I think some golfs came with those type seat though

Few updates :)

New dizzy fitted.

studs fitted in head ready for mani!

got a larger bore gasket as the standard size gasket is to small after the porting

rothe mani on! painted it with POR15 manifold paint

Then put the turbo on k03-029 turbo that I got refurbed with and uprated thrust bearing. Look brand new!

hot side painted with same paint as manifold!

forge actuator fitted setted the preload up.

aux air valve cleaned up fitted with stainless bolts new clips etc. knock sensor re-wrapped in loom tape

door lock mechs

Edited 16 October, 201510 yr by RyanC

new powder coated brake disc backing plates with stainless bolts.

striped down the wiper linkage got the bracket powder coated and painted the linkages and motor then re greased all the joints

then fitted it

put it off for to long so got the brakes sorted

stripped the callipers down so I could get them powder coated girling 54 fronts for the 256 audi setup and mk4 golf rears

Back from the coaters they look mint!

cleaned the paint off the rear callipers where the banjo fitting seals seats.

so got cracking building the callipers all new seal kits pistons were fine just needed a clean up.

rears more complex than fronts being handbrake callipers but not to bad really with the right type of cir-clip pliers it make it a lot easier!

Done! Look good as new, used proper red grease to rebuild them makes it much easier and less mess the just using brake fluid.

New bleed nipples too.

carrier sliders cleaned and painted

front coated carriers on, new gen lock bolts. new slider boots.

same with rears.

expensive brake pads! but lots of good reviews, a lot of the g40 lads use the ferodo pads

Such a clean build, totally love it!

front callipers on, flexi hoses for the fronts are wrong sorted that and got the right ones.

nice red ones ha

rears..

Had to make two brake pipes to join the polo flexi hose to the mk4 flexi hose both hel brained lines too!

Handbrake nearly sorted just need to put it together and then bleed up the system!

Edited 16 October, 201510 yr by RyanC

rear strut brace I made years ago! finally fitted haha

Washer jets and new pipe work, need to sort out washer bottle yet so left it at that.

Front sound proofing in and foot rest thing.

completely stripped the heater box unit in two and cleaned it up. it was disgusting! new foam seals as well haha. I must be mad going this far into it

Same with the heater fan unit. new heater matrix and butyl sealant where the inside box and fan unit meet. sfs hoses on with new spring clamps

Edited 18 October, 201510 yr by RyanC

Got the windows in the doors. powder coated centre rail between both windows all mk2 seals as I'm using mk2 door cards and trim.

Stripped the wing mirrors and got the arms powder coated the rebuilt them too now all fitted.

All door handles on with mk2 chrome plates, I think they look better than black plastic ones that use to be on there.

Starting to look like a car again now :)

Edited 16 October, 201510 yr by RyanC

Ohhh very nnice!!!! :)

Thanks Mark :).

I am missing a few photos but really hard to remember to take photos then you get stuck in.

We are getting there finally. I've only owned the car 4 years haha. Drove the thing about 15 yards!

More to come soon!

Some stunning attention to detail and it's going to look amazing when it is finished.

This makes my own project seem so insignificant [emoji23]

Looks like I could eat my dinner off any part of this car it's that clean

Blimey.

I had no issue spending half hour with a mug of coffee reading this thread from start to finish. Inspirational stuff. Makes me want to start my car all over again to work to your standard!

By far one of the best builds I've seen for a long time, love the attention to detail! What a fantastic achievement so far...keep going!

Thanks for the comments 😊.

Few more bits done today. Heko wind deflectors fitted. I was a bit unsure about them before but seeing them on they look better than I thought!

Now the callipers are on I could get the hand brake connected up.

As I'm using golf rear callipers but polo cables the nipples on the end of the cables are not the right style for the lever on the calliper arm. So got hold of Pete again and he made me some stainless cable knarps so the cable would work without the chance of it pulling through the arm.

Cable adapters fitted, I had to cut them down 15mm to get them to fit because the cable was over adjusting the handbrake but after that it works perfect :) all the cable links and brackets have been powder coated btw just so you know 😂🙈

Ordering some p-clips to hold the cables up because as you can see 👆 they hang low, would be ok but rather they were tucked up neatly.

Edited 19 October, 201510 yr by RyanC

Few extra shots I took today.

Got all the suspension tightened up today aswell then got my wheels on

New genuine centre caps from Germany!

Found a bag in with the mountain of polo parts I have that had a full set of pretty much new genuine wheel bolts, still look gold from being plated from factory!

I'm happy with the colour, was a bit worried they might be to dark but I like them! Can always change them at a later date if I get bored.

Needs to go a bit lower yet. But while I'm still jacking it up etc it's better at that hight won't be a lot lower though, subframe is close enough already to the ground. I happy with the fitment too could put spacers on but I'd rather it handle well the have good fitment, sleeper ftw!

Day off tomorrow so more time to get stuff done!

So today I thought I would check all the locks work as it has been 4 years since they were used. Both doors were fine so greased up the barrels, but the boot lock was not. I managed to get it moving but wasn't unlocking with the key properly so had to take the boot plinth back off and remove the lock. I don't have a clue why I didn't check it before I fitted it but oh well. Anyway stripped to lock down and pulled the pins and micro springs out and soaked it all in WD40 the barrel was corroded so it was just holding the pins in all the time.

Put it back together after removing all the corrosion from the barrel, works spot on now.

Then dug out the looms....

Yeah... What a mess! I forgot what a state it was! All the tape was covered in oil and was just soaked all over with oil!

Anyway got it laid out and when its all spread out there is nothing to it! Working on BMW's everyday with massive looms makes you realise how simple polos really are!

Got the wiring diagrams out and started going over all the looms making sure there was no high resistances it the cables all seems fine but part of the loom are just messed up!

Lots of these!

Also part of the main dash loom has been cut then re-attached but some of the loom has quite thick wires from the ingnition switch and they have just attached them back together with smaller amp profile wire... Not good, so need to repair a lot of the loom with the right size wire. Lucky I have a spare mk2 loom from my old bready I can take bits from.

That's all I did today working out what I need to repair and checking the resistance took most the day.

Got my work cut out with this. Need to order my battery cable also as battery is now in the boot.

Edited 19 October, 201510 yr by RyanC

I thoroughly enjoyed reading all of this. Unbelievable work!!!

Can't wait to see the finished product!

Had work this morning so not a lot done today really.

In the week I ordered two new earth straps. One for the chassis leg to engine mount and one for the coil to gearbox mount. Bonnet Earth strap was in okay condition so I kept that.

New ones I ordered are custom made so measured the old ones so they would be the same.

Treated myself to a soldering iron today as I needed one for work anyway. Thought I'd solder the ends of the straps.

All three straps got new heat shirnk!

Then got them fitted!

The gearbox mount I had to remove as it wasn't earthing on the gearbox because of the coating on the mount, so removed the paint from the flange area so it can earth out on the box.

All sorted! Hopefully will start on the loom tomorrow.

Edited 24 October, 201510 yr by RyanC

Where did you get them made? Whats the measurements for all 3. I need to do this

Looking fantastic sir. A real testament to your years of hard work.

Looking good dude! Can't wait till it's finished!

Looks really good Ryan!, I need to do that with my boot lock as mines stuck open. Good to see another G looking good!

Thanks guys

Kiran, there off eBay a guy makes them as you order. Bonnet one is 280mm, coil one is 300mm and engine earth is 180mm.

Few more bits done last week.

New seal for the tank sender inspection cover

Rear lamp loom checked and re-wrapped.

Boot door card back on.

Then loom running front to rear fitted after checking it and wrapping it.

Now the bigger looms need sorting! Won't be as bad as I thought. Ordered battery cable to run front to rear and connectors, junction box etc after working out what size cable to use and how I'm going to set it up but all sorted now. Bought proper unisulated crimp terminals too to look OEM.

Chip also ordered from PPP. Need to work out where I'm going to put the water/meth injection tank too.