drivetrain really mate. well id probably buy a set of 5 pistons and rods, but then again id probably end up melting 2 pistons or something!

I've made an 020 box fit my afh easy enough just made an adapter plate and machined the bell housing

Shouldn't need custom driveshafts either as from what I measured the drive flanges are same distance apart as an 085 box

It would just need a new mount for the gbox at the front as the mount sits directly under the chassis rail so could mount directly to that and some of the sheet metal cut away for the box to poke through into wheel well a little

For the rear mount you would need to adapt the polo item and could probably sort of mix and match with the standard golf item to make a good strong mount

I haven't looked into the rear one yet but mine will be custom anyway

The later type 02* as fitted to so many post 90s VW's, including my mrs '02 Golf TDi, looks really short compared to the previous design with the rod clutch release mechanism. It was used in the 6-speed Lupo and they're not the widest car in the world, and a well known couple of 6n2's didn't need chassis legs chopped afaik.

There's an assumption that the chassis will need chopping up, but does anyone actually know it does..? (wife's out so i can't measure it atm)

You'd need the right cylinder block, being the iron Golf/Bora/Lupo 1.6 16v block if going for that deck height, or as Guy says the MK3 Golf 1.6 AEE block if going for AEE for the tall deck (yes it's an AEE, yes it takes the 02 box).

Chop chop:

http://www.polog40.co.uk/forum/index.php?topic=3343.0

That's a 6-speed from a Lupo, which are still shit...

Considerations for small block to big block gearbox swap:

Driveshafts (need to be golf inner splines, Polo outer splines)

Gearlinkage/shifter mech

Speedo Drive to clocks

Starter & ring gear (I think Sorg conversion retains 085 setup)

Clutch release bearing actuation - hydro/cable

PTO splines

Lots to consider, and lots of cost- it's £8k for elite racing tranmissions to make you a gucci box capable of 550Nm (6-spd Seq) that's worth chopping stuff about for!

Interesting thread:

http://www.clubgti.com/showthread.php?2464...ck-bolt-pattern

Worth e-mailing Sorg to see the true costs...

Guy- If I knew what I now know, I'd go 20v from the off, dry sump solves ground clearance, and bonnet scoops have been cool since MadMax Granted there's lots more engineering to be thought about, but I'm getting bored of replacing 085 boxes.

Will see what tinkering can be done over winter.

I suggested the diesel box in the Golf which may be the same unit but ours is a 5-speed, it's not gonna handle 500nm of torque but i don't know if Nick wants to run that much. It does handle smashing a turbo diesel through it with 205 tyres in a car weighing nearly 1.4 tons on a daily basis, so with the right clutch damping it should give Nick a bit more strength than an 085..?

How much effort to fit in that link?! If he'd have used the right block in the first place he wouldn't have needed to make an adaptor plate. You don't have to find a Lupo GTi lump, the Golf4 1.6 is the same and the gearbox on it is of course an 02*.

And doesn't that adaptor plate space the gearbox out further to the chassis leg?

Gearbox drive flanges - big and small are interchangable. I swapped a small pair for a big pair on an 02* Golf3 diesel gearbox to fit it into an Ibiza Cupra GTi as it had the bigger inner CV joints. Donor flanges were the original Cupra ones.

Couple of examples there where big money parts aren't needed - just knowing what to look for in a breakers. Handy when you start getting through them!

How much taller is the AEE block to a normal polo short block Mikey do you know

The AEE block is taller than the common height by the difference in stroke between the 1.4 and 1.6. I know this by fitting an AFH piston to an AEE and the crown sat precisely to the surface as they do in the AFH. Guy says the rods are the same length. The strokes are reputedly 75.6 & 86.9. That'll be 11.3mm then - i once said 'about 9mm' but that was from just looking at the two blocks though, i wasn't far off.

I said about 10, closer than you, does this mean I'm the new CP know it all? Hahaha

Didn't you say that after reading me write a couple of years ago that it was about 9 though..?

drivetrain really mate. well id probably buy a set of 5 pistons and rods, but then again id probably end up melting 2 pistons or something!

you wont melt a forged piston very easily! more likely to throw a rod and take the piston out that way. either way you dont want to have it smash itself as it could take all 4 out and cost hundreds as well as a new block.

this is going to sound like a shameless plug, but if you want a small block bigger capacity engine which isnt a g40 motor i have one in the classifieds. strong diesel crank, forged pistons and a 1.5ltr capacity

I suggested that to him Kiz as its well worth it and I'd have it if I could