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Kerm(it) Mk2f Coupe (Rebuilding + porting engine)

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Looks great mate I'm already getting ideas for mine thanks

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  • Ill pick your brains on them mods once I've got mine back together, K. I know the head rebuild isnt easy, just interested in what actuqlly goes into it :) Good luck anyway

  • v-dub-ee-dan
    v-dub-ee-dan

    Been quite a while since I last updated this thread. I'm in the process of uploading pics and writing quite a bit of things that I've done to her and things that will be coming. Some bad time and some

  • Author

cheers lads it was on 175/60/13s on the rears on that pic but they used to catch the outer arch the front were 155/55/13 on the steels. Its on fk -65mm rears and -45mm fronts

shes on 165/55/13s now i think and they dont catch anymore.

Heres a few more recent pics of my mirror shine :)

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And the best

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thanks for looking peeps

  • 1 month later...
  • Author

Well been a fun month :/ original engine decided to blow its head gasket again after one year! so instead of paying a huge amount in getting it re done again... we took a trip to Bradford to pick up another 1.0l and within 3 days it was in and running :)

Now I know you are probably scratching your heads now thinking why didnt you stick a 1.3/GT lump in? And the answer... its been done soo many times and you just arnt seeing original 1.0ltrs anymore so I decided to keep it a 1.0l lol

will get pics up of the swap soon

ALSO...........

I am wanting to swap my alloys for something else? what do you have? I'm really after some weller steels :D

  • 3 months later...
  • Author

CAM00798_zps0aa6448d.jpg

After alot of swearing CAM00800_zps3d4d9ebd.jpg

It was at this point I was tempted to sell the dam thing haha glad I didnt though :)

Looking forword to what this year holds however since my backbox ended up in a ditch already I'm not sure anymore haha o well just means more updates. Happy new year again peeps!

  • 2 months later...
  • Author

So with the new engine running well and mods going slowly I've decided to mess about with the original engine and see if I can get anymore power out of it.

yes I know it would be easier to get a gt motor however this is just sat 10ft away from me lol

Anyway stripped the head off and christ its been burning a sh*t ton of oil. I've never seen one so ruff but anyway the bores are fine no pitting or egg shaping so piston rings are fine, took the cam and followers out and you can see light through 2 of the valve seals so thats were its been pumping it in.

Plans are to fully clean everything so like new then port the inlet amd exhaust so it will match the 1.3 inlet mani and exhaust then get it skimmed and painted. Need to find a gt cam and start getting final bits for the carbs them slowly build it back up from bottom to top with new bearings and seals and see what power you can actualy gain from doing it.

This is more of a exprament than anything else tbh I know i wont gain much but its worth finding out. Ill get pics up of what I've got done so far up soon. watch this space...

Good to see. I'm wanting to go down this route too. Would be more impressed with myself for tuning a 1.0 rather than replacing with a 1.3 for similar power.

I'm also in the same situation of doing the head gasket. Mine didn't blow though and the original engine is still in use.

How do you actually do the valve seals? I've read a little bit about grinding them back to improve combustion but I wouldn't know where to start.
A step by step rebuild of the head in pictures would be good.
  • Author

On removing the valve seals I'm not quite sure ill be asking a profesional for their tips but once i know I shall let you know via this :) I've been wanting to do it for a while now for the same reason tbh and ill keep taking pictures as I'm going along bud I'm on porting the inlet atm and its going to be a lengthy process but the results will hopefull pay :) if not well no harm atleast people can see what can or carnt be done with a 1.0l lol

  • Author

Oh sorry with valve seals use a grinding paste with a valve lapping tool bud its my valve stem seals that have fooked but ill be lapping mine in also near the end of the build

Nice clean little coupe, I'm impressed :)

Sits just right and the colour really sets it off.

My first Polo was a little Mk3 1043cc coupe, mine got modded with a 1.3inlet, throttle body and injector, GT cam and I straight piped the exhaust. Played about with the ignition timing a bit too and it was nippy for a little 1.0.

It blew up before I had the chance to get it on the rollers though.

Good luck with the new engine and up and coming mods.

Ill pick your brains on them mods once I've got mine back together, K.

I know the head rebuild isnt easy, just interested in what actuqlly goes into it :)

Good luck anyway

  • 2 weeks later...
  • Author

so heres some pics as progress is slow atm.

heres is what I saw when I first took the head off :/

some very burnt oily piston heads...

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and the very clean one that had been leaking lol

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However on closer inspection the piston liners themselves are clean with hardly any lip near the top or and scoring. also the pistions themselves have no play making me think the rings are fine (further inspection says yes they are all ok)

so here is the head.. as you can see its been burning ALOT of oil before it died. Reason for this is the valve stem seals are well (best way to describe) slacker than a sluts lips.. You can decide on which ones lol they are screwed!

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as you can see they are BLACK and soooo oily :(

anyway after a clean up...

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they look ok still but as for the surface of the head.. well it looks like its been skimmed by a rusty axe. Its awefull. I took it to my local skimming place and they were horrified at the state of the skim. We came to the two possible answers to why it blew the gasket so soon.

1. The steve wounder skim job

2. This..

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as you maybe able to see the water jacket has corroded and was quite close to the headgasket seal, mate this to the second rate gasket (honestly looked like it was made from tissue) did not help the situation lol

however they assured me with a good gasket it would be fine after a discounted price skim as he was that appalled by last one so all is ok to continue :D

I've been looking for a cheaper long collet spring compressor but to no avail so I started cleaning the valve heads.

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Under all of that build up they look new! however they all have not been seated properly :x there is about 2cm on each one that has actually seated against the head on every one of them so the gasses have just been pissing back through :( however that will get sorted later on with the help of mr lapping tool lol

So took the cam out next and its unmarked! its ridiculously clean. however i took out the tappets and got ALL of the watery brown oil out of them and got to cleaning them up..

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they clean up well and again look serviceable again, they were very quiet when the engine was running well.

NOW the good bits :)

as you can see the gasket on the 1.0 head is miles away from the ports

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so all of that is coming out :) I've started one and its about half done. I'm porting it all the way to the valve seat and tapering it around the valve stem seal to smooth the airflow. Also going to open up the exhaust ports but these wont have to be so neatly done.

shall get pics of this as I go along but its going to open them up loads! should be interesting so see how much it improves airflow once its all done.

However I got sick of breathing in alloy so I decided to paint the head now lol

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soo stick around to see more progress soon peeps :)

Edited by v-dub-ee-dan

Yes to this. Looking good, interested to see what else you do.

  • 1 year later...
  • Author

Been quite a while since I last updated this thread. I'm in the process of uploading pics and writing quite a bit of things that I've done to her and things that will be coming. Some bad time and some awesome ones to follow. :D

  • 1 year later...
  • Author

June 2015... my last post. The polo has had a lot of work since then and a lot of new parts thrown at her including more lows and new rims. Really need to get this build thread back up and running again. I will in the coming weeks get all the pics uploaded and start writing the massive update on what's been happening. 

Looking forward to seing the update :) 

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