Car: 2000 polo variant estate 1.9TDI 90bhp SE model (so has electric everything, foglights and an electric tilt and slide sunroof as standard). Was on 60,000 miles which is low for year and these engines. Full service history. Well looked after and completely standard so a complete start from scratch affair.

Engine:

1.9 TDI 90 bhp.

EGR removed and allard EGR delet pipe fitted.

.205 injectors fitted taking the power up past the 100bhp mark (ready for remap very soon).

Shallow 2 piece sump (steel bottom) fitted after popping the cast alloy item.

Timing belt all changed and engine fully serviced up so running very nice indeed :-) (had full service history so keeping up with it).

Suspension:

Coilovers all round with unknown ride height (still tweaking it daily to get it right), front is as low as i can go on current wheel setup without breaking something important.

Interior:

Black seats fitted onto the original seat frames and plastics so it matches the dash nicely.

USB headunit fitted that matches dash colours.

Boost gauge fitted that matches the dash (same dash as mk5 polo/lupo)

New gear gaitor and general tidy up.

Exterior:

Pressed plates

Stubby arial

Lamin-x light smoke lights

Lamin-x yellow fog lights

Black front badge

Huge black rear badge

mk3 'polo' badge painted black, and mk3 golf TDI rear badge painted black as i hate the silver letters but wanted to keep some badges

Rear lights tinted with spray very carefully and enamel lacquer over the top so look standard and similar to standard valver lights.

Wheels and tyres:

BBS RX 16x7" VW fitment. With 195/40/16 falkens. H&R bolt to hub 25mm alloy spacers on the rear.

Plans:

Not so distant future:

Matching satin black stubby mirrors both sides

Straight through decat exhaust from turbo back

Remap (140 + bhp and lots of torque)

Sigma short shifter

Ibiza cupra splitter (have it but needs fitting)

Get the car sat perfect on maybe some different wheels

Sort a few minor boddy issues out

Next year:

Bigger turbo VNT 17/22 probably

Bigger injectors

Bigger intercooler

Bigger map sensor

Bigger clutch

Remap

Hope to see 200BHP

Following owning my dream car (G40) i wanted something that would save me some money and be a good hack around with very little drama but still retain some fun and not wanting another hatchback/small car i went for the estate and i haven't looked back.

Pics:

Most recent (last night)

Wheels:

Pre spacers etc:

Pretty rubbish pics as they are all from the phone and pretty boring but thought i would share and will update when i get new stuff etc. Probably forgot loads.....

:-) :-D :-D :-D :lol:

Edited 17 April, 201115 yr by demolover

absolute rudeboooooooooooooooi!

Been waiting to see pics of this...and the thing in the metal but not spied it about yet. Looking cool - keep being tempted by variants!

I've got a 100bhp 1.6 lump thats been detailed and such ready to drop into one of these! It's also cammed, should run 115 bhp? been told its a very lairy cam. I've got everything to complete the conversion aswell! I'm after penuts. strap a set of carbs onto it and you got a damn sweet looking engine bay to acompany a sweet looking car! go like the clappers too...

Food for thought.

Best variant I've seen Demo.

I think some wider wheels or spacers would complete the look for me.

pimpin aint easy barney! but you make it look easy man! hahaha! looking sick!

it was about time you got this up i just love it

Thanks guys. Been a quick turn around with this one. They look pretty terrible standard :)

Fake lows time

Well i had this lying about for some time now and thought i would finally go about fitting it. Not usually a fan of wanging a big splitter on but I think this works perfectly with the bumper and the overall look. Bit of a pain. Had to cut all the mounting clips on the sides off and trim some of the ones along the leading edge. Also had to cut some of the inner bumper away where it fouled and the used a tiny drill bit and 8 self tappers along each side to hold it in place. So after a lot of swearing and junior hacksaw work its on and i think it works well.

Bumper removed and splitter fitted to it:

(ignore the crap in that room its been taken over with car junk)

Remounting it:

Done and done:

Dog wanted to see what was going on:

So here's before shot with the old splitter:

After:

Also a quick pic of the rear and how it looks (i love my perfectly sized oversized badge):

:-)

Edited 10 April, 201115 yr by demolover

Here is a picture I had on my phone barney:

Cheers richard. The good thing about buses is that they are majorly reliable

Need to figure out how to raise the engine slightly there is engine spacers for mk4 golf chasis but i don't imagine this will have the same mounting even though this engine was available in the mk4 golf. Hmmmm. Hockey puch engine mouting time? 20mm raise would be perfect. Will keep this updated should i find a cure.

Well after a quick read/research it seems that the variant has exactly the same (or there abouts) subframe as the mk3 golf. So therefore has the swiss cheese cylinder shape engine mounts. One at the very front of the frame and two at the rear. So the options are ghetto drilled hocky puck fitted on each mount (they are the same size and fit exactly) with longer (higher tensile) M10 bolts to ensure they hold well. Alternatively get some proper machined spacers for the engine like these ones clicky for motor spacers.

They look excellent quality and i have emailed the company regards what the difference (including amount raised) between the two kits is and what "hardware" is included with the motor spacers to save buying different bolts etc.

For $70 they look like just the ticket and coupled with my shallow sump i should be able to wind down a little further.

Watch this space :-)

Edited 11 April, 201115 yr by demolover

Looks muchos better with the new splitter, i like it a lot. Be really useful for doing the school run too, trips to B&Q on a saturday morning, and taking the dogs for a walk, as well as taking the kids on holiday

Oil patch looks worrying though, hope its nothing serious. May have found myself a summer job out here but I'm looking forward to seeing this whenever i get back!

wellll cool!!!

when you sell this shout me! man that is so badass good work

Cheers fellas :) To say i bought it standard only a couple of months ago its come along alright.

Skatty the oil patch was from when i popped the original alloy sump on a speed bump. They sit stupid low. It was just the best pic i had of the previous splitter. Fitted a new sump that instead of being a fully cast alloy (brittle) construction it is a two part sump that has a steel bottom (see pic) they call it a 'shallow sump' but it isn't really. It has a better shaped bottom as it isn't so square and the drain plug which is the main weak point on the original item is moved and recessed so will hopefully last better :)

Sump (mine is same design as the one pictured but without the turbo oil feed return hole as thats for the 1.8T engine and not needed on the diesel)

A front engine mount spacer will be fabbed up as soon as the materials that i ordered today arrive this week which should give me another 20mm to play with at the front :-)

The wheels may look narrow but they have a high ET (42) so they sit snug in the arch especially with the 40 profile tyres. Spacers on the rear help but i still want something different......

Anyways i will keep this updated as i plod along and i am glad you approve so far.

The wheels may look narrow but they have a high ET (42) so they sit snug in the arch especially with the 40 profile tyres. Spacers on the rear help but i still want something different......

TSW Venoms?

The Cupra splitter makes all the difference. Its amazing how it transforms it. Good work fella!

I need to look at mine, its a bit raggedy round the edges now. Suicidal rabbits and low curbs in car parks don't help

looking good..

Right well a bit of work gone into this car this weekend.

First i went onto my dads work as it is perfectly level inside and basically spent a few hours fooking about with C spanners trying to get my car sat right. It is going to awesome GTI on Tuesday all being well for full geometry setup etc so i need it all dialled in. Still managed to not get it exactly how i wanted it. By the time i got home it all looked completely different to when i finished mucking about.

Anyway a pic of it sat:

Then got home to meet a good old friend and we got started changing the gearbox oil. Always worth doing and my paranoid brain was sure there was some gearbox noise so that was first port of call.

Resident bitch getting to work as i lashed him for not working hard enough:

Following the gear oil change we did some engine raising

Czech republic finest:

And yes that is a ice hockey puck. A whole 25mm thick slice of vulcanised rubber. These things are seriously tough, and strangely enough the exact diameter of the front engine mount. Its as if VW were teasing me into ghetto modification You can do the rear mounts as well but after much reading there is really no need and this will raise the sump 20mm or so away from the road without putting excess strain on exuast components, cooling pipework etc.

So a hole was drilled through the puck and a longer very high tensile bolt and high tensile washer were used and the puck just sits on the top of the front engine mount. This is great as it is an easy (5min) mod to do. Cost very little and is visible from looking in the bay so you can see the condition of the puck if you are worried. Before anyone attempts to flame me for engine raising on sports goods there is a mk3 VR6 turbo running 350+ bhp and does regular track days and after 40,000 miles use of the puck it was removed and apart from dirt the puck looked as the day is was fitted. Might fit a metal sleeve in the hole in the near future for a better finish but it really is solid as a rock.

The reason for this mod is the silly lows that the engine sits originally. I have now removed my engine undertray and got some evidential pics for you.

There should be no holes in that and should be one solid piece The small hole on the right centre was where my sump got eaten.

Anyways wheels and spacers update to come

hockey pucks are used all the time on drift cars and the like, cars looking good

wow.... x

saw this on saturday going towards cow and calf, ilkley.. looked ace!!

Car looks sweet now, you've not been hanging about with it have you. Really like what youve done so far & those wheels definitely suit it, also some great modding tips within this thread for the tdi variant owners as well, something the forum has been lacking

Now I've really gotta stop looking on here as just put mine up for sale & having seen this it makes me wanna keep it, Got a few bits you might be interested in (stubby drivers mirror, debadge grill, rear wiper blank) although only really looking to sell seperate if whoever buys the car doesnt want the bits, have a look at my for sale thread & drop me a PM if theres anything you might want

Yes Barney this is so sick love your work man.