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polo6n2g40

slow progress

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pohlohmadness

one word ollie legend

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Mattnaz

Great work as always Ollie. You probably have to give you some money soon when it comes to wiring my polo together...it'll all plug in but i bet it wont work :lol: ill chuck you some cash to come stay in a hotel and do it for me ;)

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polo6n2g40

well the ally welder rang me today, parts were done :nod:

also the start of the final list of parts started trickling through - manual boost controller as this management has no N75 valve

noz20vt41212001.jpg

barbed outlet for uprated pump

noz20vt41212002.jpg

but for the main event; T-piece

noz20vt41212003.jpg

inlet mani lug for cable

noz20vt41212004.jpg

turbo to FMIC boost pipe

noz20vt41212007.jpg

noz20vt41212006.jpg

8mm take off for actuator

noz20vt41212005.jpg

fitted up the inlet

noz20vt41212008.jpg

noz20vt41212009.jpg

trialed the boost pipe

noz20vt41212011.jpg

noz20vt41212012.jpg

noz20vt41212014.jpg

T piece for coldside DV

noz20vt41212013.jpg

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polo6n2g40

oh started it up too.

thanks for the comments chaps :-D

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Jake Ellis

Ahh Olly I'm so jealous of your car knowledge

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Frascano
Ahh Olly I'm so jealous of your car knowledge

Jakey boys in love <3

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Koop
a friend of mine asked me to put a 20v turbo in his mk2 golf gti 1.8 8V

Wish I had a friend like you :lol:

Nice work dude.

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polo6n2g40

haha thanks chaps :thumbsup:

looking forward to getting the last bits and the final fit and clean :unibrow:

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mikethebike

You'll have to record a video of it driving for us to watch :)

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polo6n2g40

hopefully most of the remaining parts will arrive today so can get it finished this weekend bar the down pipe that is on back order from Qpeng

more updates will follow this weekend :-D

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polo6n2g40

had more part to use that had come during the week

first up was the shifter tower 02j - 2001

mozmk220v81212001.jpg

'new' mk3 16v

mozmk220v81212002.jpg

new plastic linkage bracket

mozmk220v81212003.jpg

fitted

mozmk220v81212004.jpg

then was the water housing, the old one had died and the centre that locates the o ring crumbled away

mozmk220v81212005.jpg

mozmk220v81212007.jpg

a little more trimming on the fmic elbow for more clearance

mozmk220v81212008.jpg

fitted, just clears

mozmk220v81212009.jpg

mozmk220v81212010.jpg

mozmk220v81212011.jpg

the oil catch can mounting needed better fixing

mozmk220v81212012.jpg

i enlarged the hole to 9mm

mozmk220v81212013.jpg

and got my m6 rivnut

mozmk220v81212014.jpg

fitted

mozmk220v81212015.jpg

i fitted a second one and made a new bracket

mozmk220v81212023.jpg

mozmk220v81212024.jpg

mocked up the new run for the breather pipes but need to order some clips

mozmk220v81212017.jpg

mozmk220v81212018.jpg

mozmk220v81212019.jpg

mozmk220v81212020.jpg

mozmk220v81212021.jpg

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polo6n2g40

also made brake servo vac

mozmk220v81212027.jpg

mozmk220v81212025.jpg

mozmk220v81212026.jpg

packed away for the day

mozmk220v81212029.jpg

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damians1992

<3

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polo6n2g40

not a very productive weekend, rain cold and missing parts :-(

well DP arrived friday trial fitted bt no gasket :lol: so i text fitted bt there was a problem

nozmk220v161212002.jpg

nozmk220v161212003.jpg

obviously i'd rather the car had a full system to compliment the engine upgrade but it's not mine so i have to do the best with what i've got so assembled what bits i cold lay my hands on at short notice

nozmk220v161212004.jpg

nozmk220v161212005.jpg

nozmk220v161212007.jpg

nozmk220v161212008.jpg

nozmk220v161212009.jpg

nozmk220v161212010.jpg

when the DP comes back off to fit the gasket i'll put some slits in it and clamp up the centre section

other than that i've been making up loom sections to sort the little bits, temp sensor, rev counter, lambda loom and heated element, speed sensor loom and wired in the mk3 gti clocks. also started to tidy the dash loom but pics of soldering and wires are hardly worth taking pics of :-D

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polo6n2g40

been a while, been waiting on parts and weekends :lol:

got the gear linkage specific bolt / washer and nut

nozmk220v231212001.jpg

loom plugs for mk4 header tank level sensor / speed sensor and starter wire

nozmk220v231212005.jpg

and 'repair' wires

nozmk220v231212006.jpg

despite the weather decided i'd set about fitting the mk3 16v clocks to the mk2 dash

decided roughly where it needed to go, unfortunately the mk2 brackets were no good so made some new ones up from stainless

nozmk220v231212009.jpg

nozmk220v231212010.jpg

nozmk220v231212011.jpg

final 'cut'

nozmk220v231212012.jpg

the problem with the mk2 shroud is it covers parts of the mk3 warning lights and fuel and temp gauges

i cut grooves in the back

nozmk220v231212018.jpg

heated the plastic and flared the edges and pulled the bottom down

nozmk220v231212017.jpg

nozmk220v231212016.jpg

dash back in

nozmk220v231212019.jpg

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polo6n2g40

as it's christmas i thought i'd do some work

removed the last of the grime and waxoil off the drivers chassis leg and gave the bay a once over

P1020010.jpg

P1020013.jpg

then turned my attention to the 'new' centre console

P1020003.jpg

P1020004.jpg

i had the cut the window switch plate out and fix it into the new section

P1020002.jpg

P1020005.jpg

trim the front off the original console

P1020006.jpg

P1020008.jpg

drilled hole for cig lighter loom

P1020007.jpg

wired in the new boost / volt / oil gauges

P1020009.jpg

and made looms so an be unplugged individually

P1020016.jpg

P1020014.jpg

bolted the ecu to the tray under the glovebox so the serial port is accessable when it goes in for mapping

P1020019.jpg

P1020020.jpg

fitted the center console and wired in

P1020018.jpg

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polovr6man

Brilliant, TOP work there mate, can't wait to see it finished

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polo6n2g40

todays task was to tackle the alarm 'wiring' if it had been my car i would have ripped it out and started a fresh with a new system, this job was not on the to-do list from my friend but i honestly couldn't force that jungle of wires back up abouve the dash tray and been happy about it

loads of lovey cheap black tape

nozmk220vt261212002.jpg

and most wires had to or 3 joins and near enough all joins looked like this - all with black tape

nozmk220vt261212003.jpg

chopped out the joins and resoldered all and insulated with proper heat shrink tube

nozmk220vt261212006.jpg

nozmk220vt261212005.jpg

then bound the looms in fabric tape

nozmk220vt261212007.jpg

again de taped

nozmk220vt261212008.jpg

chopped wired to length, soldered, shrink tubed and taped. all bound ready to be fixed up out of the way

nozmk220vt261212009.jpg

secured

nozmk220vt261212010.jpg

removed all this

nozmk220vt261212011.jpg

just need access to 1 or 2 more wires then the tray can be refitted and screw the alarm port and program button in place

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polo6n2g40

thanks vr6man, shouldn't be too long, to do list is very short now :)

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MaxGT
thanks vr6man, shouldn't be too long, to do list is very short now :)

Awesome work dude, you really have a nack for doing this sort of thing,

Loved your old arosa!

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daveb142

Fantastic work and an interesting read! I like the fact you do things properly where most people cut corners! Keep up the good work :)

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polovr6man
Fantastic work and an interesting read! I like the fact you do things properly where most people cut corners! Keep up the good work :)

X2, my thoughts exactly

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polo6n2g40

thanks chaps, much appreciated :thumbsup:

well not many pics today, absolutely peed down all day. spent most of the day doing the niggly bits;

checked all nuts / bolts etc were tight

pressure bled brakes and clutch

drained and refreshed P/S fluid

put the dash under tray back together and column shroud

sorted out the brake light switch

dropped the down pipe back off to put some slits in it to clamp it to the centre section and fit new turbo - DP gasket

nozmk220v291212001.jpg

now the drivers side dash undertray was back on i could attatch the alarm port and MBC

nozmk220v291212002.jpg

it moved off the drive today under it's own power too, took it down the road - the tracking is a mile out and the splash guard was touching the disc, other than that the speedo wasn't working, double checked the wiring and checked the voltage on pin 1 + 3 and was getting 12v so is either speed sensor on the box or the clocks :(

couple of finishing bits left to do and fit some new arb links and should be all done :)

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polo6n2g40

as there's very little to do now i thought i'd tidy it up ready for the final parts

emptied all the old parts from the interior and gave it a good hoovering

nozmk220v301212003.jpg

nozmk220v301212007.jpg

then treated all the plastics

nozmk220v301212010.jpg

next was to give it a good jetwash in all the seals / shuts and wash n wax with meguirs

nozmk220v301212002.jpg

then treated all the plastics and rubbers

nozmk220v301212004.jpg

nozmk220v301212005.jpg

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polo6n2g40

before

mk220v101112002.jpg

after

P1020013.jpg

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