Hello Again, as i said i would i will put together a build thread from the beginning as of when i brought the car 09/07/12.

The Car: 1989 MK2 Polo Coupe, in Red, with only 31,000 miles at the time, interior and exterior was original, and has a 1043cc Engine (Code HZ) and a 5 speed GearBox (Code AHZ).

This is the first VW i have owned and quickly become very addicted to them. The fact that my friend owns a MK2 Golf also helpped me along the way.

So when i saw this for sale around the corner from me i had to have it, interior was clean, apart from the fact the drivers seat was a little dirty but i soon cleaned that up.
The exterior well to start off i would like to thank the person that keyed the roof! And it had a dent on the drivers side rear quarter, not to bad i can live with that its a 24 year old car what do you expect?

Here is a couple of photos when i brought her:





As you can see i quickly lost the side repeaters...



Soon After i found my self buying a Set Of Ats Classics 7x13 && 8x13 with Continental tyres Size 175/50 R13

The Rear wheels && tyres sit perfect little bit of strech with tyre tread tucked under the arch, but i soon found out i couldnt have any weight in the back other wise the tyres would rub.
The Front wheels looked good with the staggered stance, but i was unhappy with the tyres as they are the same size on all 4 corners, so once the tyres are worn out on the front i will change them to match the strech on the rears.










The Car sitting on Supersport Spring Suspenion Kit which is a 60/60 Kit. Front None adjustable, rears adjustable can be lowered by a further 2/3 notches.



As i was unable to have passengers in the rear i decided i wanted to strip the rear interior out, while i was doing this i completly striped the interior out to see how the car looked under the carpets. I was surprised to find the footwells in very good condition with no visible surface rust. Although i did have a slight water leak coming from somewere as all the sound deadening was soaked, so it all went in the bin. I later found that the leak was coming from the raintray, someone decided to resecure the glove box with a self tappet which was to long and went through to the raintray. so this was then repaired with a small tack weld and some silicon to be sure it wouldnt leak again. Carpets were all cleaned and left to dry and i decided to buy some Corrado Front Seats, They needed a clean and a minor repair no big deal!



And Then i hit my rear wheel... bent the lipp flat. So next morning car went back on the steels, I stripped the tyres and all 4 wheels went to Spit 'N' Polish to get a full refurb and alloy welded. I Decided on Anthracite Grey Inserts with Diamond Cut Faces And Lips. The wheels were not in the best condition when i got them they all had been lipp grinded and the lacquer was starting to peel. so now was the perfect opportunity to get my wheels done in a colour i wanted!

From:



Too: They look black in the photo but they look different in the light and in person!



Its was now winter time, so I stored the wheels and seats in my bedroom next to the radiator. The Seats were Damp from being cleaned. So left them to dry out.



I Then Treated My Self Too:

Retro Fit Areo Blades



Pressed Plates



&A Venom Rear Wiper Blank



End Results











Soo now i had added all of my own personal touches that made the car mine... i move on to something a little more important.

Handling and Braking, I moved on to these components first to see how she would feel and drive with the standard 1.0 engine before i moved on to the 1.6 16v AFH.

Soo i waited for a set of VWII Calipers to come up:









So i took them to work cleaned them up checked to see if piston moved freely and checked the piston rubber covers all appeared fine... so i was happy.

Cleaned and degreesed:



Painted Up:



And then this turned up...











So i made a day of it i stripped the front brakes off (Calipers, pads, flexi's and disc's) and fitted my new components. But when i tryed to put my wheels back on i had a problem didnt i the ATS Classics dont fit... so i had a choice put the old bits back on? or get some spacers? so i made a trip to halfords and brought some 5mm spacers which did the trick for the time being.

Then a couple of days later i recieved this...







But I was still waiting for one more item to arrive...



PPP Stage 2 SubFrame!

So i got the black hammerite out and gave the subframe a coat of paint heres how it looked...







When it came to fitting the subframe i decided to remove the exhaust and the gear linkage, and at the same time remove the rear axel... which i also cleaned up and gave a coat of black hammerite before fitted my new Rear Axel Bushes, and also gave me the chance to change my rear flexi's.

While the underneath of the car was stripped i decided to underseal it.



I Used 4 Cans



I masked up the spare wheel, i did this because when you look from the back of the car you can see it so i thought that it would look better red!



Sadly i have no photos of the subframe/ brakes/ rear axel fitted i will get some and post them up.

Will try and update soon...

Edited 7 May, 201511 yr by mark_crox

looks great! nice and clean!

Looks good

Mate

Could do with a exhaust too

Love the grill

Edited 16 June, 201313 yr by nas1989polo

Wow what a stunner!

Looks good

Mate

Could do with a exhaust too

Love the grill

Thank You For The Kind Comments :-)

Dont Panic The Exhaust Will Come Once The Engine Is Built!

Nice work and a nice set of mods going on.

LOOOOKIN' GOOOD!

I'm seeing more and more ats classics coming up, really fancy a set :(

It's been a while so I thought I would post some thing up... I have been fairly busy and haven't had the time to post things up as they have been happening.

We'll I purchased a vw polo 1999 1.4 16v (AFH) with a stainless steel manifold... This has been broken up and now has been scrapped as the shell had been left to rot.

I also purchased a 2000/01 AVY engine block... Which I have taken the internals from... Both of the following engines have a direct crank driven oil pump which makes it easy to put the AVY internals in to the AFH block.

The following engine work has been done:

Engine block acid bathed... Bores hooned... Deck checked

Cylinder head acid bathed... New valve stem sills... 3 angle valve seats... Valves lapped... Head skimmed

Crankshaft, pistons and conrods and flywheel have been fully lightened and balanced.

I have since purchased:

New oil pump, rear main oil sill, thermostat housing and rear water pipe, timing belt kit and water pump, 3pc clutch kit, piston rings, main and big end bearing and thrust washers. New bolts all round as most are stretch.

I have also purchased a set of cbr600 carbs.

So far I have painted the block and cylinder head, followed by the sump and bottom crank pulley. The rocker cover and gearbox are yet to be painted. (Gearbox is still on my car).

I had an engineering company pop the rings on the piston and insert them into the block as I didn't want to risk breaking them...

Engine is now on a stand at work. Bottom end has been built up and torqued up, and so has the cylinder head. Original cams installed for the running in of the engine. All timed up and ready to go.

Things to do:

Fit rear main oil sill

Fit & sill sump

Fit thermostat and rear water pipe

Paint rocker cover & install

Heat wrap manifold & install

Get an inlet manifold

Send bike carbs to be jetted and cleaned

Send distributor off to get vacuum advance removed(Still on car)

Paint up gearbox(still on car)

This is all I can think of for now... Will try post up some pics and update soon!

Edited 20 October, 201312 yr by Chris1991E

Soo here are some photos of my engine parts as of when I got them back from the engineering company...

The block and bores...

Some photos of the head...

Pistons...

Crankshaft...

And finally the lightened flywheel...

Looking good, pal.

I miss my S solo bad

I havn't really done that much this week just been ordering parts... and sending bits off...

Soo carbs went off to boggbros for re-jetting + cleaning and for an inlet manifold to be made also got rubber joiners from them as well... All should be back with me today.

I had the EGR Valve and Inlet Heater Tube cut off and the Hole Welded up on the Exhaust Manifold, and Purchesed Some Heat Wrap.

Brought a CBR600 Bike fuel pump and VHT Wrinkle Black Piant for the Rocker Cover.

And thats about it... For now. Soo i will leave you with some more photos of the engine being built/painted.

Block At Work All Painted Up... As you Can probally see the pistons are already in.

Now on the stand...

Flip it upside down and pop in the Crank... New Shells/thrust bearings + Main Bolts. All Torqued Up.

Connect Conrods to Crank... New Shells + Big End Bolts. All Torqued Up.

Oil pump and Oil Pick Up Bolted Up + Water Pump.

Cylinder Head Painted And Torqued Down, Cams Installed, New Guide/Tensioner/Belt and CrankCase Breather.

Spun The Engine Over A Couple Of Times To Make Sure Everything Was Ok And Engine Timing Was Correct. Everything Was Ok.

Soo Sump Was Painted And Went On.

Followed By Rear Water Pipe + Thermostat Housing.

Crank Pulley was Also Painted And Bolted On With A New Bolt. Plus New Oil Filter.

Things to do:

Fit rear main oil sill - Done!
Fit & sill sump - Done!
Fit thermostat and rear water pipe - Done!
Paint rocker cover & install
Heat wrap manifold & install
Get an inlet manifold - Done!
Send bike carbs to be jetted and cleaned - Done!
Send distributor off to get vacuum advance removed(Still on car)
Paint up gearbox(still on car)

Thats All For Now...

Nice work. Polo looks good.

Great work pal, body looks in awesome condition and the engine looks great too!

Keeping my eye on this!

Sweet build :)

Cheers for the comments guys makes all the work worth it. Will try and update soon.

Soo i recieved my Bike Carbs back from BoggBros very happy with what they have produced...

I will most probally remove the original air box and buy and install a pipercross air filter and base plate...

Finally got round to heat wrapping my manifold, not the easiest of jobs in the world as there is no much space between the down tubes.

The Exhaust Manifold was like this as standard...

I have now removed the hot air fed to the air box and the mounting for the EGR...

I then Heat Wrapped It...

Edited 7 November, 201312 yr by Chris1991E

Only a small update sent my distributor off to h&h ignition solutions for them to do a complete overhaul, removal of the vacuum advance mushroom and adjust the advance curve.

This is coming along a real beauty mate. Cant wait to see where your at in a few months time

So today I received my distributor back from h&h ignition solutions, and for a cheaper price than they quoted as they had a show to go to last week and no one was working in the workshop result for me.

Here are a couple of photos...

Great work mate :) that's going to be quite a handfull of an engine, I think I might give them a ring for a price as I've been looking for somewhere that refurbs distributors.

let me know how you get on when thats fitted! you gonna dyno it?

let me know how you get on when thats fitted! you gonna dyno it?

Once the engine is run in, I might take it over to pdq in slough. I would like to get schrick cams and vernier pulleys first before I get it properly set up that way I will only have to pay for it once.

nice. yeah thatd make sence. reckon they would let you do a run with the modded distributor and a normal one to see the difference? or would you have to pay twice?

I haven't got a normal distributor, sent off my only one :( I just hope my 1.0 engine still runs ok on it as I need to drive it to my garage. I reckon they would just charge you by the hour just start off with the normal standard one. That way you won't waste any time.