not updated this thead in eons had a welder come and look at the polo, quoted me 150 for all work including collecting and returnin so I'm made up, will be gettin booked in as soon as possiblle, cannot wait wooho

woop woop engine is coming out on sunday, gearbox is sold and the welder man is collecting it next week

happy days

Woop Woop

beautifil car

cheers mucker,

its all welded up now, back from holiday in the new year and it should have been dropped back off at the unit, so looking forward to getting it back together, still gotta procure a few bits and pieces but wooohooo super excited

well due to some random occurances, the engine is now no longer going to be a standard lupo gti lump, far from it.

Mk4 1.4 16v AFH Head

Lupo 1.6 16v GTI Bottom End

CBR600 Carbs

Schrick Fast Road Cams

It will be running the lupo 5 speed gearbox, unsure if i'm going to run cable or hydraulic clutch.

Anyway I used an afh headgasket, polo aex headbolts, afh relay roller(modified)

Note, 6n 1.0 AER & Non AVY GTI lumps have the correct length headbolts

6n Polo 1 Litre

036103384B

bolt, with multi-spilne socket head

M9X1,25X138 / AER,ALL

Lupo GTI

036103384B

bolt, with multi-spilne socket head

M9X1,25X138 / AHW,AKQ,APE, AUA,BBY,AFK, ANM,AQQ,AUB

Polo GTI

036103384E

bolt, with multi-spilne socket head

M9X1,25X97 / AVY

The correct part from GSF is

01163

CYLINDER HEAD BOLT

PO 1.4 AFK/AHW/APE/AUA/AUB Engines 99> & PO 1.0 AER Engine 96>99

£2.00 each and you need 10.

the relay roller

part number 036109244

the guys made me a bar threaded to 10mm at one end to fit into the block and 8mm to fit through the sleeve of the roller, it was impossible to drill through for guys with thousands of pounds worth of machinery so dont bother trying it at home, I'm glad i didnt bother!

cambelt fitted and everything timed up, engine plate and alternator fitted

I pick up my lupo 5 speed box from my parents house next weekend, and will hopefully have the lupolo back at the unit soon, its all welded up now, just waiting to get it delivered back

disclaimer :- I've not ran the engine yet, so it may all end in disaster but no harm if it does, as if it doesnt, its going to be a little screamer

Looking good,though i expect you'll be better using the less restrictive AFH cast manifold than that skinny thing,as the AFH ports are too big for it.

Nice find with the head bolts,i have to use standard AFH ones which are are more expensive.

It will be running the lupo 5 speed gearbox, unsure if i'm going to run cable or hydraulic clutch.

I'm not sure if this will help, though there seems to be a VW cable conversion for a Hydro box?

I'd seen it mentioned over here

Hope that helps,

Paul

Haven't got access to EKTA, though I think this is the part number for the adaptor VW 02B141708A

Edited 8 February, 201016 yr by wadders

hi matey, your an absolute star, i actually have one of those in the unit, as you do!

ill have a read up of that link tonight, cheers matey saved me over 180 quid!

Looking good,though i expect you'll be better using the less restrictive AFH cast manifold than that skinny thing,as the AFH ports are too big for it.

Nice find with the head bolts,i have to use standard AFH ones which are are more expensive.

hmm yeh i heard that but i never bothered measuring up the exhaust ports on the two to check the difference.

well the poopo gti manifold is going to stay until i manage to get a stainless 4 branch but not really on highest on my priority list

well the lump is getting closer to completion.

mated up with a lupo gti 5 speed gearbox.

all good bar the casings cracked where the mount bolts on, but ill just run it until it breaks.

i do need a new one of these if anyone has one (bell housing plate and gasket) as mine is damaged and leaking.

also picked up a set of CBR 600 FX carbs, and I'm getting a 2nd manifold made up this week and my existing inlet mani modified to be able to use the rather rigid and perfect mounting rubbers that are used on the bikes

updated the original post with a sorta lil backstory and up to date history for easier reading

well some updates on the shell

I poked this bit of filler to reveal this

which when provoked more turned out to be a full rotton corner of the wing but all was done well by Gray.

this was welded up but I couldnt get decent pics of it after in the dark

Welded up heater matrix

seat rails

patched up some holes on the rear panel

mk3 gearbox mount back in

dewipered bootlid

mmm

so need to get the bare metal cleaned up, skim of filler on the external bits and por15 on the seat rails, and get a lick of primer and paint on the fresh welded bits, I can deal with mismatched paint at the moment

then I need to get some 200mm drums and finish rebuilding the rear axle, and rest of brake lines, get all those plumbed up and bled and the engine can go back in along with the bucket seats and harnesses.

inside in going to be bare as fook, just 2 buckets, harnesses and a fire extinguisher.

its gunna be a foookin beast!

well after another sabbatical, work continues on the mk1 this weekend,

some goodies to fit

200mm passat rear drums, back plates, stub axles and wheel cylinders, new vw shoes and bearings.

256mm ebc x-drilled grooved discs, lucas 54 calipers and ferrodo ds3000 pads

and the new lump is nearly done, just need to get a water pump, gearbox and clutch kit and woop.

its now an 1.6 16v sporting Shrick Fast Road cams. laaarvly.

will get pics after this weekends frolics

done today

undersealed rear inner arches after welding

undersealed welded engine bits

sprayed and undersealed the bucket seat mounts

removed old 180mm drums

fitted 200mm back plates and stub axles

fitted bearing races into new 200mm drums

fitted handbrake lever and front part of handbrake cable

fitted wiper mech - need the clips, nuts and grommets to attach the spindle bits tho if anyone can help

ate donuts drank irn bru and got baked <3

tomo

handbrake cable

circlip for brake/clutch pedal x 1

dremel rounded rear brake line

fit pedal box and pedals

steering column UJ

fit engine wiring loom

studs for seats and fit

keys

coupe s wheel

get brake lines made up

buy - 2 rear flexis, 1 wheel cylinder,

cirlip for throttle cable x 2

fit rear drums, hb cable, brake lines

fit front calipers/discs/flexis

gear lever

Edited 30 May, 201016 yr by grungeisdead

got 28 days till the unit gets turned into a helicopter pad =/ so thats my deadline to get it running and out of there, if anyone wants to come grab some free/cheap parts to save them from mr scrapman, pop over

wouldnt mind a helping hand too =D

anyway engine loom found in the unit, main earths connected and fusebox screw in place, battery fitted.

badly need the nuts and grommets for the wiper mechanism, anyone got any kicking about

6,7,8 wiper locknut and washers and any plastic or rubber gromets

pics of seat mounted, pedal box and steering column fitted.

although i broke the clevis pin, so if anyone has one?

6a and 6b clevis pin

12 cirlcip

engines internals cleaned, sprayed down, drained and wd40'd up, sump bolted on to stop dirt getting in, but not cleaned up the mating surfaces or gasket pasted them up yet.

just need a waterpump and i can get the tensioners fitted, head on and cambelt fitted. then i need to get hold of a 5 speed box, or just bolt ad's 4 speed in as a quick fix

Looking good, been waiting a while to see this thing on the road, the helicopter pad thing is motivational !

indeed! nothing gets you going more than the thought of dodging helicopter blades midst car bodgineering.

also part number based fail, will grab it tomo if some of my parts come in the post and i pop up to the unit, i probably will do as i want to get this interior loom all wired up, tested and then stick the dash in

finally found all my hub mounting bolts so the front brakes are on - lucas 54 calipers, ferodo ds3000 pads and ebc discs

200mm rear drums and v dutty powdercoated rear axle, still awaiting my rear handbrake cable, when thats here i can get the bearings fitted. gotta order me wheel cylinder and brake lines tomo, but still desperatly need a clevis pin pedal pushrod thing for the master cylinder and the MC spacer. should also get hold of an uprated suspension kit for the rear as these shocks are truely pwned but should be mot'able for time being

grille and lights fitted, bonnet just rested in place, got another black one but need to get the vent holes are the rear welded up

trial fitted top fill rad, unfortunatly its gonna require some slam panel butchery, i think rather than just messily cut it out, i've got various hole saws, so ill make a circular cut out big enough to pull the cap out from and notch the inner part of the panel so i can get some grippy action around das cap. id rather retain as much of the original slam in place for fear or it collapsing!

note the grille cut out in this pic, I'm going drill the panel behind it, and fit an air scoop as fitted on GT's iirc and feed that over the carbs, eventually getting round to sorting out a plenum chamber for them

random pics

then spent the rest of the time sorting out bits in the unit, getting rid of pap ill never need, and boxing up the rest ready for an ebay flex.

heres what i uncovered from the house alone, its all gonna go on ebay at 99p starts when i get round to putting them up (next week or two)but if anyone wants owt gimme a shout

Mk1 Golf

GTI Magnecor KV65 Competition Leads Red with 2 Cable tidys

GTI TSR Drilled Airbox

GTI K&N Panel Filter

GTI Warm Up Regulator 438 130 073

GTI Cam Pulley - 056 109 111A

GTI Lower Crank Alternator Pulley

GTI Water Pump + Near new thermostat+housing

GTI Near new Bosch Starter Motor 055 911 023B

GTI Drivers Engine Mount - Rubber needs replacing

GTI Rear Gearbox Mount + Rubber

GTI New Downpipe Gasket

GTI Complete Series 1 1600 Metering Head/Injectors/All Braided Lines/Fuel Filter

GTI Semi Polished Alternator

GTI Oil Cooler / Hoses / Mounting Brackets

GTI Series 1 Contact Breaker Dizzy - Near New Condensor & Contact Breaker 049 905 205E

GTI Series 1 Parcel Shelf

GTI Complete Series 1 1600 Head / Cam / Water Housing / Inlet Manifold / Throttle Body

GTI Short Driveshaft - Good condition, relatively new inner CV

Bosch Starter motor 055 911 023L

Gearbox Selector Shaft

New Tensioner Stud

New Linkage Rod Bush

Tintop 3Door Green Tint Glass Front Passenger/ Rear Drivers / Rear Windscreen

Tintop 3Door Clear Glass Rear Passenger

Polo

Mk1-3 Lower Strut Brace - Adjustable but ONLY for cars up to -40mm.

Mk2 Polo Coupe S Contact Breaker Dizzy - Near New Condensor & Contact Breaker 023 191 009 / 052 905 205

Mk2 Polo Coupe S Airbox/Filter/Elbow

Mk2 Polo Coupe S Exhaust Flexi Section

Mk2 Polo Coupe S Metal Cambelt Cover

Mk2 Polo Powdercoated Water Housing & Thermostat Housing 052 121 117 / 052 121 171C

Mk3 lower steering cowling cover 171 953 516B

Mk4 Polo 1.4 16v Power Steering Pump Pulley

Mk4 Polo 1.4 16v Power Steering Pump Pulley + Pulley

Mk4 Polo 1.4 16v Crankshaft Cambelt Sprocket

Mk4 Polo 1.4 16v - Plastic Dizzy Cover & Lead Tidy 036 103 565A

Mk4 Polo 1.4 16v Power Steering Pump Pulley

Mk5 Polo GTI 1.6 16v Inlet Manifold

Mk5 Polo GTI 1.6 16v Cylinder Head

Mk5 Polo GTI 1.6 16v Red Rocker Cover / Cams / Pulleys

Mk5 Polo GTI 1.6 16v Standard 4 Branch Manifold

Mk5 Polo GTI 1.6 16v Decat Downpipe

Mk5 Polo GTI 1.6 16v Flywheel

Mk5 Polo GTI 1.6 16v Engine Wiring Harness

Mk5 Polo GTI 1.6 16v HT Leads Red x 4

Lupo

Lupo GTI 1.6 16v Standard 4 Branch Manifold

Lupo GTI 1.6 16v Decat Downpipe

Lupo GTI 1.6 16v Hydraulic Clutch Release Cylinder 600 721 261A

Lupo GTI 1.6 16v Engine Wiring Harness

Others

VW Cable Change Conversion for Hydraulic Clutch Gearboxes

Coil used in Emerald Setup - 089 04B 00104 - Leads from top left, clockwise are 14,32,27,41

Audi 3 Pod 52mm Guage Facia - 812 863 321C

2.5" NOS Veglia Borletti 8 Bar Oil Pressure Guage

BMW Smaller, Lighter Power Steering Pump Pulley to fit Mk4 Polo 1.4 16v - 1715769

52mm VDO 150 degree Oil Pressure Guage

12" Slimline Fan

Opel Manta GTE Tartan Recaros

320mm Aftermarket Steering Wheel

Slimline Ali Rad 12"H 1.75"D 20.5"L 23.5" between mounting lugs

Yo dude - what was that rad made to fit? How much you want for it and the fan?

its got water outlets at the cambelt side with a little take off for a header tank, i was going to flip it round so i could use it on the small block but not sure if i can just block it off.

40 for rad, 30 for fan with mounting kit

best for mk1 golf big blocks as the water outlets are the correct size

irn bru!

brilliant build so far mate!

sorry for the tread jack but how much for the VDO gauge? is it a pressure or temp as you say '150 degree pressure' doe it come with sender?

Epic, epic build! Keep at it mate!