs/nuts

    [​IMG]
     
  9. Yoof Forum Member

    Joined:
    Feb 20, 2005
    Likes Received:
    217
    Location:
    United Kingdom
    Common Polo mod to stop the chassis leg cracking, some CDS tube welded in:

    [​IMG]

    The front compressions trut has also been fitted here, to allow castor adjustment, the TCA and top mount provide camber adjustment to about -4'

    Cooling pack in:

    [​IMG]

    First time on it's new wheels/tyres (Speedlines/ V700 cut slicks)

    [​IMG]

    Carpet in:

    [​IMG]

    Engine built back up:

    [​IMG]

    [​IMG]

    EGT welded onto manifold:

    [​IMG]

    Awaiting blower:

    [​IMG]

    Crackly Paint:

    [​IMG]

    Turbo, lines and more bits on:

    [​IMG]

    Looking fairly car like:

    [​IMG]

    Ouside for the first time in 18months, some may recognise the Blue Mk1 and the donor vehicle parked next to it lol

    [​IMG]
     
  10. Yoof Forum Member

    Joined:
    Feb 20, 2005
    Likes Received:
    217
    Location:
    United Kingdom
    Ready for downpipe to be made:

    [​IMG]

    3" to 2.5" downpipe:

    [​IMG]

    Subtle tailpipe:

    [​IMG]

    And just about complete:

    [​IMG]

    So, next up was to book Bruntingthorpe so me and Andy (elder brother) could spend a day mapping it, shaking the car down, and generally checking things over. No mechanical mishaps at all, recorded 153mph GPS in the wet, with lots of runway to go! oh, and this happened about 140mph:

    [​IMG]

    lol

    Vid of the run:

    [video=youtube;vdr8VUh3gu8]http://www.youtube.com/watch?v=vdr8VUh3gu8&feature=youtu.be[/video]

    [​IMG]

    So after that, time to hit some trackdays :thumbup:

    Blyton Park, video from my mates AX GT (Saxo VTS motor, Leda Suspension, Slicks etc- he can drive well too) Polo has much more power, but I'm not quite as brave! See the Polo about 10min in to the vid:

    [video=youtube;ZDrPymSYsgw]http://www.youtube.com/watch?v=ZDrPymSYsgw&feature=relmfu[/video]

    So after that, decided it was time to get some proper slicks, but I had 256mm 4-pots, and slicks aren't cheap in 14", so:

    Compo CXr-2 13x7 ET0:

    [​IMG]

    My arches didn't thank me...

    [​IMG]

    So, a trackday at Oulton later:

    [​IMG]

    [​IMG]

    Gutted after the work that had gone into it, but hey ho, built to be ragged!
     
    Nige and fasteddie like this.
  11. Yoof Forum Member

    Joined:
    Feb 20, 2005
    Likes Received:
    217
    Location:
    United Kingdom
    So, time for another strip down:

    [​IMG]

    WL Motorsport Gruppe H GRP Arches:

    [​IMG]

    Complete with some GRP front wings and NACA ducts for brake cooling (managed to melt my centre caps on a trackday!):

    [​IMG]

    [​IMG]

    [​IMG]

    Finally a GRP boot to replace the bent metal one:

    [​IMG]

    I've had lots of GRP panels on various different Polos, and the fit is usually middling to poor, these, I was amazed, you could run the panels 100% stock fixings if you wanted, found a German Supplier called Timeless Car Designs, I have used them since for more parts and they're just as good, deffo reccomended :thumbup:

    [​IMG]

    Rubber rivnuts used to hold the rear arches on:

    [​IMG]

    [​IMG]

    [​IMG]

    Now, I had to make things a little faster after the accident, so I had a better chance of a repeat incident, so out with the glass:

    [​IMG]

    That got sent of to Mr Paskal (who kindly drove to meet me on a few occasions) for some Lexan margard ones to be made.

    In the meantime I purchased some road wheels, forgot how heavy these are:

    [​IMG]

    Ready for the bodyshop:

    [​IMG]

    [​IMG]

    Oh, at Oulton, after I crashed, we bent the car back out with a rachet strap so I could continue breaking things (second gear went in the afternoon), so, before:

    [​IMG]

    During:

    [​IMG]

    After:

    [​IMG]

    So whilst the car was at the bodyshop I stripped my box down, scraped 2nd gear off my diff, and stuck it in another box:

    [​IMG]

    Bit o' bog and a new VW repair panel (thank you eBay):

    [​IMG]

    [​IMG]

    Bonnet repaired after Bruntingthorpe incident:

    [​IMG]
     
  12. Yoof Forum Member

    Joined:
    Feb 20, 2005
    Likes Received:
    217
    Location:
    United Kingdom
    Home from bodyshop:

    [​IMG]

    So, got it built back up, windows from Mike, and ready for MOT:

    [​IMG]

    Passed 1st time, MOT man was generally confused as to why someone would do this to a Polo, but he gave me a thumbs up and fresh ticket :thumbup:

    [​IMG]

    Then went to a Pistonheads meet, after telling someone the bottom ends on these are good for 300bhp mate 'no sweat' :

    [​IMG]

    B*gger. :cry:

    Stripdown again (the mrs has given up all hope at this point):

    [​IMG]

    Punched clean through both sides of the block, and ripped the starter from the box.

    [​IMG]

    Solution:

    [​IMG]

    [​IMG]

    To quote someone on Club Polo:

    "Rod WHYYOUNOSTAYINBLOCK

    because boost." lol

    So, time for an update. I have the Club Polo trackday booked at Blyton in a few weeks time, and BVF was falling on my birthday weekend, and I'd just shat my engine fairly comprehensively.

    Sat 14th I picked this up from Surrey:

    [​IMG]

    Saved some time as it came with a 1341cc bottom end (but no BVH).

    Already had stuff booked that weekend and Monday, so that basically gave me Tuesday- Friday lunchtime to strip en engine out the black G, rebuild with forged rods and a BVH, get all the rebuild parts, repair my leaking ally rad, put it in the car, and drive to BVF. Simples eh? Quickly filled my holiday sheet in on the Friday, and told work I'd see them in a week...

    Here in, lies the tale, of the engine I have aptly named, 'the *******'.

    So we start on Tuesday, engine out, gearbox split, and head off... to find its a stock head, bugger. Quick call to previous owner and PeteG40 sees me with some cash back, and me due to pick a new head up from Pete (thanks Lewis/Pete).

    [​IMG]

    Spend the rest of the day splitting parts off my failed 1341cc motor. That evening I drive up to collect the head from Pete and have a brew.

    [​IMG]

    Wednesday- parts arrive from Germany, and rods/bolts are already here, so split the new 1341cc further and take rods from pistons, install new rods. Start to put new rods back in bottom end, torquing them up happily (ARP torques not VW), and SNAP.

    [​IMG]

    ****. Game over.

    So a call to the supplier and some head scratching later, I realise I've been an utter rainman and torqued them up to the incorrect bolt spec. 15lbft too much. With my background this is an epic failure. Call back to supplier, 80 later, lesson learnt, don't be a smart **** and read instructions properly.

    Removed the other bolts, which had started to neck, they're now on my shelf of broken ****.

    [​IMG]

    I didn't take many pics over the next day or so...

    Thursday comes, and rod bolts arrive by courier about half 2. Hmm, leaving Friday lunch looks highly doubtful! Anyway, put everything back together and find on Thursday night, 'the *******' strikes again, this engine can't like the thought of 1.5bar up it's **** or something... fighting every step of the way, 2 cam bearing studs pull. ****, they're M7 and need helicoiling, not a problem I've got a kit as this is a common problem, kit is at my old unit 120miles away. The ******* strikes again.

    [​IMG]

    [​IMG]

    So I get everything back together anyway, and figure I can sort it Friday, this is 7hrs of work:

    [​IMG]

    [​IMG]

    [​IMG]

    I finished about 10.30pm Thursday night, engine still not fired/checked.

    5am Friday morning, drive to Chelford, collect Helicoil kit, tell myself I'm mad, and drive home. Helicoil both studs, torque/angle them and they're good, sweet! Fill with fluids, and then fire it up. Running on 3 cylinders, ****, it's half 12 now, should be leaving in an hour for BVF.

    Whip the plugs out, carbon deposit stopping cyl 1 firing, sound. Back to the full 4 now. Time it up and chuck the tent in the back, have a shower and wonder what I've not torqued up...

    Andy gets home from work, we load the car up and leave about half 2 to meet Pete and Sam and convoy onto BVF. Car starts smoking.... hmmm, I did wonder where all the oil from my bottom end went, most of it seems to have been soaked into my manifold/downpipe wrap, que smoking for the next 50miles whilst other road users look generally worried.

    Arrive at BVF, beaming. It's my birthday weekend, and my car and mates are there, sweet!

    [​IMG]

    I was utterly shattered all weekend, but well worth it. Currently got a boost leak, but no other problems!

    Or so I thought....
     
    Nige likes this.
  13. Yoof Forum Member

    Joined:
    Feb 20, 2005
    Likes Received:
    217
    Location:
    United Kingdom
    Buggered the turbo too with some debris, so needed to replace that with a new unit. Anyhow, made Club GTi curby day:

    Some pics from the day from GEAR Photography:

    [​IMG]

    [​IMG]

    [​IMG]

    [​IMG]

    [​IMG]

    A vid and some pics from the other week. Think this was my quickest run, but still missed 3rd twice.

    http://www.youtube.com/watch?feature=playe...p;v=oGjdpb-JsOU

    Tow Car & Track Car:

    [​IMG]

    [​IMG]

    [​IMG]

    [​IMG]

    Inside Vid:
    [video=youtube;hgmGmDNWnGs]http://www.youtube.com/watch?v=hgmGmDNWnGs&feature=youtu.be[/video]

    The Polo then got a little too excited about being used again on track, and ****ed itself:

    [​IMG]

    3rd gear (for a change) making a bid for freedom:

    [​IMG]

    The box was cack from the start, so will get that rebuilt.

    So that's about where I'm up to currently, in several ill-organised pictures! Will be doing some spannering over winter, and back out for some track action next year :thumbup:

    Cheers

    Pete
     
  14. Yoof Forum Member

    Joined:
    Feb 20, 2005
    Likes Received:
    217
    Location:
    United Kingdom
    Time to blow the dust/snow off the old girl and spruce her up- I've got a house move looming, and would like the car running before then (April).

    Current state it requires a new actuator bracket/actuator rod, clutch re-sintering, and a new gearbox.

    I'd thought for quite a while the Gripper LSD + big turbo was making things quite hard to drive, plate diff is obviously best for grip, but I think it's partly to blame for so many broken gears, so bring in the Quiff- which I'm hoping will enduce a little more wheelspin, and ease the load on the gearbox (turning the boost down isn't really an option...)

    So, the quiff:

    [​IMG]

    Have another 085 ATV for it to do in, fresh diff bearings on their way from VW, and will build it up ready for once I have space to take the engine out (after I've put the engine back in my blue G40... ::))
     
  15. ShaunyC

    ShaunyC Forum Member

    Joined:
    Jun 10, 2011
    Likes Received:
    15
    Location:
    N.E Lincolnshire
    Tidy/quick motor :thumbup: sounds like you had your work cut out to get her to your birthday weekend.. glad it all panned out, the b******! lol Look forward to your next updates :)
     
  16. ReDBull Forum Member

    Joined:
    Sep 25, 2006
    Likes Received:
    0
    Nice car it looks like good fun.
     
  17. 1990

    1990 Paid Member Paid Member

    Joined:
    Oct 22, 2003
    Likes Received:
    1,457
    Location:
    Rochdale, Lancs
    What a good read!!!! I know one of the guys on your 'ratchet strap' photo lol
     
  18. jmsheahan CGTI Graphics Designer

    Joined:
    Aug 6, 2009
    Likes Received:
    105
    Location:
    Wiltshire
    As above, great read. Car really does look the business and certainly shifts too!
     
  19. EZ does it Forum Member

    Joined:
    Oct 25, 2007
    Likes Received:
    29
    Location:
    Coventry
    Love the development on this car, nice work!

    I admire your perseverance too :(
     
  20. benny Forum Member

    Joined:
    Nov 3, 2003
    Likes Received:
    22
    Blimey, you've had some 'luck' with it, eh!?

    Still a cool car though! Hope the diff plan works for you! I found Quaifes to be quiet slippy like you say - so it might be right for the job!
     

Share This Page

  1. This site uses cookies to help personalise content, tailor your experience and to keep you logged in if you register.
    By continuing to use this site, you are consenting to our use of cookies.
    Dismiss Notice