Hey Everybody,

I've decided to make a build thread as work is about to start on my car, plans so far are to put in the 1.6 AFH, Upgrade the brakes and suspension and fit some 14" wheels.

Hope you enjoy.

I've been building up this engine and collecting bits for a while now and it's finally ready to be taken to the unit and fitted to the car.

The cars current spec is MK3 Polo Fox, 1 Litre engine, 4 Speed box, its pretty much standard except from a set of ATS Classics, Lowering springs on the front and adjustable shocks on the back currently rocking out the anti rake with the adjustable shocks all the way down and it also has a GT Exhaust System from Cat back.

Here's some picture from so far on.

Here it is need to remove the rest of my splitter and find a new one, believe it is from a MK3 Golf

Going to be running a set of CBR600 Carbs, manifold was made by phataz on here and i got it anodised red

All my other bits, Alternator, Fuel Pump, Filter ect ect

More Updates Coming Soon Engine Should Be In End Of The Weeks

Peace Guys

Edited 6 February, 201313 yr by forbes-1234

Ooooosh! aruns makes some awsome manis!

Keeping tabs on this thread

That is a mk3 golf CL splitter too :)

Yeah man he's mint at making them, gives a really professional finish and whole round job.

Would recommend him to anyone wanting a mani.

Looking great mate you have any problems with the AFH AVY Hybrid?

Nothing that big mate, but its not in the car yet might come across a few problems when fitting it, but hopefully things go smoothly.

At first i tried timing it up without the rocker cover on and i found it hard to get the timing right but once the cover was on it was so much easier to line up the dots and i did it first time.

Looking at the pictures now though i kinda wish i'd polish or painted the gearbox but ohh well i'd rather just get it in the car.

Ah i see should be sweet dont you need vernier pulleys to time up the engine correctly? Is i remember reading through the thread on the Hybrid conversion but wasnt sure on what timing marks where used. Also what sort of power you after?

Don't think that vernier pulleys are a must but someone please tell me if i am wrong.

They are defo something i am thinking about for the future i have a spare set of cams with no pulleys so might get those ones re-ground (think piper do it for around £270).

Power i have no idea about standard gti engine is 125bhp so with a 4-2-1 bike carbs properly set up i'm probably looking at around 135bhp maybe a little more, it will be quick enough anyway especially for now as the brakes are standard and the ride quality is terrible.

Brakes and suspension will be the next thing after the engine then maybe more power, would like to use some itbs and omex but its stupid money and i'd probably want to move onto something with a little boost maybe a g40 turbo but thats years asway yet.

Oh My God

Got everything moved to the unit tonight, getting my car in tomorrow and getting the 1 Litre lump stripped out and getting the bay cleaned up.

More pictures soon.

Got alot of work done over the past few days, stripped the old engine out and cleaned up the bay a bit.

Got the new engine and gearbox in mechanically just need to fit my alternator, exhaust manifold and make a de cat pipe.

Then its down to the wiring, I've removed the ecu from the bay and have removed most of the ecu loom leaving wires from oil pressure switch, water temp, alternator ect

Need to remove my old fuel pump and filter and fit the new facet solid state pump, anyone know where is best to mount the new pump, nearer the fuel tank or the carbs? Also anyone know what relay is for the fuel pump is it the one with the fuse above it?

Going to upload some pictures when the engine is running along with a vid, should get the rest of the work done tomorrow.

Cheers Guys!

Right I started this a while back and completely forgot about it.

The engine has been in for a while now and i've sorted out most of the expected running in problems.

Booked in for a custon exhaust on the 15th of june, this should get it running better as my exhaust now is blowing like fuck and leaking were the manifold coupling is, so should get more back pressure for the carbs and the wont go out of sync as fast.

Need to fit my mk5 rad and fan unit aswell, get my spare afh cams reground by piper and fit them with some vernier pulleys.

Brake and suspension upgrade after that.

Need to tidy up the back a bit aswell and sort the wiring out so fuel and ignition is off a ignition switched relay instead of dash switches but i'm being lazy and working too much atm to get anything done.

But yeah really happy with it and it goes like fuck!!

Edited 25 May, 201214 yr by forbes-1234

Need to sort this out and the dent on the rear quarter, its only getting worse and worse.

The dent was there when i bought it and i think the rust had been cover up with a quick layer of paint before i got there.

Shot from the rear

Need to get rid of the reverse rake aswell

You'll probably see around 140-145hp mate :)

Maybe once the cams are in and its been tuned properly, still dont know if i wanna spend the money and take it to bogg brothers and get the carbs tuning or put it on injection

Still in two minds

Also need a needle kit for the carbs and the needles that are in there now are not adustable

someone has 153hp with cams and carbs mate :)

Also, mine arnt adjustable but I use shims to raise/lower them :)

Didnt even think of that did, how thick are the shims you use?

Did you make them yourself? I'm guessing washers are too thick?

My carbs are running pretty rich atm with 155 jets and pilot air screw out about 2 3/4, gonna put the 150's back in and wind screws out a bit more.

Some days they run well better than others when there is a bit of moisture in the air and its denser its much better but when its sunny and hot like this not so good, just gotta get the balance right i suppose and thats whats better about injection, you dont have to mess around so much

Carbs are a compromise, you can set them good but never as good as EFI.

I used small washers, their thickness is less than that of the distance between grooves on adjustable ones lol.

Yeah carbs are good for just getting an engine running straight away with minimal wiring, and they sound mint just a tad unreliable compared to efi. Fuel economy almost goes out the window if you they arent set up too well.

Think ill most definately switch to efi at some point.

Maybe an eaton with megasquirt in the future too, just dont wanna pay from forged internals

I think i have a set of those carbs in the shed somewhere, yours for free if you want them mate. Think they had a leak somewhere on the casing but they will be good for spares

Cheers dude, can meet up some time and admire cars lol

Got the car booked into jp exhaust in macc for the 15 of june so it should run much better then and i wont be as scared of taking to far from my house , always thinking something is gonna go wrong and i'll be stranded didnt even dare drive it to all types last weekend

The G's bottom end properly buggered then?

Edited 27 May, 201214 yr by forbes-1234

I'm guessing yes just need to find/buy a headbolt tool then i can see whats what.

Where about do you live btw

Right a quick little update,

Had to postpone the exhaust fitting untill the 2nd junly

Plan on taking the carbs off and fitting the gti inlet manifold, afh throttle body, gti injectors and megasquirt injection ecu, fancy having a go at a bit of tuning and megasquirt seems perfect for the price

Also got my eyes on some parts for the engines future including rods and pistons to bring the cr down to 8:1

Unsure on what type of forced induction yet but it will probably be an eaton maybe a turbo unsure yet

Also been tidying the bays wiring up and pump the fuel and ignition on a relay instead of dash switches, hiding wires ect it looks much nicer now

More pictures soon

Edited 11 June, 201214 yr by forbes-1234

Bits have started arriving for injection conversion

Wideband lambda sensor

New coil pack

Adjustable injection fuel regulator

Waiting on fuel rail and dizzy body to come back from anodizing

Injection pump and megasquirt ecu are in the post should be here soon and get it all fitted at the weekend

Then its down to the long task of tuning the engine hopefully all goes well!

Also got some cams coming from piper from having a re grind and getting some adjustable pulleys

No way, that looks amazing! I was a bit worried when you said you were getting it anodised because I'd previously read that the grade of alloy I'd used to weld it together turns grey when anodised?

Looks fucking superb though, must have been a load of bollocks that I read

Brilliant work aside from that anyway Russell

Yeah its a shame I dont want carbs anymore the anodize gives a nice finish to the engine bay.

Manifold is going to a one of my mate now anyway so if i ever change my mind i may be able to get it back lol.

Most alloys are fine to anodize, its only when it has been cast that it goes a horrible grey colour due to the silicon and other elements added to aid casting. Just chanced anodizing my fuel rail but it came out soo shit and grey spoke to the guy that does it and he said try polishing up the surface really well then send it back.

You can see a little bit grey on the welds but this rubbed off and left a nice red underneth. If you want anything doing give me a shout.