Auto smart wheel cleaner if your ever after some fairly epic degreaser dude, use it neat and its frigin lethal Sure you've heard of it before but still.

Engine paintageee, nice colour. Coming on quick

Nah I haven't. Used a combo of carb cleaner, wd and gunk with rags and wire brushes. Mission dot com could do with getting the compressor out and spraying the box clean with diesel or summat.

Will get on that auto smart stuff, shame I'm not still on the farm as there was an auto smart guy there.

Back today to get weldy on crossmember and finish the patch of the floor. Another coat on the engine and refit the drivers wing

Started retrofitting a crossmember in the car this eve

More cleaning on the box

woop woop bits started arriving for the engine rebuild

Crankshaft Seal (Gearbox End) 068103171F

Crankshaft Gasket (Gearbox End) 026103181B

Crankshaft Gasket (Oil Pump End) 052115189B

Crankshaft Seal (Oil Pump End) 068103085E

Oil Pump Drain Pipe Gasket

Water Pump Gasket 030121043B

Sump Gasket 032103609B

Sump Washer N0138492

Flywheel Bolts N90206103

Just waiting on a new cambelt and leads, got a brand new dizzy of a seat ibiza mk1 for an electronic ignition conversion and a new old stock alternator I've had sitting around the shelf for a couple of years

Will give the engine block another coat of paint today and can start building it back up over the weekend.

decided i need to get all my parts in order, for each of the cars and the best place to start was clearing out my stock cupboard

that made somewhat of a mess

all the parts boxed, tagged up and stored again

comet ready with all his parts

new welder arrived which made me a very happy bunny, old one went this weekend too to help another polo owner.

finished up some more welding on the cross-member, nearly done now, could do with a power file jobbie to get at all those awkward nooks and crannies

ground down the welds on the floor again, to redo them with this welder

and got some paint on the box and another coat on the engine

and poking around by the filler neck made some holes! so tank and axle will be coming off and a perfect excuse to get use the new welder woop

so tomorrow I'm gonna mooch over to toolstation after work, pick up a odds n sods, give the engine and box another coat, hopefully finish up the welding on the floor and crossmember and get them in paint.

Armed with a array of attachments for grinders, dremels and other power tools, i spent most of tuesday grinding back all the welds on the cross member and was able to get in on all the nooks and crannies.

sorted the gas feed line for the new welder, so I'll be going rewelding the crossmember now from the underneath so it'll look loads neater. no pics atm as I'm still on the grindy flex.

today i decided to start bolting the engine back together

dremel was handy to clean up the sealing faces for the gaskets

refitted the two gaskets on either side of the crankshaft, popped out the old oil seals and replaced those (was screwing because i had forgotten to order the seal for the oil pump, but a quick rummage in my service parts box turned up a triumph :)

water pump was good so cleaned up and refitted with a new seal

got a nos cambelt plus a couple of other service bits off a forum member but unfortunately the cambelt looked pre-loved when i took it out the box, so a new VW cambelt was sacrificed from my g40 pile

refitted flywheel - new bolts a must (with thanks to PeteG40 - top dude for polo rebuild parts)

replaced oil pick up pipe gasket and refitted sump with new sump gasket

anyone got the outer metal cambelt covers going spare?

waiting on a new clutch plate in the post (old one was slipping) and then i can refit the gearbox and give it another coat.

went to refit the inlet manifold/carb and realised i didnt have the right gasket (correct one on order now!) - anyone know what the extra bits are for?

also any ideas on why this pipe at the bottom of the carb was blocked off by the previous owner? water heating for the carb?

tomorrow I'm going to fit the cleaned up engine mount, NOS alternator and refurbed seat ibiza distributor and then the engine can get put to the side until i the clutch and inlet manifold gasket turn up and i can crack on with the welding

Edited 21 February, 201313 yr by grungeisdead

The extra ports are temperature control for the manifold dude,

Never seen that bottom pipe before!

I've got the same manifold as you. solex one yeahh? means you could bolt a renault 5 turbo carb straight on

I'm just leaving mine open

The pipe is part of the exhaust gas heated manifold , a few early Polos had this :-D

ahh right cheers Mark, so are the exhaust gases fed up through that pipe into the inlet mani and out of the two little ports?

if so does that go into the inlet stream or straight out the exhaust again? confused?! going to have a peek on vagcat now

alternator fitted, belt on and tensioned, gearbox bolted on so i could clean the underneath and give that a lick of paint, decided to do the sump while i was at it

it'll be awesome to hopefully get erics, liz's, mikeys and this comet blue all pictured together, i'm well looking forward to a little blat about in a polo again, its been too long

dont forget Marks got a Comet Blue one too now

dont forget Marks got a Comet Blue one too now

, be a while, its in the queue !

Saf , I've no idea on how it works and it only appeared on the 0.9L HA Hatchback from 1975 - 1979 chassis numbers 86A0005858 - 86BW128588 and Saloons fitted with the HB or HH Engine from 1981 - 1984 .

I only spotted it because i have a Klarius Exhaust catalogue , ill try and do a scan of the page at some point .

Ta da !

it'll be awesome to hopefully get erics, liz's, mikeys and this comet blue all pictured together, i'm well looking forward to a little blat about in a polo again, its been too long

that would be really cool!! i dont think any of them have been together yet! although theres pics of liz's with another at a show a few years back. hopefully liz will get hers sorted soon, as its unlikely mikey will ever turn up

great work by the way! coming along nicely. what paint you used on the block?

Edited 22 February, 201313 yr by erixtar1992

woop woop, got the crossmember fully welded

floor above

floor below

first coat of epoxy mastic

seam sealer and another coat of epoxy mastic and its golden, then time to whip off the petrol tank and give the a run over with a knot wheel and see how much far the rust has gone

eric dude it was halfrauds hi temp enamel, i had most a tin left after doing a set of 256mm calipers i painted for this when i first built it, but i had since put the calipers on the golf.

I've seen mikeys comet a few times now, ed38 and polo show(s)

saf do you still have the 3'' exhaust that was on it when it ran the turbo setup? and would you sell?

saf do you still have the 3'' exhaust that was on it when it ran the turbo setup? and would you sell?

Just the backbox turned the rest into a system for the golf. That's coming off for a stainless system I got and ollys got dibs on it for his Jetta. The twin upswept dtm is for sale 25 quid

ah no probs dude. already got a backbox just need the piping haha!

thanks anywaysss :)

found alot of fibreglass and holes - grr!

not as bad as the perils but went in the same places, shouldnt be too hard to sort, already got a sill bought for the peril that can donate to this

Inlet mani gasket came so stuck that on, along with the metal cambelt cover and airbox off Azbar. ledge.

As the welding is probably going to take a few days just to even get to cutting out all the rot and making up the repair sections, I'm planning on pulling a few bits off the engine to get powdercoated, along with some bits for the golf. I just can't help but think the half rusty bits just look pap against a painted engine.

Are you feeling alright Saf ?

What happened to the days of bolt in and go!

Great work Safatronic. I'm gaining inspiration to head over to my unit.

Hah, I know Karlie, it seems like a distant memory!

I need to get another car on the road soon, and with the end of the month coming up, it means were coming to a good point to get the Golf insured and taxed again, so I think the rest of my week is going to be spent fitting a new alloy rad and stainless exhaust on the golf, change a fuel line, harness pre-tensioner and the ecu.

I miss driving something fast and I really miss driving a polo!

Yeah mandemz get inspired - what you busting out next?

would you be selling the bimmer?

that second to last rot pic... is that down the side of the rear bench on drivers side??

if so mine is the EXACT same haha!!!

nope sorry d00d, I'm quite attached to the big black bastard now

that second to last rot pic... is that down the side of the rear bench on drivers side??

if so mine is the EXACT same haha!!!

Yup!

If its coming through on in the inside, then its probably because its rotten on the outside by the filler neck!

Scary considering, especially when the Peril was in a worse state and got driven 4k around europe with 170brake and the potential for the rear axle to go SEE you at any moment =/