Ryan the level of detail is amazing.

I saw this car what 18 months ago sitting in your garage? I cant believe how many hours you have put in on it.

Would be great to see it when its done. Will you be going to the Polo social in the summer?

PS. your old engine and bike carb set up is running beautifully.

This is truely an incredible build. you have the skills knowledge and attitiude that work very well. Keep it up

Thanks Guys,

Glad its all running now! Yeah was quite a while back. I'm aiming to make it to polo social yeah, if everything goes to plan haha.

So I had a week off work so got quite a bit done.. Never as much as i want to but most of the wiring is done.

While I remembered and managed to borrow the DTI gauge from work. I wanted to check my exact TDC and mark it on the crank pulley for reference when setting up ignition timing and vernier pulley. Found the d-well and set it in the middle.

mark on left and right 5deg before and after TDC.

The pulley mark is well out from standard but it is off a different engine.

Plugs in BPR8EIX NGK plugs and fitted the Magnecor KV85 8.5mm leads.

Got a carbon weave effect filler cap because why not ha.

Reconditioned Volvo T5 310cc injectors ready to fit.

Rail cleaned and injector loom wrapped

Injectors in rail.

All fitted.

Started on the throttle body cleaning it up and fitting a Boost switch and removing the what switch.

Took the what switch off.

Drilled a hole in the side plate to fit the switch.

Test fit.

Nylon washer to space it out so it do not move it the side plate.

Put that to one side for a bit and started on other stuff.

Little progress pic.

new little lock washers for the door check strap pins as the old ones were missing and the pins carried on coming out.

Got the battery tray fitted. Put some rubber of the bottom to help it sit more flat and seal of the bolt holes.

Made an aluminium plate as I didn't want the battery sitting on the 4 bolts holding the tray down.

Loom time... What a mess.

Didn't get that may pics of the repairs on the loom as I forgot really ha but here are a few. New temps sensor plugs loom cut, new wire put in with new terminals.

Same with the oil pressure sensors.

some of the loom repair work

All repaired. Took 4 whole days, a lot of head scratching and soldering. All solder repairs a double checked them to make sure they were good and checked resistance. Then heat shrink on all repairs no sticky horrible tape.

All looms rewrapped in cloth loom tape all circuits checked.

Then for the power supply. Using and junction box where the battery use to be to branch off of. M8 eyelets crimped with correct tool to the extended main loom. Then heat shrink.

Junction box fitted to the earth point.

Also drilled a 10mm hole in the old battery tray base so I can fit this tool to make a perfect 25mm hole.

One side on top and one underneath then just tighten it down.

One 25mm hole ready to fit a cable grommet for the battery cable.

Edited 6 December, 201510 yr by RyanC

Then got on with making the battery cables. Borrowed this awesome tool off a friend. Works spot on make everything look OEM.

One crimped end.

Same with the earth cable to battery.

Then all crimped ends soldered just because. BIG soldering iron needed to do this.

Then all heat shrinked

Main cable routed down the drivers side.

All connected to the junction box

P-clips using to secure battery cable to drivers side. Will get some pics soon.

Starter to alternator loom made. Old vs new.

New high temp loom cover like what is used from standard. Again all end crimped, soldered and heat shrunk.

Then made junction box to starter cable. Heat shrink used where it is close to body.

Both ready to fit.

No pics of them fitted yet but nothing special just replacing the old stuff.

Looms all back in. ECU mount re-zinc plated.

Stripped the Throttle body. I'm glad I did because the spindle bearings were full of flakes of aluminium from when it was machined to 51mm

Test fitted to check port match.

Boost switch soldered into old what switch wires.

all ready to fit, just need to set the switch to 6psi.

Motorbike fascia heat shield that i got for the tunnel and the bonnet where the turbo is. Foil tape around edges.

Tunnel all done too, got some more on the way for the tank.

Back to work now after a week off but in the week at work I painted the throttle body. So this weekend I put it back together. Bearings greased after cleaning all the flakes of aluminium out. New butterfly screws used thread locked and ends burred over just incase.

And fitted, new gaskets that I made from gasket paper.

NOS driveshaft heat shield

Dug out the PPP system, new gasket and stainless bolts for the flange.

Was going to use/make my own hangers for the rear section as they are good a snapping rubbers but decided if I get some powerflex poly hangers it should be fine.

Ant going nowhere!

Test fitted system, ready to down pipe to be made next weekend.

I remember seeing PPP systems on other cars hanging quite low. But seems to be tucked up quite nice. Will need to make a bend in the down pipe behind the sump as its so high in the tunnel. Result!

wow

Ryan, all credit to you but it looks like your Polo is going to be way beyond better than factory fresh by some margin!

Your going to need some magazine articles on this.

If this thing doesn't get in a magazine at some point I will eat my own jeans. The attention to detail is astounding.

It's almost a shame to drive it! Belongs as a centrepiece in a Polo museum.

If this thing doesn't get in a magazine at some point I will eat my own jeans. The attention to detail is astounding.

I'd pay to see that!! ;-P

Thanks for the kind words people! 🙈 I never planned on going this far with it but it sort of snowballed 😂.

It would be nice to get it in a magazine but I'll be using it a lot so I don't know how long it will look as clean as this for 😐 I will be taking lots of pictures when it's finished before I use it to remind me how shiny it was ha.

Few more little bits done.

Peter James ( with the 4wd bready in the making) has been a big help with a few little bits I've needed making. lots of little adapters etc. He made me this awesome turbo inlet adapter to fit a 3" intake pipe too. I just gave him all the measurements and how I wanted it to be etc. So happy with it! Better than a pipe reducer.

3 grub screws to hold it on. Internal diameter same as inlet of turbo to match.

Throttle cable grommet was dead so measured the hole a got a new grommet

Then fitted the cable

Wired in the uprated fuel pump

I put p-clips on both handbrake cables at the rear beam to hold them up as they hung quite low with the cable adapters, a lot neater now.

Powder coated lower brace fitted

Put heat shield on the fuel tank

Hand brake cable needs to be protected and secured yet.

Fitted both front door cards today.

Made new membrains to make them water tight.

Then got the black vinyl door cards on. As my seat colour has changed G40 door cards would look crap. Also always liked black vinyl mk2 doors cards. All mk2 trim fitted too.

Love the more retro look!

Edited 19 December, 201510 yr by RyanC

Ryan where did you get your new header tank from?

Nice work mate! Especially about the wiring, funny enough I've just messaged pete about making me a k03 airfilter adapter like yours 😂, if i was running the exhaust rubbers like you with that system id weld a bar inbetween the 2 hooks to stop them bending inwards 👍 But good luck, hopefully see you at polo social 👌

Edited 21 December, 201510 yr by Buxton

Header tank was from VW heritage about £15

Thanks man! Yeah wiring was a nightmare! Ha yeah Pete has done a few bits for me always spot on . I'll see how it goes seems pretty solid tbo, can always modify it if it dosnt work..

Will be there next year I hope

It's almost a shame to drive it! Belongs as a centrepiece in a Polo museum.

lol + 1

Header tank was from VW heritage about £15

Thanks man! Yeah wiring was a nightmare! Ha yeah Pete has done a few bits for me always spot on . I'll see how it goes seems pretty solid tbo, can always modify it if it dosnt work..

Will be there next year I hope

You don't happen to know what their part number was? as under Polo 75-94 there's nothing, cheers

You don't happen to know what their part number was? as under Polo 75-94 there's nothing, cheers

Have you looked on Vagcat ?

1H0121407A

I will try and update this next week, bit behind [emoji849]

I got so excited when your thread came up with your name too

I got so excited when your thread came up with your name too

werent the only one :D