Small update.

Painted some engine mounts

Couldnt decide what color to do them, was swaying with silver as the AEE mounts looked quite good but then thought it might look crap because these mounts are abit old and havnt got the tools to get them blasted smooth.

So i went with matt black and they look okay i think. The paint i used was 'Rust Not' from Halfrauds, never used it before but i quite like it, its thicker then normal spray and should keep the mounts healthy for longer.

They arnt perfect but they'l do for me :-)

Also been working on the inlet idea which I'm not going to put up yet :p its still in progress but i really hope it works because i dont think its been done on here before.

Someone on here said the bolt patterns look the same on the AEE and the GT, they are so close

All should be revealed on Wednesday on the inlet issue and I should have the third engine bolt issue sorted as well.

Once those jobs are out the way i should be well on my way to getting it finished.

I still need to:

Mod the cam cover to fit the polo engine mount, and plastic weld a section in to remove the hole for the old engine mount.

Strip and paint the block + sump

Polish/paint rocker cover

Service everything

Align clutch

Probably lots more bits and bobs.

I've did the same as you're thinking with the inlet when i did my conversion.

Grinded the original bolt holes off the GT inlet, and welded 2 plates to the inlet, one to go on the top and another on the bottom, with the AEE head bolt pattern.

You will obviously have to match the inlet ports to the head ports, easy job but just time consuming.

Good Luck with the conversion!

Rob

Cheers, not sure if I'm going to go with the origional idea. Going to try and use gaskets instead. Will see what happens after today. Did you run the engine on GT injection? what did you think to it?

Yeah, used a golf gti afm though. When I did the conversion I had to use a G40 inlet manifold as I didn't have a GT one, the car was alot quicker than a GT.

I have now stripped the engine and used a GT inlet manifold and matched the ports better, I will hopefully get it running tomorrow so will let you know how it is.

I have a G40 inlet too but I'm going to get a GT one to put on this, have you got any pics of your inlet fabrication?

Should be having a good crack at it tomorrow, trying to do it using adapter plates but the bolt pattern is so close the bolts might collide. :(

Let me know how you get on mate.

Not updated this much due to not being able to take pics because of the shite weather.

Last few days i have:

Stripped and cleaned the block.

Designed and Started to make the inlet plates

Aligned the clutch

Fitted engine mount

Painted a few bits

Designed extra engine support.

Pics coming sooooooon :-)

UPDATE!!! :-)

Got a car now!

(Black one by the way - red GT is for sale very soon (excuse the steelie still waiting for a new tyre) )

Its an orgional 91 GT, dark interior - very moody, i like. found it hiding local so i snapped it up last night.

Crap pics i know but limited room and i was well tired.

Very happy with the car, my dad drove it back and he was loving it said it drove really well. He finally admits the Polo GT is a nippy little car

First thing in need of doing was the brakes they are shocking, pedal goes straigh to the floor and they need pumping to get them to work.

I whipped the drivers discs and pads off and they are shot.

Quick blast to GSF, was going to get vented discs and pads but remembered they dont fit GT calipers so until i can afford some VWII's i will stick with these. (single Brembo discs and pads)

Some copper grease for the project too.

Looking good, will be watching this project closely!!

Get yourself down to this Derby meet on the 2nd July man !

I wanna see this car

Bring everyone form round your area too we want to make it a big one !

Update:

Been a shitter of a day, BRAKES more to the point POLO brakes - 5 hours of seized bleed nipples, seized flexi pipe, covered in brake fluid and some serious leg crampidge. Managed to get it all done though, its now got G40 calipers, brembo vented discs and pads. Still hasnt fixed the brake pedal going straight to the floor though altho it doesnt lurch to one side now. I think i need to inspect the back brakes, anyone know if I'm right in thinking if theres barely no pads at the back the pedal is going to uber low - back right also sqeeks on braking so I'm sure thats where the beef is.

Oh yeah i managed to snap the handbrake cable too back to GSF tomorrow then....

Anyone know if GSF sell braided hoses for the calipers?

Yeah i think i will come down steve, not sure if it will be in this black beast though - soo much work to do. I'l bring my red GT instead if not.

Update:

Been a shitter of a day, BRAKES more to the point POLO brakes - 5 hours of seized bleed nipples, seized flexi pipe, covered in brake fluid and some serious leg crampidge. Managed to get it all done though, its now got G40 calipers, brembo vented discs and pads. Still hasnt fixed the brake pedal going straight to the floor though altho it doesnt lurch to one side now. I think i need to inspect the back brakes, anyone know if I'm right in thinking if theres barely no pads at the back the pedal is going to uber low - back right also sqeeks on braking so I'm sure thats where the beef is.

Oh yeah i managed to snap the handbrake cable too back to GSF tomorrow then....

Anyone know if GSF sell braided hoses for the calipers?

Yeah i think i will come down steve, not sure if it will be in this black beast though - soo much work to do. I'l bring my red GT instead if not.

Pull the rubber seals back on the wheel cylinders mate and you'll probally find that the brake fluid is gushing out, nice and cheap to replace though and new cylinders equal no seized nipples (ow err) :-D

Nice project btw i'll keep an eye on it.

Yeah I'm going to have a look at the drums tomorrow, not done back brakes before so will get the book of lies out soon, looks like the cylinders are pretty cheap so thats good.

oh my DAYS back brakes are annoying. I've been having problems doin mine past couple of days, combined with my last a-levels probably arent going to make for a nice results day!

Just replace the fudging wheel cylinders for £6 each, bleed nipples are also extremely annoying on the back!

ps mint project :) I'm going to do the tried n tested 1.4 on gt injection this summer, so it'll be nice seeing how much more power and torque this puts down!

Dont worry mate, shoes look daunting at first but do one side at a time obviously so if you loose your memory you've always got one to go look at. I've done 3 sets of shoes on v-dubs in the past couple of weeks so i'm pretty used to em now lol.

joe - carnt wait for the engine to go in, should be interesting seeing as its going to feel and drive like a GT until you press on. Will most definetly get this on the rolling road when its done.

drewbar - just been reading up on the back brakes doesnt look tooo bad, hopefully get it all sorted tomorrow!

I've heard that a well tuned 1.6 conversion in a mk3 can bring you upto around the 120bhp mark, and they'll torque steer and spin up to 3rd when the foot is planted!! Will certainly be rapid!!

:biggrin:

86c off here made 104bhp and plenty of torque - GT injection + GT Cam + g40 exhaust + thinner H/gasket

Ema made 111bhp - Again GT injection but with 4 branch, cam, ported throttle body

Joel made 104bhp on bike carbs

I will be well happy with around 100bhp for the time being and then il creep the power up so i get the most out of each mod. I'm not too sure what to do about gearbox either, the sensible thing to do would be fit my CL box as the 1.6 has plenty of torque to pull it quickly but I'm thinking GT box would be pretty insane not sure if it would kill the GT box quickly though..

gsf mk1 golf gti braided hoses work mate

haha yes mate i did a search last night and noticed you pissing on the group buy for them at nearly double the price, lol classic.

Good to know i will get me some of them from GSF.

Small update - i keep forgeting to take pictures!

Still havnt done the brakes due to seeing the missus................

Managed to sneak abit of work in when she was on the way down, the new gt had an intermitent fuel/temp and oil light. Whipped the clocks out and stripped them down and found the temp and fuel unit wasnt pushed in properly. Gave it a good clean and a check over and put them back in and they work fine now!

Need to do a few things on the red one today to get it ready to sell, should get on the back brakes tomorrow if i get the time.

Made a start on the brakes today, totally fucked they were.

Trip to GSF in rush hour...

Stripped the drum down to see what i was up against...

Shoes are wasted, springs were rusted, and sure enough the cylinder was the origional and abit leaky

good job i bought the lot at GSF :)

The brake line bolt was seized solid but a decent spanner and some bravery sorted it.

A few minutes later it was all stripped

New handbrake cable

New cylinder bolted on

Camera battery died at this point so i assembled the shoes and the puzzle of high tension springs.

Just need to put the shoes in and bleed the brakes, then do the other side!

Edited 16 June, 200818 yr by carver

UPDATE:

No pictures because i was struggling as it was.

Back drum brakes could make grown men cry, what a disaster - was pretty difficult to get the shoes and springs assembled but as per usual they are easy when you know how.

I managed to snap the bleed nipple on one of the new cylinders lol (bit heavy handed after fightening them strong springs) had to bite my tongue and buy another one, will put that down to experience.

Worst part was i snapped it when it was fully assembled, drum on brakes bled.

Anyway, the brakes are working now. Pedal is much higher up and the handbrake works now - should be even better when i get the braided hoses and fresh brake fluid next week.

I'm going to start stripping the engine tomorrow, should have the 1.6 in this week all being well.......................

Took the black GT for a spin today, got abit sea sick with the sloppy suspension

Really not used to soft suspension, kinda like it though - give it a few months and il be back on nails :-)

Brakes seem alot better, still need braided hoses and new fluid but that can wait for abit. :-)

Took a few pics of it, threw some water over it - no i mean i hosed it down. Waiting till the engine is in till i give it a good polish.

And of course i couldnt leave the red one out, bless parked on the other side of the street looking sorry for its self. Someone buy her

She looks dope sat there on her arse

Comments welcome, found a few more faults with the new GT.

Handbrake light is on constantly - switch looks abit dodgey.

Temp isnt working still although petrol gauge is, hoping its the sender otherwise i need to take the clocks out again.

Oh and i went to put the masooove airel down and as i pushed it down loads of green gunk squirted out lol . made me laugh.

Drives well though.

Edited 19 June, 200818 yr by carver

Sick project dude i love that new GT. 1.6Gt sounds interesting too wish i had the knowledge to do this shiz

Watching this closely :) Handbrake light (if its dim?) might be brake fluid level?