In regard to your ITB manifold, how do you plan to shape tubes from the clover shaped holes to a normal cylinder for the itb boots?

Wait and see Dan I'm not shaping any tubes I'm making it complete from that billet

And Si I more than likely couldn't do your block as you won't have the castings to machine in it

Mine does because it is an AVY block basically

That seems impossible to make it entirely from that billet as the bodies wont line up exactly surely? and now you have drilled the clover shaped holes you cant offset that into a smaller hole for the bodies?

Edited 1 March, 201313 yr by higgo

It will flow mate don't worry all the port machining is done just a little port matching and that side of its finished

Just need to machine all the excess material off now

Dan I'm guessing you've got whatsapp add me mate and il send you pictures before I upload them on here this weekend so you can see

Edited 1 March, 201313 yr by StinkyPete

so i have finished the majority of my new ITB manifold just need to machine all the excess material off it to save weight and make it look prettier

The manifold so far

will hopefully get on this and machine the excess material off in the next week or so

also drilled the block for fitting the mk3 shallow sump as this block usually runs an alloy sump and they are slightly wider that the steel ones and so the bolt holes on one side are different

but easily fixed for me

the difference

the new holes drilled

while i was up in Sheffield this weekend i popped over to Leeds to a compant called Mount Panels to collect my new old stock front panel and slam panel

got them seriously cheap so not too much i need now front panel wise as i should be getting some standard wings to modify soon off a good old Guy on here

managed to do some work on the polo as well today when i got back

i now have the passenger main door bar in to protect the passenger and make the shell more rigid on thats side

thats all for now but more to come this week

hope you enjoy

Excellent work Pete! i like to look at the machining you do

Was good to see your work in the flesh Pete! Also it was nice to meet you. Hopefully again sometimes soon! (y) keep going!!

Lucky! You got a slam panel. Was that listed on ebay too?

yeah i dont actually need a slam panel as i made mine bolt in but as i want the front end removable i thought i could use a new one to do it

and yeah he has a few on ebay left not bad either at £40 mate

Juat had a browse, didn't see them the other day. I was up there today, but I don't really need a new one. I butchered the bottom of the bracket where it's spot welded to the lower valance, but I think I'll just ask my brother nicely if he would weld a little bit on for me :-)

Just had a browse, didn't see them the other day. I was up there today, but I don't really need a new one. I butchered the bottom of the bracket where it's spot welded to the lower valance, but I think I'll just ask my brother nicely if he would weld a little bit on for me :-)

I'm probably gooing to chop that bit off anyway

i want it so i can make the front of the car bolt off and removable so i can work on the engine real easy or if i need the engine out for reasons its easy peasy

i was thinking about making the front end panels into one piece so its like a flip front mini they can be removed in a oner like american hotrod racers

but not sure yet il see when i get to it

Exactly what I'm going to do. Was just going to have around 4 bolts holding the valance on, 2 bolts bolting the slam to valance, then 2 more attaching the slam to the 'wings'

Good progress,

Is the non-matched ports not going to cause issue pete?

Nope it will flow Max I haven't finished fettling with the port matching yet

right well heres an update of progress from this weekend feels like i got quite a bit done too

saturday morning the car inside started like this

and i had all this ready

so work began

tunnel bottom lengthway braces

rear bottom braces around diff front

Tunnel top lengthways braces going in

rear top tunnel braces above diff

tunnel vertical supports rear and mid

Tunnel bracing all fully welded in

Also lowered the chassis onto the new chassis dolley i made so it is now movable and can move it in and out the garage

will be nice in the good weather as i will be able to work on it outside on the driveway

also made a little quick start on sorting the rear old floor pan out

removed all the seam sealer ready to drill out the spotwelds to remove

i have now started on the rest of the front frame starting with the front bottom tunnel bracing that the bottom engine chassis frame will mount off

finally worked out a plan of action and design for it tonight and started bending the two tubes for the front bottom tunnel bracing

its really starting to come together now

enjoy

Wow ..

Your gonna be fucked if you drop somethign in the rear when its complete lol

Looking good though :)

Fancy making me a rear cage

The floor pan isn't on yet lol it will be open plan so to speak

Just need to finish the front, get engine and gbox into right place to sort mounts

Then I can get in on a roll over jig and do all the floor pan and rear arches

Mental! Looks like the Eifel tower in there!

hope thats a nice complement Simon lol

quick update new sills arrived

and heres some pics of my Audi TT quattro 6 speed 02M gearbox

then some of the front fire wall and the front bottom braces of the tunnel in the making

gearbox on the floor in rough place in engine bay

loads of room

supposedly the 6 speed gbox is 25kg's heavier than a 5 speed i honestly dont think there is that much of a difference

plus its shorter so will fit in the bay better just need to sort some driveshafts now :) then can get front wishbone mounts sorted and engine mounts done

can we nickname this project cobweb? haha awesome :)

Ahh so youve gone for the 02M now, good choice Might make mine a 6speed when i get an LSD.

yeah i got the gbox quite cheap its not a direct fit some modification is going to be required but i wont be machining the bell housing this time around to keep all parts standard and easily replaceable

may need to mod the block a little but I've already done alot of modding on that anyways so no biggy

6 speed 4wd it is just need a shifter tower and the rest of the cable end linkage bits for the box as not all of them come with it :/

yeah i got the gbox quite cheap its not a direct fit some modification is going to be required but i wont be machining the bell housing this time around to keep all parts standard and easily replaceable

may need to mod the block a little but I've already done alot of modding on that anyways so no biggy

6 speed 4wd it is just need a shifter tower and the rest of the cable end linkage bits for the box as not all of them come with it :/

Go to a scrappers mate