So, as I suspected, it's had a new offside rear quarter in the past. I thought it had because there appeared to be marks left from drilling out old spot welds in the window seam, confirmed when i started sanding.

Anyway, outer offside window is now sanded and primed.

Removed as much surface rust as possible, but there is some minor rust in the messy spot welds that I couldn't get shiny, so I've given a light coat of POR 15 in places.

So today I flatted back the POR 15 and finished off the paintwork on the offside window surround

I also used the sandblaster to remove as much rust from the nearside surround as I could. It still seems strong so I will treat the rust with paint but I won't worry about cutting it out as it will be very difficult to get it looking right afterwards.

Sure makes a mess.

I also began the repair on the outside as I've now got some more 0.8mm gauge steel sheet to work with.

Used my new pillar drill for the first time too. I love tools!

Edited 23 April, 201511 yr by runforrestrun

Dug my ARC engine block and crank out of the wardrobe today to test fit my new G40 cup car windage tray. it will need a little bit of a tickle with a grinder to get it to fit, but we are golden

Finished the patch on the window surround too. The pin holes are from where I did the last bit of forming with a bullet punch to shape it when it was tacked in, they will be filled, and hidden behind the window rubber anyway.

After sandblasting yesterday, I've run a bead of weld along the seam where there once was rust to add material again.

This is inside, just behind the nearside B pillar. There was rust there which I've removed with a finger sander, it's left a hole as you can see. I'll use a piece of copper behind and fill the hole with weld, it's too small to patch.

So today I've finally managed to get a little more done on the Polo after crashing my SEAT and spending my time repairing that. Oops.

Anyway, I've repaired the small hole inside by fill welding it and shaping it back. I will spray zinc primer inside to protect the back of the weld.

Here's a photo of the finished seam before painting that I sandblasted a few weeks back.

Coated with Prep n Ready etch

Good work lad, it must be hard keeping up the motivation. It's good to see that you're doing right though.

Just think of the end result. :-D

Thanks, it's good fun but I'm such a perfectionist and I love frequent tea breaks so it's taking a long time.

Anyway, today I flatted off the POR 15 undercoat and have sprayed on two coats of etch. I'm very pleased to see the back of this rusty repair as I can move on to something else now.

Now I will repair the back of the rear arches, where the old cage was mounted to with spreader plates. I took the plates off a while back and tried to tidy up the 8mm holes that were left from the bolts, but it didn't turn out so well, so I've got some repair panels from Andy (with the derbeetle) which I will use to replace the pressed section. i want it to look like it's not been pissed with.

Good solid metal under all that underseal. Made a right mess getting it all off.

Edited 3 May, 201511 yr by runforrestrun

I've enjoyed reading this, after a set of those front topmounts my self but cant see them on the ppp website? The floor in my rally car is reinforce with 2mm plate, then theres 3mm square washers welded to it to mount the seats, it looks a bit more original but i did it to keep the seats low. If you havnt already have a look at the msa blue book in reguards to seat mountings, belt mountings and cage. Even if its not going to be a rally car if its done to the spec then it will be easy to get an msa logbook for it which will add value and make it eligable for more events. Gravel cars and tarmac cars are different specs, a gravel car can do tarmac events but a tarmac car cant do gravel events, nice car :)

Nice one Jacob. If you email Pete directly through their email address then they can sort you a pair. I've seen your car a few times online. Exciting stuff.

I will be looking at that when the time comes - like you say, best to do it correctly to get it certified, and even if I don't get it certified at least I know it will be safe.

The window frames are finally done, and can now be left until final paint prep.

I've made a repair panel from the spare arches now too, ready to weld in tomorrow.

It fits the hole exactly. I will weld it in and dress the welds in the cabin. I believe it will be plenty strong enough as the arch is only 0.8mm gauge steel anyway. The original strength comes from the fact that it's not got a big hole in it.

Thanks for reading

Super work Jim lad!

want to sell me your exhaust manifold? please

Thanks Kieran

Sorry retromk11 - I wouldn't find another and the car deserves it!

shame, you're right, its an epic build.

how did you manage to get one? any places I can probe in hope to find one?

Just read the whole thread, a lot of work gone into this, looks amazing!

So.. no physical progress in the last few weeks due to exams

However

I now have centre caps for my wheels which will make them look extra pretty when they are painted and polished

My PPP track control arms arrived too which will compliment the subframe nicely, complete with nylon outer bushes

I've also picked up a pre '79 dashboard, and a NOS front slam panel.

ooo like the wheels! :)

I'm also tempted with some PPP track control arms. Not that it would give me that much adjustment running the ARB but perhaps enough for road use.

So I've been busy shopping again

I've now bought (at a cost of about £250)

Brembo Max 256mm front discs (mk2 Golf etc)

Ferodo ds2500 front pads

Pagid OEM 226mm rear discs

Black diamond rear pads

I've also bought the following

More dishes for the wheels to give me more fitment choice

A spare wheel centre with the right PCD in case I ruin one

Found some of my favourite design of centre caps on eBay which of course I just had to have

A decent pre '79 dash and a not so decent one in case I do decide to have a flocked one (Thanks Kiz)

A NOS slam panel

A mk2f handbrake lever assembly so I can upgrade from the early inferior design

I've now finished my exams, so time to crack on again.

Edited 21 June, 201511 yr by runforrestrun

I've finished welding the nearside in now.

And the offside is ready to weld in too.

Edited 22 June, 201511 yr by runforrestrun

Is this done yet? Is it on the road yet? Hmmm?

Good question. It will be one day.

I've bought a T25 as a daily now which needs a few jobs doing to it, but this will of course be continuing!

sell me the manifold to free up funds?

sell me the manifold to free up funds?

Oh you don't want my manifold any more then??? fine!

The manifold is not for sale I'm afraid.

No updates due to pressures of work and having a T25 that needs constant love

It will happen

Update - the T25 is still being needy. Will possibly get back on with the Polo after the christmas season, although I start university in January too, so we shall see.

Anyway, Ryan's G40 will be done soon so we can play in that.

Wow this is awsome. Top work. Love the mk1-3 polos and miss mine so much when I see things like this. Takes me back 8 years lol. Can't wait to see this done

Update - the T25 is still being needy. Will possibly get back on with the Polo after the christmas season, although I start university in January too, so we shall see.

Anyway, Ryan's G40 will be done soon so we can play in that.

T25s are always needy I have a panel 1.9 DG love it but nightmare at times.

Now this build is incredible man hope to see it sometimenout and about or at a show!