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Mattie's 6n Polo 1.8 20 Valve Turbo Project

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So a few pictures of what i got up to yesterday including the shallow sump fitted that i bought from Awesome GTI, came with all the new bolts, new seals, gaskets, new oil pick up and an adaptor for my oil feed. Proper decent peice of kit.

Then started cleaning it all down with some heavy duty de-greaser and scrubbing down. Got some more to do yet before it gets painted so no pictures of that till its done, anyway heres some more.

New oil pick up, slight kink to it sits higher.

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30 by mattnaz, on Flickr

The adapotor plate for the turbo oil line.

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31 by mattnaz, on Flickr

This is what happens when people dont put filters on "hand tight" and i couldnt find my filter wrench...

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32 by mattnaz, on Flickr

Big screwdrivers are useful for many, many things :)

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A much needed update!

Had 2 days off work last week (thurs and fri) to get up the unit and work like mad on the car. Spent a good 20hours there those days then another 16 hours over the weekend, phew!

Got lots of stuff done, it might not seem a lot but its the most that I've done in a while and just need to get back in the kick of things...

Kicked things off by doing my rear disc conversion that I've had lying around for a good 7 months! A set of brembo discs and pads, new wheel bearings and chucked in a couple of camber WASHERS :ninja: for good measure! Looking around -3 degrees of camber as far my mate worked it out... over my head.

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46 by mattnaz, on Flickr

Then cleaned the rest of the gearbox up and painted it along with the block and some other bits and bobs, I've got crackle black mad!!! :unibrow:

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48 by mattnaz, on Flickr

Fitted my G60 Lightened flywheel and a Carbon Kevlar Clutch, gave the release arm a good clean up and built it back on the block. Then fitted up the gearbox onto the engine. The rebuild the rest of the bits onto the gearbox, Cable Clutch Conversion got bolted on, cleaned and rebuilt the gear change system.

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44 by mattnaz, on Flickr

Got a little sidetracked so thought id slip my Momo Team 300mm (not saucer sized 280mm) wheel on that my Mrs bought me for christmas ;)

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42 by mattnaz, on Flickr

Thought i'd tidy up my slam panel that i had cut out for my Golf Rad. Previously i had drilled a series of holes and then cut round with a junior hacksaw... so much easier with a compressor, air line and an air saw :thumbsup:

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43 by mattnaz, on Flickr

Stripped my subframe off...well what a fuck about that was! 4 bolts hold it on, 2 came out fine. The other front 2 bolts decided that the captive nuts would shit themselves so i couldnt get the bolts out. By shitting themselves they were spinning...

So ended up cutting the heads off the bolts and then drilling holes in the side of the mounting brackets and re-welding the nuts up...JOB DONE!

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47 by mattnaz, on Flickr

And heres the subframe after a bit of welding and a quick coat.

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45 by mattnaz, on Flickr

After the few days i'd had I'm glad it was St Patricks Day saturday! a good excuse to have one of these ;)

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41 by mattnaz, on Flickr

I'm on my phone and for some reason i cant see pictures... :-( but when i get home I'm looking forward to seeing the crackel back! It goes really well in an engine bay. good choice.

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Smashin mate! well deserved pint its coming on well :D:thumbsup: i love textured paint also.....

Cheers mate, tell me about it! Went down so well that night, I've gone mad with the stuff :-)

I'm on my phone and for some reason i cant see pictures... :-( but when i get home I'm looking forward to seeing the crackel back! It goes really well in an engine bay. good choice.

Ahh! Yeah man its such a good paint, lays really thick and well, covers any odd mark or deep scratch too so like you say perfect for bay and engine bits and bobs.

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Introducing the smallest and most pathetic "probably not much point in doing" update to the world.

But progress is progress ;) anyways... got the Audi Interior loom out of the bin liner I dumped it in all those months ago and blew the dust off (bag had a hole in it) then started to unravel the mess i had laid before me.

(45 minutes later)

I had sorted it all out and got it lying pretty much laid out except in the picture below the front lighting looms are the wrong way round (Right->Left)

Then went round marking out the lighting plugs, fuel pump, ignition etc... so i can start removing all the shit i dont need such as air-bag sensors, door looms (running windy windows), seat belt charges, alarm sensors... it goes on and on. I bet i actually half the weight of the full loom by discarding the rubbish these modern cars have! :-D

Anyway here's the 1 picture i took, then i left the unit because i was hungry, needed a poo and it was too nice to not sit in the beer garden and have a pint.

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loom by mattnaz, on Flickr

there's a lot of bits you can remove from the loom, was it from a/c model car?

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there's a lot of bits you can remove from the loom, was it from a/c model car?

Nope no air-con. Dont know how to go about removing it yet, need to have a word with my mate. Do i literally trace the bits back i dont need and lop them off?

drivers side you have headlights / washer bottle / level sensor / carbon canister / bonnet switch / brake fluid res' / header tank level sensor and maybe a few other bits. you can lose all except headlight and re route washer bottle pump wires to passenger side.

bonnet switch can just cut wires back as far as you like, washer bottle level and heaader tank level need to be earthed out so can be cut right back and looped. brake fluid level sensor can be left open like bonnet switch so just cat right back / tape up.

passenger side is a lot more, i've reduced to, headlight, 1 horn ( two wires) external temp sensor ( two wires) and ripped out all wires to fan control module and ran a permanent live (old style) to fan switch then to fan and an earth for fan.

there's also lots of silly bits like power for windscreen washer jets etc than can be cut off.

if there's a plug you're not sure of drop me a pic on PM and i'll see what's what.

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Brilliant, thanks for that Olly. Cleared up quite alot, i think it would of helped if i had of labelled when i took it out. Oh well! All a learning curve for me.

Cheers.

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Stripped the hubs down, had some trouble with one of the carrier bolts, couldnt get it to move with love nor money. Tried everything to get it to move even got it cherry red then hitting it but wouldnt shift.

So ended up cutting the bolt of the head off with a grinder... still couldnt get the disk out the way to get the carrier off so the grinder came out again and this happened...

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17 by mattnaz, on Flickr

Anyway i nipped up today to get a few things such as part numbers for my big spending spree later on at GSF/VW/Eurocarparts and stuck the slam panel on so i could give it a once over with some sanding pads to neaten it up. Then decided to chuck my Depo lights and new indicators in to see what they look like.

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19 by mattnaz, on Flickr

I think they look ace personally but not sure wether to black the headlight inners or not!?

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18 by mattnaz, on Flickr

Peace out!!

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BLACK THEM! black the slam panel too 8-) Gloss black ofcourse, id personally black the white/grey bits of light on the outsides too :-)

Yeah man having as much black as loss, not quite murdered but scary? Lol yeah gonna wap some gloss on the slam and might crackle the tops of the lights ;)

  • 1 month later...
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Right a much needed update, haven't done alot these past 2 weeks as i had a break and went on holiday to Greece for a week with the Mrs :)

Anyway less about the sun more about Pearl ;)

Started to strip down the interior loom so i can tidy it up, as my plan is keep it pretty minimal inside with the interior plastics. There will be some sort of DIY dash in there but i haven't planned that yet untill its all up and running. So started to strip out everything i dont need such as Airbag wiring, ABS wiring, Aerial wiring, Speaker and Sub wiring as the Audi came standard with a sub in the rear side compartments, and then took anything else out that i dont need so i just went mad with the snips!

In the rear i was left with just the lighting loom :) This will have loom tape over it once i get some ordered, just leccy tape on to neating it up for now.

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51 by mattnaz, on Flickr

Dont need this...

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55 by mattnaz, on Flickr

Finished my mounts before i went away, it may look rough but i just used the box section for mocking I'm having a Aluminium mount machined up as i write this ;)

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53 by mattnaz, on Flickr

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52 by mattnaz, on Flickr

I'm using the rubber out of the original polo mount to use on my new mount, i also chopped off the threaded bar off the original mount and welded it onto the cable clutch conversion mount so its a Hubrid mount basically or Mongrel mount! haa! but yeah if you get it i do! Less blabbing now...

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59 by mattnaz, on Flickr

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54 by mattnaz, on Flickr

This is how she sits... I haven't put the rubbers on as it didnt matter in all fairness.

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541 by mattnaz, on Flickr

I also treated myself before i went away and these were waiting for me when i got home after my flight :D

165/50/15 Toyo Proxie R888's

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57 by mattnaz, on Flickr

BMC CDA Filter

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56 by mattnaz, on Flickr

MIJ Performance 3" Backbox, Flexi and 3" Rolled Tip

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58 by mattnaz, on Flickr

My exhaust is getting made up over the next week but before i can get it up to my mates unit so he can do it i need to get my steering rack back on. So i stripped clean, painted and rebuilt it and then forgot to take a picture!

Anyway updates next week...maybe...if i remember...

About time :p Looking good though mate! You running the R888 on the front and back? What J wheel you putting those 165/50 on?

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About time :p Looking good though mate! You running the R888 on the front and back? What J wheel you putting those 165/50 on?

Sorry man! ;)

Cheers mate, I'm running them on my comps which are only 7j. And no I'm not! especially at £115 each! Plus i bought some brand new Nanknag 185/45's for the rears not long ago so gonna keep them on the back till they die and ill put 888's on the rear too then.

About time :p Looking good though mate! You running the R888 on the front and back? What J wheel you putting those 165/50 on?

Sorry man! ;)

Cheers mate, I'm running them on my comps which are only 7j. And no I'm not! especially at £115 each! Plus i bought some brand new Nanknag 185/45's for the rears not long ago so gonna keep them on the back till they die and ill put 888's on the rear too then.

Ahh okay man, I was going to get some R888 but I just spent all my money getting the car finally finished so just bought normal tyres and going to see how I get on and then get some later on :)

yeah dude! looks rad! I'd love to drive a 6n with a 20v... it looks mad fun-

Great progress man! Like what you've done with the loom, keeping it simple 8-)

Looking forward to seeing more updates on this ^

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About time :p Looking good though mate! You running the R888 on the front and back? What J wheel you putting those 165/50 on?

Sorry man! ;)

Cheers mate, I'm running them on my comps which are only 7j. And no I'm not! especially at £115 each! Plus i bought some brand new Nanknag 185/45's for the rears not long ago so gonna keep them on the back till they die and ill put 888's on the rear too then.

Ahh okay man, I was going to get some R888 but I just spent all my money getting the car finally finished so just bought normal tyres and going to see how I get on and then get some later on :)

Yeah there not cheap mate! I want to know what wheels you've got!

yeah dude! looks rad! I'd love to drive a 6n with a 20v... it looks mad fun-

Cheers mate, I wanna know what its like to! Cant wait :)

Great progress man! Like what you've done with the loom, keeping it simple 8-)

Looking forward to seeing more updates on this ^

Thanks mate :)

  • Author
AWESOMEEEEE! Not long til all the hard work has paid off :p Look slike most of the hard fabrication is nearing the end :D

I know Mr Mon! ;)

I've only got to plate up the p/s chassis leg then its exhaust time...

its quite easy to forget that your doing this project too lol unlike Harry, your not quite as stuck to the forum as he is lol how long do you thing you have left before this will see tarmac???

  • Author
its quite easy to forget that your doing this project too lol unlike Harry, your not quite as stuck to the forum as he is lol how long do you thing you have left before this will see tarmac???

Haha, its not that I'm not stuck I'm on it everyday pretty much (only at work mind) i just dont always have effort to update!

Its a lengthy process... take pictures, email to work, upload to flikr, do a write up, copy pictures into right place. I'm an idle one ;)

Well its getting taken to my mates unit this weekend so he can make up my exhaust looking end june with fingers crossed that everything goes well which it usually doesnt.

its quite easy to forget that your doing this project too lol unlike Harry, your not quite as stuck to the forum as he is lol how long do you thing you have left before this will see tarmac???

Haha what you trying to say :lol:

looking end june with fingers crossed that everything goes well which it usually doesnt.

THIS :angry: nothing ever goes right! Anyway both be there soon!

Edited by haz911

  • Author
its quite easy to forget that your doing this project too lol unlike Harry, your not quite as stuck to the forum as he is lol how long do you thing you have left before this will see tarmac???

Haha what you trying to say :lol:

He's saying GET A LIFE ;) i joke...

looking end june with fingers crossed that everything goes well which it usually doesnt.

THIS :evil:

What? Not soon enough? Too soon?

The :evil: face sends me mixed signals... not in a gay way.

  • Author
looking end june with fingers crossed that everything goes well which it usually doesnt.

THIS :angry: nothing ever goes right! Anyway both be there soon!

Now it makes sense.

Damn right, it never does!

Bwwwwaaaaarrppp PPSSSSSTTTTHHHH!

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