You're my hero

Me too

Never felt so loved before! [emoji24][emoji954]

Looking really good mate!

i haven't long started my own coupe and this has literally blown my mind, the attention to detail, the engineering work and the dedication put in to this is second to none.

absolutely outstanding

you good sir deserve a beer

I'll never be good at updating this ah!

Anyway lots done.

Start where I left off I guess, so boss positions for the boost pipe I'm putting the intake air temp sensor in the elbow before the throttle. I was gonna put it in the inlet itself but I would have had to remove it and I didn't want to do that so elbow will do.

The just back from that on the boost pipe is my boss for the water/meth injector.

Then just back from that is the co-pot boss.

So that all done time to weld it up and see if it fits!

Boom! So happy with it, all the bosses I filed down on the inside of the pipe to help air flow.

So the two small lugs of the pipe are to secure the turbo coolant return line.

Brass t piece and hose finisher to connect into coolant circuit.

Mist injector fitted with check valve justify behind it to prevent vac draw

Intake temp sensor in intake elbow

Few little extra pics

From now one I kinda steamed through it and didn't take that may pics. But I'll put up what I have

Made a boot floor to give something to hold down the mist tanks and battery cable, plus makes it look a lot neater.

Recessed edges so the centre can sit flush and lift out to gain access to the spare wheel.

Rear bumper on[emoji41]

Hole drilled just by the battery for the battery vent pipe

Boot carpet fitted in place, wasn't cheap stuff

Yet another bay pic

Sent from my iPad using Tapatalk

Bit off topic but did a F10 M5 engine at work was like the size of my car!

All back in ready to go back to customer. £25000 in parts [emoji15]

Sent from my iPad using Tapatalk

Messy me ha

So shit loads of wiring done spent a good 3 days wiring in my Immobiliser, gauges, radio etc etc. Didn't get anywhere pics replay as I was so brain washed but it all at the time [emoji23][emoji849]

Main gauge set up in my DIY gauge pod that I got flocked

3 warning lights I'm wiring in. Amber is WOT indicator to tell me when the boost switch flicks on at 6psi

Green is water/meth pump activation and blue is water/meth low level warning

Dash in after being flocked and all wiring sorted.

Then it was just a case of building the car back up inside. Carpets, seats, belts etc.

Steering wheel is perfect [emoji7]

Before the carpet went in I put sound isolation around the interior as I had lots spare.

Seats in carpet in! All ready to be woken up for the first time in 5 years!!

Drivers view set up. Intake temp gauge fits nicely in the right spare switch blank.

Oh and then the dash come back out as I thought I had a wiring issue ha but it ending up being the ignition switch after some testing.

Spot the difference!

Only ignition switch didn't have terminal S at all so I had no radio power etc. That will explain some issues I had when I got the car.

I used the steering wheel boss of the old wheel that was fitted thinking it will be fine but I think it was an eBay special as it was awful and the horn contact ring rubbed on my nice new flocked

Coluom shroud and made a horrible noise, so spent more money you wouldn't believe and got a top quality mono one

Few little gay touches picked up these NOS mudflap badges ages ago for free and they fitted perfect on my floor mats!

Sweeeet! [emoji4]

Sent from my iPad using Tapatalk

So it all came down to this!

Filled the levels up, back filled the oil pump and filled the turbo oil feed so the turbo had oil flowing through it when it was first started.

Pumped oil through it until it came out the drain plug.

Filled it with 10w40 mineral running in oil and cranked it over without injectors or coil plugged in got oil pressure very quick so went on and started it up...

https://vimeo.com/181311785

Excuse my mum ha parents wanted to be there to see first start up.

https://vimeo.com/181311920

Bedding in the cam first with rpm at 2000 for 15 mins

then went of a quick spin[emoji16]

My face [emoji38]

Sent from my iPhone using Tapatalk

Got the tracking straight. Will be obviously doing proper laser 4 wheel alignment at work when it's all run in and ready.

MOTed that week! Got to keep an eye on it while working too [emoji23]

Took it home that night. Few issues that I'll explain later

Needs a good clean but still was nice to see it outside!

Sent from my iPhone using Tapatalk

Anyway all fun stop very quick 75 miles to be exact

The clutch isn't man enough at all as soon as you hit boost the clutch slips and it just try's to redline.. So box came out to find this [emoji24]

Killed the flywheel on its way to. Tried to skim the flywheel but the heat marks are so hard it's just got raised parts all over it so will judder with a paddle. If I was using another organic I think it would be okay but oh well

Boo. So more money for a paddle clutch and new flywheel so they are on there way.

Because of all the mods I've done it was quite a long task taking the box out, but it had to be done.

And dash came out AGAIN because the flock had flacked in the lower pocket. So sent that back to be re-done.. [emoji35]

And to top it of my exhaust mount melted

Bit foolish of me really I knew it touching the pipe but didn't think anything of it.

New hanger design for the centre needed now.

Car runs lean before boost and on idle to so need to have a play with that as well.

But hey I guess that's the joys of it! It was never going to be perfect straight away but we are nearly there!

Polo social 17 is a deffo!

Just went retro rides last weekend was awesome!!! so will be doing the hill climb in it next year too!

Sent from my iPhone using Tapatalk

Some cool stuff at retro rides.

Sent from my iPhone using Tapatalk

wake up on my birthday to see this updated, best birthday ever. it all looks amazing great work mate

I was so sad not to get to see this beauty at retro rides! Luckly we had the dolomite to entertain us. Might get the park my heap next to it next show season

So cool man!!

Sent from my iPhone using Tapatalk

Thanks guys! Just waiting on the flywheel. Then I can get on with getting things sorted again!

Sent from my iPhone using Tapatalk

Still waiting on the flywheel as they sent the wrong one [emoji849]. But got my dash back again after they re-flocked it

Few bits I've got ready to fit

Got a quick fill tank for the water/meth. I'll try not to drill the hole to big this time ha!

Helix 4 paddle (good bye left leg in traffic)

Car looking sorry for itself a the moment [emoji20]

Hopefully I'll get the flywheel this week then I can get back on with it!

Sent from my iPad using Tapatalk

This is so smart

Great work

Very impressive (re-)building on that pretty "T"40!!

 

I had lot of questions during I read all pages today, but I should have note them... I missed all except one:

Why have you replace the switch on the throttle? What is this "pressure sensor" you install instead?

 

Many thanks to share all this good and interesting job with us! It give me some idea for my future work on my mk2 GT bike carb' AVY !!

What an awesome build!!! I must go on page one, and read all from the start. I like the photos too. 

I remember an other question!!

 

Can you please make a review of your Gaz-shock coilover? What's your mind about them? I'm realy interested on those coilover for my mk2 GT, but it's hard to find some review on Polo 86c... what about the height adjustment? the hardness adjustment?

 

Many thanks!

Quite a productive weekend.

I've given myself another list to go through. Just so everything is ready for next spring when it all begins again.

Got quite a lot of wiring to do again as I'm adding a few extra things in.

But hopefully this will sort most the things that were bugging me.

So after the nightmare with getting the flywheel, as the one they gave me was not the correct weight as advertised they sent me 3.5kg fly and I ordered a 2.9kg.

3.5kg was still light enough but that wasn't really the point. I wanted what I payed for.

So it turned up last week and wow is it light!

Flywheels are 5kg standard. My old lightened fly was 4kg I thought that was light this is 2.9! It stupid!

Also I'm very happy with the quality of it. Very well made. And it's been lightened in the correct places so it's not weakened.

So got on and fitted the fly and helix paddle

New flywheel bolts too obviously

Old vs new

Boom!

Clutch ready to go on next

All lined up and fitted

New LUK release bearing

Box ready, had to touch up a few areas were i caught it coming out.

Decided to get new bell housing bolts too as the old ones let the bay down a tad

Sorted! Clutch doesn't feel to stiff at all will wait and see what the bite is like though ha!

Started making a new injector loom to as the old one was a bit past it and had gone all hard.

All new crimps etc trying to make it just like the standard ones. I can't believe MaxRPM try to sell this for like €60 euros I think!

That's a far as I got with that will finish it next weekend. Just need to join them all together.

So got stuck in with the exhaust. So wanted to remove the centre box as it was rattling (the baffle was a bit loose and it was quite quiet so wouldn't hurt removing it)

Also need to design a new hanger for the centre as the old one was too close to the system and melted [emoji849]

So chopped the box out.

New section on.

Few tacks to hold it in place ready for my mate to TIG it for me.

The old box wasn't straight at the end so took a bit of adjusting to get it to fit. Plus gave me a chance to sit it even higher in the tunnel.

New hanger made, made it so it holds it nice and high and holds the system a lot better too. Sweet!!

Rubber much further away from the system and with the rod being long will dissipate heat better before it reaches the mount.

All for now!

Sent from my iPhone using Tapatalk

On 02/08/2015 at 20:01, RyanC said:

 

Also got a new old stock audi brake fluid cap as the sensor plug sits a lot lower that the polo ones so i can still use the level sensor as my strut brace is very low and fouled the polo cap.

 

 

 

 

Finally time to fit the fuel tank! New strainer and sender seal

 

 bolts.

 

 

 

 

 

 

@RyanC

Where did you get the new strainer and sender seal?