Air intake and throttle ect removed

Bike carbs and manifold fitted

I took the first steps to doing my bike carb conversion today, i removed the:

dome air intake unit

inlet manifold and gasket

throttle body

ignition coil

distributor

removed water hoses from inlet manifold to thermostat housing

un-clipped the throttle cable

I fitted the vacuum advanced dizzy

I was going to use hose and join the feed and return on the thermostat housing, but it kinked to much for my liking, so i will be using hose blanking plugs like i did with the feed and return to the expansion tank when i removed that. I have ordered them today and also purchased a cone air filter like on my carbs, for the hose that feeds air into the bottom end of the engine down the back.

2x 20mm blanking plugs off ebay £9.50

1x cone air filter 35mm off ebay £3.65

I am waiting on my new jack to come, as soon as it is here i will be doing the fuel lines ect.

I just placed my carbs in there to see how they looked, and pretty good i reckon ha. I haven't bolted them in as i am off to a nut and bolt place tomorrow. i will be taking in all the nuts and bolts from the inlet manifold and getting new replacements, they will also need to be shorter as the flange on my new manifold is 10mm but on the old manifold it was much thicker on the bottom row of Allen key bolts. Also getting new distributor bolts and coil pack bolts, these will need to be much shorter as they now dont need to pass through the entire coil pack, as i will be using the wet coil and it mounts differently.

Edited 24 June, 201313 yr by dart_strife

you dont need any special bolts. halfords sell the bolts you need for the inlet, there just M8 allen head bolts lol

might be a wire earthing somewhere causing fault with the washer? i'm thinking off kicking mine into the boot too.

although i dont like multi-coloured engine bays, yours does look nice and clean!

super

When i was working on my car today i noticed a fuse had blown, i will replace it and see iff the washer jet will then work with the new pump, maybe it needs a higher voltage fuse, it was a white one i had in there. I looked at the but connectors were i joined the wire, and they looked solid, and they would not pull apart at all.

you dont need any special bolts. halfords sell the bolts you need for the inlet, there just M8 allen head bolts lol

i didn't think of Halford's haha, just thought of the place in town were they match them up over the counter. the four bottom ones do need to be shorter than the originals though don't they, as the old manifold is like a wedge shape to make it level when it meets the back of the engine.

yeah if u pop to halfords just pick up 2 sets of them, think theres 3 or 4 in each. find someone with a trade card if you can!

if any of your friends work in engineering though they could probably sort you with everything

yeah if u pop to halfords just pick up 2 sets of them, think theres 3 or 4 in each. find someone with a trade card if you can!

if any of your friends work in engineering though they could probably sort you with everything

I know , halfords are expensive lol , look at my other topic too bud on new posts plz

must be someone you know with access to stuff like bolts ect though. if you were nearer london i could have sorted u out. i get all my new bolts from work hah.

i saw it, i didnt answer as i dont know for sure.

- the rear stickers I love it :) well done!

- the rear stickers I love it :) well done!

cheers buddy, more to come.

Remaining new bolts needed for the conversion

Accelerator cable

Finally my last parts have started arriving to finish my bike carb conversion, accelerator cable has arrived, so i can determine were i need to drill in the engine bay to give it a more direct route to the pedal since my carbs are centre pull, and i went ang got replacement bolts for the inlet manifold, wet coil and distributor.

Edited 24 June, 201313 yr by dart_strife

oil breather hose and filter

Couple more bits arrived today, i am now ready to get under the car when it stops raining haha

Bottom end engine breather hose and filter

New jack !!!

Edited 24 June, 201313 yr by dart_strife

should have got allen headed bolts like i said...

you will probably have issues with those...

should have got allen headed bolts like i said...

you will probably have issues with those...

I was in B&Q so got a couple of bags of bolts for cheap , the only reason I have them really , I did think that , iff I have issues I will get Allen bolts . Also just had a PM from cymro regarding a catch tank , the air filter will do untill I have one sorted one :-)

Good progress here. What colour have you sprayed your engine? Looks similar to mine

Good progress here. What colour have you sprayed your engine? Looks similar to mine

Yes i guess it does bud, VHT high temperature engine enamel (SP135 GM BLUE).

powder coated silver rocker cover

powder coated rear strut brace

powdercoated vauxhall brake callipers

powdercoated hockenheim wheel

powdercoated hockenheim wheels

I went to Pontefract today and picked up my powder coated bits !! they have all come up brilliant, wheel lips are perfect too .

Powder coated :

Gloss black rear strut brace

Gold callipers and carriers off a Vauxhall Astra GTE 256x20mm

Silver rocker cover

Cream 13s Hockenheim alloy wheels

Edited 24 June, 201313 yr by dart_strife

Get them onto a photobucket account mate! :)

Get them onto a photobucket account mate! :)

cheers buddy, guess i have run out of space on this thread for images ?

Fuel line return hose cut and blanked

carbon canistor removed and cut back under car

AAU inline pump and fuel filter under the car

Fuel accumulator pulled down showing fuel lines

Fuel line accumulator showing hose joining the pump

Return line removed

Managed to take advantage of the weather today and get some more of the conversion done:

Fitted the bike carbs / manifold / air filters fitted

Servo pipe attached

Hose with air filter on for the oil breather fitted

Wet coil with MK2 loom attached / still need to add the lighting loom wires

Removed the AAU ECU and mount

Fitted the MK2 loom

Removed the return fuel hose and blanked it off after the accumulator

Removed the charcoal canister and hose as far back as the petrol tank ( will be left as a breather at the rear of the car )

Silver rocker cover fitted

Hopefully if the weather is good tomorrow i will be able to remove the in-line fuel pump and join the feed hose to the accumulator

Fit the bike pump

Extend the wiring loom in places :

Gear box connector

Lighting loom to wet coil

Bike pump wires to 12v feed and battery negative

Fit choke cable

Fit accelerator cable

I need to know what wire i can use to extend my loom wires, as i bought some wire, extended my washer bottle loom to the boot, used it and it blew the fuse, wire not good enough ?

Edited 24 June, 201313 yr by dart_strife

should have got allen headed bolts like i said...

you will probably have issues with those...

I was in B&Q so got a couple of bags of bolts for cheap , the only reason I have them really , I did think that , iff I have issues I will get Allen bolts . Also just had a PM from cymro regarding a catch tank , the air filter will do untill I have one sorted one :-)

I did have issues with them bolts lol, i had to got to Halford's and get eight M8 25mm Allen head bolts, £18 !! i removed the two studs from the back of the head to be able to fit two of them.

2 20mm blanking plugs

Chrome handle choke cable

These are the 20mm blanking hose plugs i have used to blank off the two coolant hoses on my thermostat housing which went to the old inlet manifold.

And also my chrome handle choke cable has come, just waiting on the fuel cut off inertia switch now.

I never actually used this choke cable, ended up breaking when trimming it down, i used a typical black one off ebay which can be bought for £6. Picture further down the thread, so word of warning, dont trim them down lol.

Edited 24 June, 201313 yr by dart_strife

Looks Like its coming along well :-D

hose used to replace the inline pump

Cheers bud , all ways nice to get some appreciation for the polo. I keep looking at the pic of my engine bay on my phone , I think its looking mint lol , just waiting on the custom exhaust manifold now .

A little more progress yesterday , I removed the inline pump and replaced it with this piece of hose, I cut it from the return line which you don't need when you use a bike pump. You just then need two hose joiners ,8-8 mm 8-10 mm and 4 hose clips , I have ordered a 8-10 mm one off eBay as I was misinformed and bought a 6-8 mm one .

With the wiring in the engine bay , I have been told as long as you use wire the same thickness , or thicker then your good . So I went to B&Q and bought 10m of 6mm2 single wire for £15, just need to cut two pieces for each wire I extend, when crimping them together I realised my spade and but connectors were to small for the thick wire haha , so ordered some yellow ones off eBay too which are for wire thicknesses 4-6mm2.

The reason I bought 6mm2 wire is because I looked in the Haynes manual at the wiring diagrams to see what was the thickest wire used , and it ranged from 0.5 - 6 , so just went with the thickest.

Edited 24 June, 201313 yr by dart_strife

inertia switch

fuel pump and filter bracket

The fuel cut off inertia switch came today, cheers stinky pete, will wire it into the positive wire on the bike pump this week.

The bracket under the rear of the car which holds the fuel filter, pump and accumulator is off to the powder coaters to be done black. Since i am now keeping the accumulator and filter i may as well sort it out while it is down.

And i took an old cast iron exhaust manifold and my stainless steal flanges to a friend of mine tonight, he will be making my stainless steel manifold, should take no longer than a week.

I am also having my accelerator pedal modified, the bar which the old accelerator cable joins needs to be made longer with 10mm thick bar and a series of holes drilled in it so i can fix my accelerator cable to the pedal. With my carbs being centre pull, I'm needing to drill new holes from the engine bay through to the pedal area of the foot well to get a direct line for the cable, the bar needs to be made longer so it will all meet up nicely.

Edited 24 June, 201313 yr by dart_strife

inline pump removed and replaced with hose

fuel filter and accumulator mounted

More progress today ...... when i should be revising ha ha.

Wired in the bike fuel pump to an extent / need to find a 12v ignition feed / i have earthed the black wire to the car chassis ( i have fixed it behind the fire wall )

wired in the fuel cut off inertia switch ( fixed behind fire wall )

Finished extending the looms mentioned above as my crimps came today for the thicker wire ( gear box loom / light loom wires to the coil pack / extended bike pump wires )

Finished replacing the in-line fuel pump with fuel hose and hose joiners / temporarily tie wrapped it in place until the bracket is powder coated

Drilled a hole in the engine bay through to the pedal foot well, waiting on modified accelerator pedal

I have ordered some quality fuel hose from Ebay, 8mm internal diameter so i can join the feed to the fuel pump,then the fuel pump to the bike carbs.

More pictures to follow

Edited 24 June, 201313 yr by dart_strife