Haha totally!

So... whats going on. I've had to really start thinking with my head with a lot of stuff I'm doing with Huyi.

First off, I've fitted a 6n2 flywheel and starter motor. Huyi is going to be rather loaded down on the road trip and also there could be the chance that I'm going to be towing a trailer. So the heaver flywheel will help the engine keep momentum. Also as the starter is a standard part I can buy it off the shelf for £50 from anywhere.

Suspension choice has been a nightmare. I love the G40 dampers and the Eibach springs I currently run. But the dampers are getting old and I was hoping the H&R would be the one's to replace it. But if I'm honest I knew it wouldn't be as its just too low for the road trip I can't believe I'm saying that about a 60/40 kit!! But I'm glad that I've tried it.

So I started thinking a the Bilstein B12 kit which is their B8 dampers with the Eibach Pro 40mm springs. But they are about £400/500 quid and I would be gutted if they where still too firm which I think they could be.. :-/ So after days of searching for reviews about kits and ride quality I just cam across a post I made on here back in 2011. I stated that if I was buying suspension I would opt for Bilstein B4 dampers and the Eibach Pro spring. Which basically as close as I can get to the current setup. Plus its only £30 a damper!! :-D

If you're going to be towing a lot, have a think about changing to a gt/G40 back brake setup with the load adjusting bias valve. Otherwise if you’ve got a lot behind it, things can get a bit emotional if you have to brake hard.

Been there, done that!

I thought that all that does is. When the rear end is high/light/notloaded it reduces the pressure to the rear wheels. But when its loaded down/heavy it allows more pressure to the rear brakes.

I've got a mk4 golf rear disc setup and currently its over braked. Meaning if the rear end gets light the rears will lock. Which isn't great!

So with the weight of all our stuff and a trailer I would have thought it would be ok.. or am I wrong.??

The best way to run a trailer is with a bit of nose weight (no more than 50kg generally, but on a polo I'd want less) and a bit nose down, that way under braking it loads the back suspension of the car up. Also gives a braked trailer something to push against if you're going down that route.

Definitely sort your bias out though, locking up the back axle with a trailer on can get decidedly emotional. Did it once in a transit at 60 - it got the adrenaline going.

Huyi made it to Polo Social together with a back pack

Now there are about 3 weeks before the track day and 4 weeks till our 2nd European road trip.

In this time I have to swap the suspension to the new Bilstein B4 dampers and Eibach springs, change the thermostat, fit oil cooler, replace the clutch release bearing and maybe fit a rear brake regulator.

So straight after getting home on the sunday she was back up on axle stands and the exhaust manifold was removed so it can be sent for ceramic coating to help keep the under bonnet temps down.

I've removed the suspension and fitted the Eibach springs to the B4 dampers.

now you can see the new set-up ion the right compared to the G40 damper on the left. You can see the G40 damper is around 10-20mm shorter so it could be that it's sits higher with these on. That is a bit annoying however it could be a bit of a blessing on the road trip.

What sort of price is it for the coating mark? Was thinking the same for mine!

What sort of price is it for the coating mark? Was thinking the same for mine!

£200ish for the black finish which is suppose to be the best insulator. should be back next week :) hopefully :)

Engine came out today..



and split off the gearbox so I can swap out the bearing. Interesting to see a different design.

Also swapped out the 87c thermostat and fitted a 80c one :)

Started to think on how and where to mount the oil cooler

Sweet. Whos doing the coating mark?

http://www.camcoat.com/are the ones doing it :)

made up a bracket to fit the oil cooler

Also whislt the engine was out too some time to repaint some things

Fitted my new alternator

Got some things delivererd from Germany

Brand new and original, new old stock Polo Diesel Rad which was made in 1994 in England. The box is even the original old stock one. I just find that rather cool! :)

That's a decent find Mark. Where did you find that? Heritage?

Cool, how much more capacity over stock?

That's a decent find Mark. Where did you find that? Heritage?

I got it from VW Classic Part de.. but yes VW Heritagte can get them :)

Cool, how much more capacity over stock?

Ohhh about |---------| much

Its a 525mm rad :)

Love how your project consists of frequent engine removal like it's no biggy and I haven't done mine once because I'm a coward

Love how your project consists of frequent engine removal like it's no biggy and I haven't done mine once because I'm a coward

Haha.. I don't take it out for the fun of it, even thought it might look it.I think this is 'only' the 3rd time this year. But yeah I've done it so many times now its easy. But I do remember the first time I removed an engine, it was so daunting .. :)

I will get there when the time is right and I have no choice lol

as always top work

Cheers :)

being that the GTI engine has a much larger crank/alternator pulley meant that it was very near (couple of mm) to the chassis leg. So as a few people have done before I thought about putting the standard mk2 on back on. Unfortunately the mounting is totally different. So I got in touch with the guys at Waboo Automotive https://www.facebook.com/pages/Waboo-Automotive/216164175076460 to see if they could help.

Totally amazed with the welding. They basically where able to remove the centre from the AVY pulley and the center of the Mk2 one and then weld the GTI one in place.

It was almost a shame to paint it.. but it would just rust!


All fitted

I had to space out the pulley on the alternator a bit to line up but nothing major.

So a nice mod and it means more space and a cooler running alternator as I now have a fan on it. And also I don't have to remove the engine if I need to change the cam belt! or even the alternator belt!! :)

loads of space now! :)

Also made up the lines for the oil cooler

and temp fitted the rad

nice mod that, in my mk1 there is a bit more room for the flat v-belt, but wanted to do what you have to keep the gearing on the alt the same as original. still need your manifold managed to 'dog' mine on there with a new flange, it works but isn't pretty haha.

still coming to RRG15? if so I'm planning on having a good nose over this

That rad looks cool as, cowling now seems miniature in comparison lol

nice mod that, in my mk1 there is a bit more room for the flat v-belt, but wanted to do what you have to keep the gearing on the alt the same as original. still need your manifold managed to 'dog' mine on there with a new flange, it works but isn't pretty haha.

still coming to RRG15? if so I'm planning on having a good nose over this

Cheers... it was really tight and if the engine wasn't aligned properly it would rub on the leg under hard cornering.

Yes we will be at RRG! :)

Oh I've done a mod to the exhaust manifold! :)

That rad looks cool as, cowling now seems miniature in comparison lol

Yeah it does! :)

I got the manifold back today.

It looks so cool!!!

Also got the oil cooler all fitted and primed with oil.. Added a heat shield wrap to the top of the oil lines just to protect them.

Very nice. where did you send the manifold away to?