The polo came off the road in August, its now bloody March and all I have seem to have done is take parts off and sell bits! I have been collecting parts, saving money etc and have just got to the rebuild stage. Our workshop is full up at the minute as we are finishing a full nut and bolt rebuild on a 1.9 G60 Rado and just starting a full build up of a genuine Gti Engineering Mk1 1.9 16v with cage, buckets etc etc...

Anyway, I have finally got to the rebuild stage, then i was made redundant! I thought this would be a winner in terms of money and time to get on with the car.. then i broke my hand! In to hospital for an operation to sort it out tomorrow. But i have managed to get a few things done tonight.

Mounted the charge cooler and etch primed until i paint the bay...

Sorted the bay wiring loom and re-wrapped it and used cable conduit and hid it as best i could...You cant even see its there really!

Sorted and re-wrapped then heat shrinked the wiring to the battery from the fuse box... I hate untidy and broken wiring! Its taken hours of wiring diagrams, multimeters etc but i have checked te continuity of ever wire and soldered in new bits for broken bits etc..

I'm not aiming for a show finish, i want it to be practical and how i want it to be, F*** what anyone else thinks!

Then i hacked up the crash bar to be able to mount the radiator for the charge cooler, the oil cooler for the engine and the one for the charger. Gave it a lick of paint.

Decided the slam panel was untidy so gave that a lick of paint too.. was just as much about protecting where it has had new holes drilled. Will be back red once i do the rest of the bay.

New brake lines have gone in..

Decided to try out a can of Enamel Chrome Silver I found at the workshop on the charge cooler... Not that happy to be fair, i'll see what its like once its dry tomorrow.

Still got to mount:

Oil catch tank

Header tank and pump for charge cooler

Header tank and pump for oil system on supercharger

Then i think it will be ready for a lick of paint, and by that point my rods should be here from Germany and i can start rebuilding the bottom end!

Friday is when the supercharger mount comes back from being fabricated so i'll mock everything up and take a photo so you can see how the finished article will look.

Got a lot of bits going off to the powder coater if i can make my mind up for a colour scheme under the bonnet!

Edited 2 March, 201115 yr by .Joe

Epic high five for you mate. Lysholm noise makes eatons look quiet. Make sure that the charger mount means that there is no flex in the charger. iirc flex in the lysholm charger can cause them to shit themselves as the rotors are very tight in there.

This should be excellent and i love seeing something differently.

Is that the lysholm that was on sale on here some time back now?

What engine management are you going to be going for? What kind of power are you aiming for? What gearbox do you plan on using G40/GT/8P box?

Make sure you stay heavy on the updates

Edited 2 March, 201115 yr by demolover

The charger mount has been made out of 8mm plate and is braced back to the head, uses a mount of a KR 16v to mate it up with the standard engine mount and spreader plate, should be plenty strong enough.

To begin with its just going on G40 mangement as its fully mappable, but then when it comes off the road again... ( I know, i just want the engine done for show season, then its body work) it'll go on DTA.

Power, i've not worked out. Um, i'd like to see a solid 200, then with the nitrous on top, or didnt i mention that?! The charger i found out is the SO4, so its good for 22100ltrs of air per minute, or 1.7ltrs per revolution. So I'm not sure what that works out as psi on the afh etc etc but hopefully enough for some good power. I'd like to make G40 turbo figures anyway.

Once i've had enough of the lysholm noise, i'll turbo it with ITBs. Although the ITBs may come with the lysholm this time round.

Gearbox side of things is lightened fly, helix paddle clutch and GT box until it shits itself!

I should add that I got a lot more done tonight.

Charger oil system went in, catch tank, wiring loom for the engine, radiator, charge cooler radiator and pipe work.

Then it had to come out the workshop to make way for the Corrado for its final checks for the MOT on friday.

More to come at the weekend i hope.

Been waiting for this update for a very long time! Think your plans are spot on with the exception of the GT box. doubt it will last long.

Sounds plenty storng enough to me and it sounds like everything is being done properly so i am super excited to see/hear some videos of this thing :-)

GT box should be fine for a while if it is a good one. People have ran them on G40's before, won't have an epic top speed but acceleration will be a hoot. Plus if a GT box shits its pants it's no big thing. A G40 box would be a best shout, especially with some LSD action but thats all cost and to be honest i am sure you just want to get this beast out on the road.

Sounds plenty storng enough to me and it sounds like everything is being done properly so i am super excited to see/hear some videos of this thing :-)

GT box should be fine for a while if it is a good one. People have ran them on G40's before, won't have an epic top speed but acceleration will be a hoot. Plus if a GT box shits its pants it's no big thing. A G40 box would be a best shout, especially with some LSD action but thats all cost and to be honest i am sure you just want to get this beast out on the road.

LSD is a definite. So is a G40 box. I'm not too fussed if the GT shits itself, I'll chuck any old box on to keep it going!

Back down there today so i'll get some more photos.

Plan for today is, rear beam off and painted, tank and straps painted, rust proofing, continue test fitting bits, rear disc conversion on, possibly start on the body work. All depends on if my hand stops giving me shit as it kind of slows progress!

Oh and take the Corrado for a blast as it passed the Mot yesterday first time. Been off the road for 18 months for a full nut and bolt build up. 1.9 stage 4 G60

Edited 5 March, 201115 yr by .Joe

I'm starting to think about exterior...Definitely going a darker red, but what are people opinions on wheel colour.

Yes they are all badly photoshopped.

Oh, and thanks to ebay, I have just won myself a direct port Nitrous kit too!

Edited 9 March, 201115 yr by .Joe

Nitrous too

Fuck a duck this is gunna be savage

Gearboxes are now really starting to worry me. I should be pretty quick at changing them mind! Next thing on the list before I buy anything else power related is a DIFF and rebuild.

If customs release my boxes of shiney stuff, hopefully i'll start putting photos up of the bottom end rebuild this weekend!

I plan to get it in, fired up and a video taken by the end of March!

Keep the wheels all one colour. Think it looks best on those type of wheels :) so first of your two chops for me.

Keep up the good shiz.

What kind of figures does the rebuilt rado put out? All this talk makes me miss my g40 :(

Keep the wheels all one colour. Think it looks best on those type of wheels :) so first of your two chops for me.

Keep up the good shiz.

What kind of figures does the rebuilt rado put out? All this talk makes me miss my g40 :(

Not too sure yet, only just finished running it in, but it shifts!!!!

That engine will be up for sale, picking up a 20vt on sunday for it!

Crank and rods went in the AFH last night, i;ll sort some pictures out tonight once I'm back from work.

Any updates on this? Hope it doesn't grind to a halt like some of the exciting stuff that turns up on here :-D

Any updates on this? Hope it doesn't grind to a halt like some of the exciting stuff that turns up on here :-D

No, it wont grind to a hault but redundancy has slowed things up!

As with all projects you seem to get more than you bargained for. We started stripping the car for paint last weekend to discover so much rust in the arches. I'm going to have to replace both wings and both rear arches. Colour scheme is still being decided but it should be very bright. Not to everyones taste, but it will be different.

Anyway, engine is now built.

All i need to get the engine in and running is:

4 branch (possibly custom)

Paddle Clutch

G40 ecu and remap by PPP.

I'm still trying to work out if its possible to use a dumpvalve as a charger bypass. I have seen it done on a lupo engine, but I'm unsure. It wont provide very progressive power unlike a g40 throttlebody would but i have a few sat here so i might give it a go.

I'll get some pictures up asap.

Any updates on this? Hope it doesn't grind to a halt like some of the exciting stuff that turns up on here :-D

No, it wont grind to a hault but redundancy has slowed things up!

As with all projects you seem to get more than you bargained for. We started stripping the car for paint last weekend to discover so much rust in the arches. I'm going to have to replace both wings and both rear arches. Colour scheme is still being decided but it should be very bright. Not to everyones taste, but it will be different.

Anyway, engine is now built.

All i need to get the engine in and running is:

4 branch (possibly custom)

Paddle Clutch

G40 ecu and remap by PPP.

I'm still trying to work out if its possible to use a dumpvalve as a charger bypass. I have seen it done on a lupo engine, but I'm unsure. It wont provide very progressive power unlike a g40 throttlebody would but i have a few sat here so i might give it a go.

I'll get some pictures up asap.

Ahh man sorry to hear about the redundancy and rust. Those dreaded arch trims.....

Good to hear that the engine is built up.

Yeah it sucks!

The passenger wing is the worst. The metal arch under the trim came away with the trim itself! The rears are due to a bad rolling job, just been bent under and not sealed or painted or anything. Starting to wonder if the shell is worth saving. Mind, by the time if sourced another shell, done what i wanted etc i could have done the body work myself and paid someone to paint it. I'll probably paint it myself anyway.

The main ball ache with the engine was getting the charger mount done. The company i used didnt seem to understand "sqaure" or "line the pulleys up". So its been backwards and forwards trying to get it right. Hopefully its spot on now. Can only turn it over and see what happens. I'm loathed to put it in and try it, then have to strip it out again for paint though.

I have 13 weeks to get it on the road before Gti International. Its the only show i do and all my friends cars will be on the road by then and i cant miss it. Even if i have to cover the entire body work in detailing tape to hide the body work, so long as its running well and making good power i'll be there!

Its a tall order but hopefully it'll be done.

Photos of components as promised. Lost a lot of photos of the build and these are the only ones that i really have... I'll keep adding more as i find them.

Anyway..

16v conrods are weak. I have H-beam forged rods with ARP bolts...they should do the job i think, and look good!

Size difference between standard AFH rods

They are modified to lower the compression ratio by dropping the compression height of the piston. Essentially the same as a decompression plate spacing the head out.

Charger bracket

I'm using the alternator as the tensioner as normal. My only concern is that where I'm using a double ribbed belt, the alternator hasnt got enough belt coverage, but only time will tell.

I'm also deciding if the shell is worth it or not. The rot in the rear arches, new front wings etc are leading me to just buy a cheap mint car and transfer all my parts over. I think it may be the way forward.

Edited 29 March, 201115 yr by .Joe

Looking quality this mate, nice to see a different build :)

looks like some serious cash in this and hopefully some serious bhps

Some good r&d going on here.

Where did you manage to find those rods?

Excellent stuff. Buy a new shell if it is as bad as it sounds. By the time you have gone sourcing replacement panels, cut away all the rust (no doubt you'll find more rust), fitted new panels, welded stuff up and painted things etc etc you may as well have just bought another shell. Unless you are particularly attached to the shell for some reason.

Those rods look beefy

This thread is bi-winning.

So you've lowered the compression ratio by increasing the piston deck height , correct?

This thread is bi-winning.

So you've lowered the compression ratio by increasing the piston deck height , correct?

Correct. A very reputable engine builder recommended it as an option so we went for it. I have a spare set of those rods without the deck height change, which I'm keeping for a build later on using low comp pistons and a large turbo to see what power is really available. The lyholm i already had for a g40 hence why I'm not going straight to turbo. Also they sound great!

This is just going to be a trial build essentially. Iron out any issues etc before i start putting some real money and time into it and go for the big power.

As for the shell, I'm hopefully going to look at a replacement this weekend. It will speed things up no doubt. If i get it the list of things to get this on the road will shorten and literally just become a weekend conversion with the added suspension and brakes etc.

My amazing paint sketch of the belt diagram for the charger...

Edited 30 March, 201115 yr by .Joe

i love the south park lysholm valver paint sketch. It does actually help to picture it. What is the issue with the double ribbed belt at the alternator?

Looks like this should be awesome. What shell are you looking at, another coupe?

i love the south park lysholm valver paint sketch. It does actually help to picture it. What is the issue with the double ribbed belt at the alternator?

Looks like this should be awesome. What shell are you looking at, another coupe?

We were just wondering if the alternator would have enough drive. The belt is plenty tight enough so it should do.

Just another mk3 coupe, still tornado red. I think a reshell is in order really. This is Kerrlys old one and if you remember it was crash repaired. The inner wing has a big weld line through it and as i spotted yesterday the rear turret has a crease in it. The front brace/radiator bar takes 4 people to get it on as the front is so skewed. I've found a shell for 300 taxed tested and rust free. Just got to find the time to go get it.