After alot of thought about what car to buy next i have finally decided to do another conversion

Thought about getting a mk2 Golf gti, 205 gti, pug 106 gti, G40 ect. After realising they are all have the possibilty to be exspensive and unreliable i decided another polo conversion would be best for me.

Soo the drive to this project is, I'm going to be doing 40 miles a day to uni and back next year on one of Huddersfields finest stretch of tarmac so i need something:

Reliable

Goodish on fuel

A bit of a riot to drive

Comfortable for the shit Huddersfield roads

Engine wise i have gone for the 1.6 AEE, I spoke to alot of people about various ways to go about this conversion and they have all been great about it. I was dead set on bike carbs until i had a massive change of heart due to the ecnomy and setup cost. So AEE 1.6 + GT injection is where I'm heading. :-D

First plan of attack was to get the engine, I got the phone to CMS (Central motoring salvage) in Derby the guy was sound and had a AEE in the lockup with 39K on it . As you can imagine i was down there within the hour, £100 later it was in the back of the GT.

Now i havnt had ANYTHING to do for about 3 weeks now, my GT is finished really, i have taken it as far as i want to so have been acheing to get my hands dirty :-)

I set about salvaging some parts from my old CL engine.

First thing i needed was the flywheel.

Clutch anyone? Great condition

Unfortunetly this is as far as i got with this mission as i couldnt get the bolts undone

They are unbelievable tight, I'm borrowing a impact gun tomorrow so we shall see who has the last laugh.

Camera battery died at this point but i removed the old engine mount, put it in a bucket of steaming degreaser and attempted to remove the alternator pulley from the CL engine......the allen bolts have seized like a bastard. Think I'm going to have to drill them out as they were basicly rounded before i started.

Went back to the AEE and removed some stuff i didnt need.

Anyone want some beefy injecters? I carnt believe how small these things are compared to GT ones. Not surprised the engine only makes 75bhp as standard!!!

Also removed the dodgey plastic inlet, inlet and plastic - not right i dont think

Nice thing about this engine is because its young and really clean all the bolts are like brand new, nothing was seized which was a relief.

I removed the alternator pulley as its too wide to fit the mk3 engine bay, need to put my mk3 one on if i can get it off

Then went about removing the origional engine mount which is massive compared to the mk3s

Trial fitted the mk3 engine mount on, shame about the missing 3rd bolt on the block Shouldnt be too hard to get around though, going to either grind the one off my old CL block or make some sort of bracket that goes from the lower holes.

Not much done really but I'm spacing it out till i get more bits otherwise i get withdrawals! lol

You might have noticed a lack of a car for it to go in and you'd be right i havnt got one yet

Soon as i find one things should move swiftly.

Plans for tomorrow are, a few road trips to fetch a stack of parts, removed the fly wheel from the CL engine and swap it to my AEE engine. As well as the alternator pulley.

Thanks for reading.

I will try and keep this updated!

Edited 5 May, 200917 yr by carver

Niiiiice

looks like a good little project ,

what are you doing about inlet manifold ?? are you going to weld the manifold and get it re-drilled or weld the head and get it re drilled and tapped ??

I'm still thinking about the best way. Its annoying how close the inlet almost fits.

I'm thinking about trying to weld some extra metal onto the inlet and redrill them. The ones that dont line up are about 5mm - 10mm out.

hmm

keep up the good work, i like projects/threads where a bit of fabrication is used :)

il be keeping an eye on this!!

i like projects/threads where a bit of fabrication is used :)

Me too, a bit different seeing some of the workings of the cars. :-)

I think Huddersfield roads must be the worst in England, you get out of Kirklees and the the roads seem brilliant.

Where abouts in Huddersfield are you from?

Edited 22 May, 200818 yr by PSWPolo

Cheers for the replies! I will definetly be keeping this updated.

PSWPolo - I go to uni in Hudd, staying in Kirkburton.

Welll today started off as a disaster. Got up earlyish to make a start only to realise my dad has miss placed the garage keys and hadnt left me any metal drill bits

Picked up a very handy toy this morning.. :-)

Needed the impact gun to get the flywheel bolts undone as they were impossibly tight, it did them all in about 30 seconds

Finally the garage keys were found and i attempted to put my flywheel on to the AEE.......wouldnt fit a quick talk with Gaz and i realised why it wouldn't go on, it had an adapter plate which needed to be removed so the polo flywheel has enough room :-) (nice one Gaz top man)

Its all good because its less weight on the engine and car so I'm gladly removing such items

Polo flywheel on :-D Seriously lighter then the AEE one!!! Bit dirty and has some surface rust but its okay.

I then tried to remove the alternator pulley from the scrap lump, my plan was to drill the bolts out, this didnt work due to the drill being shit and the super high tension allen key bolts. I tried grinding them off but they are in such an akward postion the disc was damaging the pulley

Whilst trying to do this the block was standing up on the side where the flywheel was, the vibration of the drilling loosened the old flywheel bolts and oil leaked EVERYWHERE.

To make matters worse i had the engine almost in the garage because it was raining, the oil started to swamp in and was heading for the tools, AEE, and very hard to get places. Had to take my trusty 'Currys' fleece off to soak it up (RIP old faithful fleece )

Spent the next half hour getting oil up from the driveway and garage floor

And once id finished it stopped fucking raining!!! lol this put me in a rather bad mood so i attacked the pulley with an axe

I killed it! Made me feel better though. Ironicly one of the bolts came out when i was killing it

So, overview, the flywheelsis on, the clutch still needs aligning i will leave that till later on, sat and thought about the mainifold issue and i think i have come up with a soultion I'm just doing some designs in CAD. Need to make an extra support for the engine mount too.

I need to mod the cam cover for the polo engine mount as well as do some plastic welding to cover up the gaping hole where the old mount used to go!

thanks for reading, things will get more interesting soon i promise. lol

haha you definatly killed that hahaha, and i like these productive threads, great inspiration threads are few and far between! good luck!

Looking great, nice one, and good find on the low-mileage AEE!

doublepostage

Edited 24 May, 200818 yr by TomW

whats the difference between fly wheels ??

why you change them ?? are they different sizes ??

The one that was on it was seriously huge, i think its to accomodate the skoda gearbox not sure if they golf AEE has this type.

It was so wide its about the same width as the polo flywheel and the bell housing! and the polo gearbox wont fit it.

This is the AEE fly

Thats the polo one!

Id say it was half the weight roughly

Good Old CMS hey :-D

Thats where all the VW engines from Loom's go

This looks to be a very interesting project you have on the go.

Fit bike carbs and you do realise you could end up with supercar chasing performance like MikeyMK did with his?!

Try not to get frustrated with it and start smashing the shit out of bits though. It'll only end up in more tears. Work at it carefully and take a bit of time and this could be a very nice engine in the end.

Personally, I'd get a manifold made and fit bike carbs. With some head work, a different cam and a 4 branch this could be very nice indeed.

Good luck.

Richard.

Thats where all the VW engines from Loom's go

Aye although aparently there is no such thing as a Mk1 & 2 polo

breadman - The one i smashed up was the old engine lol The AEE is living a life of luxuray - Its getting paint soon!

I was going to go with the bike carb setup but and thats what i would do if i could afford the fuel cost but i always find my self doing alot of miles. Afterall when i sat and thought what i wanted from the car and i came up with 'abit more power then my GT and fair bit more torque' this seems a perfect option :) Seeing as my GT is standard and this should make 100bhp with GT injection and bigger injecters with quite abit of torque.

Should be fun to drive, if i go down the bike carb route it will probly be on a smaller engine. Even MikeyMK has gone down to the 1.4 engine so he can thrash it without emptying the tank.

Steve - Whys that lol? there was a mk2 square down there last week. - no engine though.

Not entirly sure mate . They dont stock carb'd polo motors yet looms cut them out of the cars for them ..

To be honest most times i go in i have a wander around and just pick bits up i want .

Known them for a while so its easier that way .

They have that much stuff they dont even know what they have !

Not much done today as a beer festival got my attention. Have been doing some very quick designs on the inlet problemo.

My first idea was to make some sort of adapter plate that bolts to the head and one on the inlet but because the pattern is so close together that the bolts that would hold the plates in place would have to share half a hole which wouldnt be very strong. (kinda hard to explain)

So i had to rethink the idea and have decided I'm going to try and mod the inlet, I'm looking at cutting off the origional bits that have the holes and fileing it down so its smooth and then making a plate to go over the top of the inlet and weld that in place.

Very very quick drawing, just to get process in my head. lol

This should work...... iv got a spi inlet from my old engine so i will trial it on that rather then fucking up a GT inlet.

Edited 3 January, 200917 yr by carver

thats wicked work kid....guna be a beasty :)

What car has your AEE come out of? Also i dont think a mk4 starter has enough throw to drive the flywheel. I've bin there.

Not entirely sure what car it came out of spen, I'm guessing a skoda.

Apparently a mk3 polo starter motorworks, though it has to be the right year because they changed the width at some point.

You sir, are a legend. (adds topic to favourites).

My mk3 failed its MOT so rather than scrapping it I decided a carb'd AEE was the way for me, just as a trackday toy..... and you've answered just about all my questions, keep this thread going mate and good luck!!

Will be watching this thread closely!