what mavhining do you have to do on them? are they the same length as normal afh rods then???

yes they are the same length they are just 25mm thick and standard afh rods are 20mm thick so you have to machine 2.5mm from either side i surface ground it off long process but worth it and then the small end needs rebushing from 20mm to 17mm for the afh gudgeon pins mate

that sounds well easy:-) well for me it does with my machine shop! i think il be going along this route- will give me a bomb proof 1.5 G40 motor- could you pm a link to the site or company mate please

hey polomon the rods are already machined in them pictures the main flat sides of rod arent touched its the circular flats around the big and small end that are machined down as these stand further out than the main h beam surface if you get what i mean.

and the rebush was done by buying some ally bronze bar with a bigger o/d and smaller i/d than needed and then cnc'd to match the gudgeon pin for the i/d and the right o/d to be press fitted into the forged rods. I then press fitted the new bushes in after pressing the old ones out (old ones were pressed out before machining new ones to get correct o/d sizes for press fit) once press fitted i then drilled the oil hole in the top using the oil hole in the rod to drill through. as an addition to this while they were being machined i had an oil groove machined into the middle of the i/d so that once the oil flows into the hole it then flows around the groove to spread the oil more evenly.

and as for the link i only have the guys email address who sorted me out i will pm it to you if you like just dont want to go giving it out if you get me more for privacy reasons than anything.

hope this helps you polomon

i did all the work myself as I'm a mechanical engineer and do all my own stuff at work in my own time. and will pm you the email tomoz mate if you need anymore help just let me know.

right its been off the road for a little while now since november i think but I've had gearbox off replaced diff bearings and just waiting for new diff seals in post then once they are fitted it should be back on the road and have also been sorting some running in issues but hopefully with most of them now sorted it will be running better and i can get fuelling and carbs setup properly. but it will be going into my garage in march for a full strip down and rebuild stage 3 final stage with massive plans.

right i received my new mk2 syncro gearbox, rear diff and rear driveshafts on friday and looking at the rear trackwidth i only need to widen it 50mm either side at the rear still need to sort front driveshafts yet but going to try and get hold of the syncro front ones. also to fit the box to the block just need to make an adapter at work as have all the dimensions now and get a mk2 golf flywheel and clutch. car is now off the road so will be starting getting the rollcage in for a start then butchering the tranny tunnel.

If you dont know already I'm going 4wd

will it be powerful enough to need 4wd? wont it bog down a bit?

the standard 1.8 golf engines were only 90 bhp I'm sure and the golf was quite a bit heavier than the polo and I'm not sure what engine I'm going to run yet with it

the standard 1.8 golf engines were only 90 bhp I'm sure and the golf was quite a bit heavier than the polo and I'm not sure what engine I'm going to run yet with it

fair play bro! looking forward to seeing the conversion!

just had a good read on this thread and some great bits, inspires me for the start of my conversion next week. keep up the good work and look forward to seeing the final result :)

i really like where this is going keep up the good work :)

Updates!

fair play to you mate amazing work and 100% efort can wait to see the finished product p.s dont mean to be cheeky but is there any chance in u uploadin a video on youtube or somthin???

Right bit of an update stripped all the inside yesterday and got the roll cage in just need to properly weld it in place now which I will do in two weeks as away next weekend. Once it's welded in the rear floors being cut out and rear diff is going to be mounted finally I'm getting on it and feel better.

Still need to source a mk2 golf 020 gear linkage, flywheel, release plate.

Have sourced a propshaft just need to buy it and collect it so started breaking stuff off te polo which I will no longer need to sell and fund all the rest of the bits also need some gti injectors and fuel rail and maybe manifold and throttle body so if you have or can get any of the above let me know and if your interested in any bits I will sell pm me guys need more monies :)

It's finally happening 1.4 16v turbo 4wd mk2 bready

We need pictures! Your sub title says mega update... but theres no update THIS YEAR! :)

i cant upload pics as i haven't got photobucket or anything i need to get my ass in gear and sort one out lol and that mega up date is from last year il edit it now and getting the roll cage in is quite a big thing well i think anyways

Thats mega man! What a project! Wanna see :)

also need some gti injectors and fuel rail and maybe manifold and throttle body so if you have or can get any of the above let me know and if your interested in any bits I will sell pm me guys need more monies :)

Am I reading that right that you are looking for a gti throttle body?

Good to see see your making some progress on this, should be a fucking beast petay

yeah Guy looking for a gti throttle body, inlet manifold, injectors and fuel rail just so i can get the turbo running then will get itb's on it what you think sound like a good plan.

and yep so glad to be finally able to get back on it just need to clean the garage now so i can get it in there get the rear end stripped off and start the rear drive conversion got so many plans in my head really need to get started

Well if you buy the rear disc conversion il chuck them in for free mate when do you think you could afford it as will probably start stripping the car in 2 weeks mate as already have people wanting bits

And I'm running 1.5 degrees either side and that looks pretty beastly

Edited 11 March, 201214 yr by StinkyPete

Would the gti tb being fly by wire not be an issue for you management?

Yeah sounds good but personally I'd be more inclined to use the afh tb just for the ease of having no fbw to have to piss about with

Oh yeah forgot about that lol may still have my afh throttle body il have to have a look but deffo need the gti injectors need fuel rail unless you can suggest some others that would work

Long time lurker, always top work being done and dollar being spent. But PIIIIIIICCCCSSSS

right well finally set up a photobucket account tonight so will update pics

so anyways roll cage is now in needs to be fully welded in but thats this weekend hopefully.

Bought myself a hydraulic tube bender today so i can start fabricating extra supports for the rear suspension and front spaceframe properly.

also got my mk2 syncro clutch, flywheel, and release plate on friday so got them fitted to my spare block to see what the gearbox fitting would be like and I'm glad to say its a fit will have to make some adapter plate as obviously the bolt holes to not line up especially as the golf engines lean backwards and the polo engine leans forward but this will make it easier had to trim a little bit of the excess casting off the diff housing but no biggy.

hopefully picking up a prop shaft this week/weekend and then just need to source front driveshafts and a gear linkage mechanism and then obviously get it all mounted in the car which will start as soon as the roll cage is welded in.

anyways finally pic tures and may add some old ones i missed

rear diff

syncro flywheel

clutchplate and release plate

oh and me doing a flair on my kiddies bicycle