I wondered where this car had got to! Didn't realise you had it mate, she couldn't shift it for a while I seem to recall.

:)

good work so far ,I'm putting an aee into my breadvan at the moment ,what alternator did you use and what gear box?

love the colour coded alternator too

Nice to see this taking shape and giving it the time and cash I couldn't :)

Don't forget to give me a shout when the car is running about our signed and agreed deal

This is shaping up to be something special, if this level of attention to detail is carried throughout this is gona be awesome. Nice work!

Well a bit of a written update, will do pictures on the week.

Haven't updated or ages, and tbh, little has changed. Been so busy with teacher training, winter weather, and my bastard bready breaking everytime I get a free weekend. I swear she knows shes to be replaced. If only I could communicate with her to tell her the turbo plans for herself! Anyway, this is getting odd

So things have been stripped, de-rusted including (deep breath)

Front struts

Front spring caps

ARB and mounts

Front GED brace

Brand new 22.5mc painted

Gt rear axle

Rear stub axles

All springs

Alternator belt pulley

All large engine mount washers

Driver side engine mount flange

Rear gearbox mount and plate

Gt steering damper and brackets

I have also put all suspension and chassis parts back on using stainless bolts with the aforementioned poly bushes up front.

The whole of the underside has been undersealed, although there was so little rust, I wondered if it was worth it. I have a gt brake bias valve waiting to be installed and am currently bending up all new kunifer brake lines since the old ones were beginning to corrode. Plus the copper looks nice in the bay. The steering rack has been painted and re-installed using stainless cap nuts.

Got hold of some 20mm wheel spacers front and back, as well as some rear axle spacers to take the rear track to +35mm, which allows the wheel face to practically sit flush with the arch rim. The 185/60 mean the arch almost rests on the tyre with the conservative -40 drop and they give a little poke. So I got some 165/55 and 155/55 tyres to sort the problem. The drop in ride height was achieved not by using saxo parts and adjustable rears as per the original plan, but instead using a set of -40mm springs off the old wagon and brand new dampers all round. Jumping on the back gives little movement, so i'm hoping the springs should be firm enough not to crash onto the bumps all the time. Not that it's likely with the small reduction in height. I must say though, the stance is gorgeous fon the back. Hard to tell with the front as there's no weight in it yet (yep, engine still innthe garage) and the tyres are flat. However, it gives a good enough indication of the finished height, which looks nice!

Anyways, back to the engine. I broke a piston ring when installing and got a new set sent out but they are the wrong ones. I was going to sort this problem today, but didn't. Which was gay. However, i went to a kit car show the other day to pick up some bits and bobs, and got all the parts for the exhaust, which is going to look really nice when finished. I also got some mirror finished stainless for the inlet mani for the bike carbs. Hopefully this should be tacked up to the stainless flange tomorrow, and finished, along with the exhaust sometime this week. Looking forward to that. Oh, also picked up a set of csatelettes too, which I'm debating to put on instead of the tear drops (broke a centre cap earlier, Grrr), but they have a little curbing. Hmmmm, advice?

Interior wise, little has changed. It's used as a bit of a dumping ground ATM as the garage is getting full up? However, I did get an mk1 dash (early type) which i'm hoping to get fitted. Will require some fettling, but possible ne thinks. Also got another vp2 amp (that 3 now, plus the vp3!!) and some vibe sk60 (iirc) mids for the front.

So, I'll try and get pics up tomorrow, and will definitely get ones of the Mani up asap, a that is going to be a work of art.

Edited 15 May, 201115 yr by prankstar2003

good work so far ,I'm putting an aee into my breadvan at the moment ,what alternator did you use and what gear box?

love the colour coded alternator too

Wow, late reply! How is the aee conversion going? If your still wondering, I used an mk2 alternator with the. Also used an aee gear box with mk2 driver side (iirc) output flange

this is shaping up nicely fella - look forward to seeing the pics.

good luck with the teacher training, i know from experience that you have precious little time for a life outside of school, lesson planning, assignments, qts tests etc etc

hang in there!

Thanks mate, nearly at the end now. Week and a half of teaching left!

Anyhow, back to the car! Picture update.

Pictures of rusty parts. All were stripped with a harsh wire brush to remove all rust and flakey paint.

New 22.5 master cylinder and brakes. Now have full set up from a golf mk2 16v with GT bias valve. This also got painted black, and the calipers, as seen above, are to be painted the same colour as the engine

TCA polybushes. Not the best of fits, but they are tight now they are mounted. Made by a polish company, and cost half the price of powerflex. Not sure how they are going to hold up, but for the price of a full front set up, I'll have a go. Company was strongflex if people are interested

Wheel spacers and front struts all painted and assembled. All new front and rear bearings. Springs are -40mm and the inserts are standard. Ride height was good on the old wagon with the -40 drop, so this one should. We'll see later Spacers are 20mm and have been teamed with 15mm axle spacers at the back

With all these chassis mods, this is how the rear sits. As said above, the front isnt sitting right due to lack of weight there.

All TCA, steering arms and tie rods are new. Things that were bare metal have been sprayed with black hammerite throgh the compressor. All chassis parts and M/S have had the same treatment aswell

Onto the interior. This is what it looks like as it stands. The rear seats are from a one year run as far as I am aware. The rears are in mint condition, but the front seats are well worn. So unless i can get a set of fronts in good condition, they will be retrimmed in tweed. Seen here are the MK1 clocks, may get used or might go with the smiths ones seen above. Also here is the 12 vibe sub. Nice!

Yesterday me and a mate got cracking on the inlet manifold. Its all stainless, and the flange has been polished as its a bit of a pitted finish. My mate Dodge is a stainless welder by day, so is helping me to fab it up. Pipe is stainless too, and the exact right size for the ports and carb chokes. Perfect! for anyone wanting to know, its 34mm and the carbs are cbr600

Sp that the update. Doesnt look like much, but the prep and paint on the chassis parts took a while, and my compressor brole for a few weeks so i couldnt spray. Fixed(ish) now.

Here's a cheeky picture of my castalettes that i got for 65 quid from a guy off here. All four tyres were good and good condition for the price.

And here's a piccy of my breadvan as it stands. All beaten up atm,and wearing her new bonnet bra. Although it flaps a bit in the wind. She had an accident when the TCA fell off. Whoops. Still, she's set for a turbo G40 next year

Have these and front skirt too. I'm going to bond these to the bready and smooth them in, making a sort of bodykit. Taped it together the other night, and it looked really good! Still, thats next years project

So thats the update, another one soon. Enjoy

so much win dude :) great progress and a very thorough build

STRONGFLEX

did you use anything like hydrate 80 for the rust treatment?

Rust treatment where? On the chassis parts it was all surface, so I just ground it all off using a grinder and wire brush. Then painted with hammerite so it should be protected fairly well. Regarding thorough build, it's gone from a few mods and tarting up to practically a full resto job

Dude, just had a look on strongflex's website and the only ones i can see for a polo wishbone is "POLO III classic" and "POLO III Variant"

surely there not the correct ones for an 86c polo?

Prankstar just for the struts etc, rust converter stuff is usually quite good for surface rust..

I know what you mean, sometimes things get out of hands with cars!!

@Max, you can get their stuff off eBay:

Audi VW Front Wishbone Outer Bushes SPORT Polyurethane,Audi VW Front Wishbone Inner Bushes SPORT Polyurethane

http://cgi.ebay.co.uk/ws/eBayISAPI.dll?Vie...em=280495836579

http://cgi.ebay.co.uk/ws/eBayISAPI.dll?Vie...em=280549487613

Seller User ID: strong-flex.eu

Total: £40.60

legend, cheers dude.

Thanks narrow lane, I'll bare it in mind in future. Think I'm addicted to that big wire brush though!!

And I got the full set of bushes, including arb bushes.

Fair fucking play dude! Thats some amazing work!

That engine looks great!

Got the stainless inlet manifold welded up today, but can't seem to get the photos up. Will try again tomorrow. I'll just say it looks awesome!

Pictures of the Stainless Manifold

Bolted to the head

And after a cheely polish on one of the runners

This looks amazing in 'The Flesh', so big up to my man Dodge for fabbing and welding it up. Its easily the best inlet I've seen, the man is a deamon with that torch!

Wow!, nothing like polished stainless.

did you paint the sealing flanges on your block?

Where the inlet meets the block? Yeah. How so?

inlet, water pump flange, exhaust flange, basically anywhere where seals fit should really be bare metal, whenever I've painted any blocks, I've always always always made sure the sealing flanges were covered, and i bought a block which had been painted, and had to sand back around the sealing faces, as it was leaking where the oil filter housing, and thermostat housing fitted.

might be ok, but I've been told not to do paint those bits up.

mani looks nice, although you should consider putting a groove in the top of the runner, most bike carb rubbers use a groove to ensure perfect positioning, leak free fit and avoids the carbs or rubbers working free of the mani

Cheers for the info. May have to rub it back a bit then.

Thought about the groove, but they seem to be a really tight fit. Won't know for certain until it's running. If there's an issue, I'll remedy it then.

So another weekend over, and only got a chance to do a bit on the car. Mostly polishing that inlet. I'll let the pictures do the talking

Polished inlet - iPhone pictures arent really the best

Few pictures of the chassis. Got the clips for the bias valve from VW so test fitted the bias valve. The spring is now obsolete, does anyone know the length, load, rate or anything about the spring that attaches ot to the rear axle? Also, anyone have an exploded view of the set up? Can't seem to log into Vag-Cat.

All undersealed at the back now, so can finish of the brake line bending

How she looks from the front, a little sorry atm!

Pictures of the steering gear an what not with GT steering damper and all stainless bolts

Front wing - check the massive arch gap! Should disappear when the engine goes in. I hope

Anyone that can help with the brake compensator, that would be awesome. Got half term coming up, so should be able to get some major work done then. Though no doubt something will crop up

Inevitabley something did crop up, stag weekends, field trips etc. so very little got done last week however, I'm finishing work super early so I've been doing a bit of work in the evenings

This week it has been clearing the scuttle and sorting/re-wiring the car. So I have stripped all the wiring out of th ebay and started cleaning it up with petrol, looks brand new.

For the more eagle eyed of you, this headlight looom should run down the other wing and along the front pannel. Didn't like the look of this so i have run it along the scuttle and along the OS wing.

Also painted the coil bracket and cleaned the coil up a bit. Its going to be hidden inside the scuttle, but i want everything looking good

Got a load of stuff from leeg40 including solid engine mounts, G40 cooler and this chromed lock mech. Unfortunatley he only had the one, really need a drivers one, so if anyone can help out, that'd be nice

So not too much done as I just haven't had the time. Picking up some more wheels later, so will update when i have them. Finish my course in 2 weeks, so I'm hoping i can really get things moving. I have most things i need now, so its a case of bolting them on and making them work. Thanks to Kiz for sorting me a compensator spring too. Top man!

Edited 13 July, 201214 yr by prankstar2003