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  #41  
Old 29-07-2007, 00:25
Sjon Sjon is offline
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.
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  #42  
Old 29-07-2007, 11:24
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Let's double the power, and the mileage
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  #43  
Old 08-08-2007, 12:08
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Teaser:





Notice anything new?
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  #44  
Old 07-10-2007, 22:46
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It's been awhile again, and not to many things done, no major updates to mention..

If you look closely to the picture above, you might have spotted the front spoiler. Yes. I did get a hold off a genuine Polo 2 G40 front spoiler!










I had to get used to it's new look, cuz there's lot of black at the nose, but after I while I got used to it.. Yeah, I know:

Have been to the nurburgring again for a nice weekend of fast-cars and bbq.. and I couldn't resist to torture the current engine some more. Luckily for the 1.3 the track was still damp and I didn't have that much grip.. Still had some fun, but not as much as an unexperienced can have on a dry track




We've been there at the weekend following the Scuderia Drivers training, so at Brunnchen the viewers-parking changed from a muddy-surface into a Porsche Dealership within 50 minutes..




Really nice weekend, and astonishing that after only a day or two you completely forget that a porsche 911 GT3RS isn't a common car in 'normal life'. At the Nurburgring there only sold by the dozen..

talking about dozen: fuel my fire




Anyway: back on project:

Had some trouble getting the belts in position, and timing set.




After some trial fittings I had to mod and order:
The diesel alternator is mounted on a M12 bolt, a G40 only on a M10, with a spacer. Modded the alternator to M10 (hammered in an alu-tube The V-belt tensioner of a diesel/petrol differs from the G40 setup: the charger actually works as tensioner. So on the pic above you still see the tension-bracket, but I had to order a G40-spec mount, since the alternator didn't line up straight: different off-set? Nope. In the end I modded the alternator again: offset is of the complete alternator is different, so I had to slice off some aluminum with a grinder.

The timing of a Diesel is quite important (I guess), but normally there's only this lumpy mark on the flywheel... How this can be used to time anything without special tools is a complete mistery to me.
Since the double-v-pulley has a timing mark on it, I decided I'd time it on the petrol way. Ordered a timing wedge, but that didn't line up at all. The mechanical-rocker-follower-head has different markings, some knowledge I didn't have before.
The lower belt cover decided it didn't fit anyway: the markings on it interfere with the double-v-belts:




So, yet another piece of specific G40 parts ordered: lower G40 timingbelt cover. It has the timing-marks build in an a slightly different spot; Fits perfectly, and lines up quite well!

In the meantime the fueltank fillerneck decided to start leaking. While my budget is going rock-bottom, ordered a new fuel tank, which is yet to be mounted. Running my 'home-made-race-tank' for the time being. Will be putting some special paint on the fillerneck, all in style of the öko-polo / 3L

More recently visited the "Volksforum Paintless Dent Repair Day" and got some parking dent removed: Have been to the supermarket a bit to often lately I guess? The doors, right front fender and left rear panel are now back in shape! Thanks to the wizards of 'X-pair' in Naaldwijk (NL).




Thanks so far to:
Marcel Statz (for every weld, grind, the workspace and coffee)
Mark Pruim (my canadian-connection for the special pictures)
Dirk and the X-pair team (for the paintless dent repairs)
Michiel Ros (for the nurburgring pics)
Leontine ( for her patience )
and my volkswagen dealership for there time and 'no-questions-asked' when I'm ordering another mixture of parts

keep u posted, but don't expect the engine running before the end of this year...
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  #45  
Old 08-10-2007, 16:38
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it looks good buddy, i was really impressed!
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  #46  
Old 09-10-2007, 17:45
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after what I understand, you are building a 640 diesel Although it has been done befre, this is innovation my friend

good luck and looking forward to see some hp measurements..
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  #47  
Old 09-10-2007, 19:10
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640? No,. G40

If it has been before, please let me know: I could use loads of info.. (but I haven't found anything (not even clue's) on this being build before).

hp measurements? Nah.. TORQUE output!
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  #48  
Old 10-10-2007, 02:04
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I know it has been done before.. Had an image on my old computer of a diesel g40 engine... rare, but doable hp or torque: same shit, different wrapping
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  #49  
Old 10-10-2007, 10:24
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This one Gallagher?




This has been an official EA (entwicklungsAuftrag) from VW in the eighties.

If not,. get your old computer running again, and show us pics please


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  #50  
Old 10-10-2007, 23:25
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There is not any hope for my old computer I am sorry to say.. I was'nt about the two cylindered vw supercharged diesel.. I am sorry.. If I had the pictures, I wuold have shown them to you..
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  #51  
Old 27-10-2007, 16:42
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Quote:
Originally Posted by sjampoo
Update

With the engine mount delivered, and the complete G40 spec exhaust laying around I hope the swap to the 1.4 liter engine within a few months


uhuh ,few months ,iff this is what you mean with the 86c register ,i won't hold my breath ,becaus i will die

but how are things going ?
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Last edited by sjampoo : 23-12-2007 at 23:33.
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  #52  
Old 23-12-2007, 23:43
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Things are going 'great'..

months fly-away: Didn't really get anywhere since my last update, I only sourced more and more parts.. and got the IC hosing done.




Don't get alarmed by the big green valve-cover: It's just the color I will use to 'stipulate' the lines in the G40 valve-cover: it's eco-thingy-character. And I've done the fuel-tank in the same color..

Fuel-tank? Yes, it was rotten-away, so needed to change it. It was leaking veggy-oil, diesel and worse: it was desolving tectyl of the tank, onto the pavement: very ugly black stains, where ever I went. Fuel-economics aren't that good either..

New tank, in 'eco-friendly, hell, where are my shades?, yellow-green'



Since I'm getting married in January, I didn't find the time to do that much though: I'm trying to get my Polo 1 to look somewhat.. ehmz..'photoworthy' Pics of that car (and day) i'll be posting after our honeymoon

Anyway: Oil-feed and return hoses for the charger have arrived, the center console which will house the various dials and switches to, breather-hosing of the sump is allmost complete: I only need time to get the engine to run for a test-cycle...

And the MOT/TUV/APK will be in March 2008 again: I don't know if the current (still the good old stinking 1300) will make it through ones more.. otherwise I'll have to hurry,. which isn't in my nature..


keep u posted.
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  #53  
Old 23-12-2007, 23:54
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You're getting married too??

Good to see some work done on the crazy veggie Pollo. Intercooler tubing looks good. Not sure about the green paint though
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  #54  
Old 24-12-2007, 11:57
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green paint

the rest
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  #55  
Old 24-12-2007, 19:20
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Quote:
Originally Posted by Stijn
You're getting married too??



Race you to the altar!
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  #56  
Old 24-12-2007, 19:23
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LOL, you got me beat already
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  #57  
Old 24-12-2007, 19:49
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did winn 9-9-99
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  #58  
Old 24-12-2007, 20:05
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09-09-1999? damn, Wendy is making sure you won't forget the date
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  #59  
Old 20-04-2008, 15:26
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* finally the 1.3 diesel died on me on *



This give the GDi40 project a bit of a boost, and might be running within a few weeks from now.

Inlet manifold further tweaked, only 16hrs after engine failure..




oil lines to and from G-40 charger are fixed, engine pre-heater installed, and the missing-parts-o-meter is going down steady..

Wot? no room?


But only just;


(oil filter is mildly in the way)

Did do a 'drive-train' upgrade in between, with G40 trackcontrol arms, which do have unibals instead of big rubber bushes. They can be demolished, so a little warning sign for the MOT guy is in place:



Sorry for not being around that much, but I did get married, and got all running (that's 4!) polo's through the MOT in the last 3 months,... all with minor to major work.
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  #60  
Old 21-04-2008, 10:57
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what does the label say? I can only read the first 2 words and NOT
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