so a good update is here

first off il get the little jobs out the way then get onto the big news

donor coupe going to the scrappy

IMG_2839 by pjdirtjumper, on Flickr

Gearbox mount stabiliser bush being added to help stop gearbox rock from where I moved the engine back in the bay

IMG_2894 by pjdirtjumper, on Flickr

I have pressed the nylon bush in now and the stainless inner sleeve but forgot to take a pic so next time

added some braces for the inner suspension turrets and I can mount a bolt in cross brace to these

IMG_2896 by pjdirtjumper, on Flickr

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also got cracking and made a nylon engine mount to match the rest

IMG_2905 by pjdirtjumper, on Flickr

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IMG_2908 by pjdirtjumper, on Flickr

IMG_2909 by pjdirtjumper, on Flickr

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Mount Fitted

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how it looks inside atm

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also got my new seat runner to start mocking up the seat mounts so need to get that mounted, once it is and I have the seat fitted I can fit my bias pedal box and work out where I need to mount the steering column

now for the big update

its finally back on 4 wheels still needs stuff sorting and bolts tightening but its practically there

poke much

IMG_2917 by pjdirtjumper, on Flickr

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so now the rear was down on wheels I had to start sorting the front wishbones so I used my hubstands to sit the car level all around to simulate as if it was fully on its on wheels

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once I had measured what lengths the arms needed to be I got cracking and welded them up

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and fitted them

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IMG_2939 by pjdirtjumper, on Flickr

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had to fit my new rear discs to fit the rear wheels so heres a pic 256mm vented rear discs wil definitely help stop the 4wd

IMG_2943 by pjdirtjumper, on Flickr

and heres the car on its wheels finally (the fronts are just to get it rolling around as my other rotas are in my lock up)

IMG_2944 by pjdirtjumper, on Flickr

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IMG_2946 by pjdirtjumper, on Flickr

rear

IMG_2947 by pjdirtjumper, on Flickr

everything needs adjusting and setting up

IMG_2948 by pjdirtjumper, on Flickr

front

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only just managed to fit it back in the garage now with the extra girth :/

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Edited 23 June, 201313 yr by StinkyPete

Pete you are my ClubPolo Build thread Hero!

I bloody love this thing, gets better and better. Really cant wait to see it in person, if you need a spanner monkey for the weekend let me know

Nutcase!

Stinkymofo!

Completely bonkers, continue with the good work, Sir...

Pete the work on this is relentless man keep it up,

That pic on the drive looks almost like you could jump in and take it for a spin!!

Good work mate!!

Edited 23 June, 201313 yr by Mk2 olop

Thanks guys appreciate the comments so happy right now its been a long time coming

just waiting on the arches then it will really start coming together

need to get it on its side to get the rest of the welding underneath done and start getting the floor panels in

Thats gonna look unreal! Even for someone who has no personal connection to this car, it's very pleasing to see it back on its wheels Proper motivating progression

Edited 24 June, 201313 yr by Phataz1

so sick! I really can see the engineering gone into this

Thanks peoples

Arun you could get a little personal connection with it if you fancy as I may need a few little ally bits tig welding if your game, also need a cad drawing doing for an AFH exhaust flange

let me know if you fancy helping me out with those or anyone else that can

let me know if you fancy helping me out with those or anyone else that can

Read through all of this from page 1, only took a couple of evenings!!! Have been hanging on for every update, thought I would show my appreciation of this and all the engineering that has gone into it.

I run Solidworks so if you need anything CADwise (also manage a CNC shop) I would more than be happy to help, as you sir, have done such an amazing job on this.

Keep up the good work.

Paul.

Just keeps getting better any idea when this is going to be on the road? need to see this in person!

I am hoping for it to be on the road before Christmas but I am moving into my own house next month so will have limited excess cash to splurge on it so progress is going to slow down but I will hopefully be doing more work for people and making more custom parts to earn money to put straight into this - so hit me up if you want anything custom making

Paul- olop16v it would be amazing if you could get me a cad drawing of the afh exhaust flange as I need to make a new turbo manifold for new turbo

I can send you a drawing of all the dimensions for you that would be great and if you would be willing to CNC a flange or two I would happily pay material and postage I do have a CNC mini mill at work its just always running on works work so everything I do is manual machined

will send you a PM thanks very much for the offer and glad your enjoying it

Luckily I've been planning ahead and hoarding parts/materials that I need to carry on quite abit of work for a while to come so updates shouldn't be slowing too much as yet but when I get my own place il finally have my own garage and all the space will be mine and not shared with other peoples crap lol

PM when you've got what you need together, glad to help.

This thing is absolutely insane, the quality of the work is excellent - one of the most indepth Polo builds I've seen to date!

Arun you could get a little personal connection with it if you fancy as I may need a few little ally bits tig welding if your game, also need a cad drawing doing for an AFH exhaust flange

Happy to help with whatever I can Pete :-) Flattered if anything

IMG_2945 by pjdirtjumper, on Flickr

Looks so sick here!

Good to see you the weekend Pikey Pete, any more updates, know you were keen to get home to work on this.

this car is a a AMAZING PEACE OF ENGNERING and its not even finshed

but i do love it :-)

great work man!

Thanks peoples

Arun you could get a little personal connection with it if you fancy as I may need a few little ally bits tig welding if your game, also need a cad drawing doing for an AFH exhaust flange

let me know if you fancy helping me out with those or anyone else that can

Pete check out whengparts mate he did my exhaust flange for my AFH.

Probs my flange in the pic.

Edited 15 July, 201313 yr by Mk2 olop

Think were just about due an update pete i keep checking and nothing new is on here, i can't wait any longer ha.

Sorry guys I'm away in gran canaria atm lol kept it on the down low but before I left I got the steering rack all welded in so now have full steering just need to drill the hub steering arms to fit the bump steer kit so I can fit the tie arms under neath rather than on top

Be back on it next week with full picture updates to follow

You kids need Instagram; more regular updates than here :p

well I might aswell get a big update in of practically everything upto now before I move into my own house this weekend and spend all weekend getting the house and my workshop setup and sorted.

first of made the nylon prop bearing mounts

IMG_2969 by pjdirtjumper, on Flickr

IMG_2970 by pjdirtjumper, on Flickr

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Quick pic of the ports on my head I ported them ages ago from the clover shape to a rounded triangle and my new manifold will match this for better flow

IMG_2973 by pjdirtjumper, on Flickr

IMG_2974 by pjdirtjumper, on Flickr

mocked up everything inlet side on the engine

new billet manifold I'm making bolted in place

IMG_2975 by pjdirtjumper, on Flickr

ITB's fitted

IMG_2976 by pjdirtjumper, on Flickr

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Plenum fitted

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New Cobra Bucket seats

IMG_2995 by pjdirtjumper, on Flickr

front end

IMG_3002 by pjdirtjumper, on Flickr

through windscreen

IMG_3003 by pjdirtjumper, on Flickr

inside side view

IMG_3004 by pjdirtjumper, on Flickr

new mini propshafts for the front and rear

IMG_3005 by pjdirtjumper, on Flickr

IMG_3006 by pjdirtjumper, on Flickr

centre propshaft bearings and nylon mounts finished

IMG_3007 by pjdirtjumper, on Flickr

IMG_3008 by pjdirtjumper, on Flickr

IMG_3009 by pjdirtjumper, on Flickr

fitted to the prop

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mini props assembled

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prop fitted into place

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Steering column trial fitting

IMG_3020 by pjdirtjumper, on Flickr

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working out fitting of steering rack

IMG_3022 by pjdirtjumper, on Flickr

welding in seat fitting rails for drivers seat

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steering column brackets made and welded into place

IMG_3040 by pjdirtjumper, on Flickr

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drivers seat fitted

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steering wheel fitted and drivers view through windscreen

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drivers footwell and area

IMG_3047 by pjdirtjumper, on Flickr

I modified the top of the steering column to remove the steering lock and fit a sealed bearing by machining a sleeve and welding it to the end of the column

IMG_3048 by pjdirtjumper, on Flickr

steering rack bracket mounts in the making

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view into car with seat and steering in place

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steering UJ fitted

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rear divershafts shortened and sleeved

IMG_3061 by pjdirtjumper, on Flickr

New steering boss fitted thanks to GUY aka MCLOVIN

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finally got the Rotas fitted on the front and this is the poke with the wings on

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Engine out and starting to fit steering rack

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Bought myself a new alloy low entry jack its so good and got it for a bargain

luckily it just fits under my new jacking points

IMG_3077 by pjdirtjumper, on Flickr

IMG_3078 by pjdirtjumper, on Flickr

rear view into car

IMG_3081 by pjdirtjumper, on Flickr

steering rack mounts all welded in

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steering rack all fitted and also welded in the bulkhead vertical braces

IMG_3085 by pjdirtjumper, on Flickr

I then put the engine back in but it wouldn't fit properly so have to take it back out and cut an excess lug off the box for clearance and shave a little material away

put it back in and it fitted JUST

IMG_3087 by pjdirtjumper, on Flickr

steering rack clearance around engine :/ its close lol

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Bought myself a Brand new turbo so I can achieve bigger power as wasn't sure the K03S would get me to where I'm aiming

Its a Borg Warner VGT AirWerks turbo which means its a variable geometry turbo its very similar to what is fitted to Porsche 997 turbos

and its electronic controlled or I can remove this and fit an actuator and run with an external wastegate which is more than likely what I will do

spec wise its like a GT28rs turbo which would be too big for my engine but as its a VGT it will spool a lot earlier than a GT28rs meaning it should be perfect for my engine it will easily achieve 30 psi and they have been proven to hit over 350whp

but its huge easily twice as big as the K03s anyways pics of it here

IMG_3167 by pjdirtjumper, on Flickr

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comparison of compressor housings

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also machined my front hubs today I drilled the steering arm taper out so that I can fit a tie rod flip kit to allow the steering arms to go underneath for a better angle

and started making the spacer sleeves for the front wishbone rose joints

hopefully that's a big enough update to keep everyone happy and more to come as and when around moving into my own house

ENJOY