If your uploading through the standard uploader in the site or on tapatalk it's rubbish so as Greg said imgur is worth using or photobucket then just copy the image link and paste it on here

Loving this thread.. was only talking about the idea of doing this to mine the other day!! Would be great to see how it is done and what issues you had with fitment etc.

Owe a massive apology to everyone for the no posts over the last few months but the thread ran out of space for pictures and I got distracted from sorting it out now but I've created a photo bucket account so I can link photos into the thread and hopefully you get them! Anyways I believe I was at the stage of showing you the doner car I would use for the build... I picked up this mk4 GTI with a AGU lump for £650, hopefully make some of that back in spares :) I didn't mess around getting the engine an everything out as I was eager to test it in the polo bay :)

Edited 19 December, 201510 yr by JoshyDubs

Edited 19 December, 201510 yr by JoshyDubs

Glad to see this getting updated again really interesting thread

Cheers man imma try keep the posts up now :) Iv'e done a bit of research on this conversion but everyone does it differently and there's only a handful of usefull threads out there but hopefully mine becomes one of them now that i had the 1.8T out and the polo stripped i couldn't wait to see how it sit in the bay... the thing really looked massive and doesn't allow much tolerance for space in any direction, so as the first task was to mount the engine i thought id better get the grinder out and start trimming so that i can get the engine to sit nicely in the bay in order to fabricate proper mounts! obviously all cut outs will later be reinforced and strengthened

Edited 21 December, 201510 yr by JoshyDubs

Now that id removed a fair bit of metal i retested the engine to see how it sat and the good news was it fitted quite nicely... so now it was time to start on fabricating some mounts, i decided to use the mk4 golf mounting point, so that was cut out and so was the polo's original engine mount point so the mk4 mount could be welded in, there was no going back after this!

Good thread which will hopefully make me a bit more confident on my 1.8T swap on my GTI :) I heard that 9N3 GTI engine mounts are a straight fit and bolt on to the mk4 1.8T motor. Doing the actual swap shouldn't be too bad but converting the loom will be the scary bit (for me anyway). I will follow this :)

Iv'e heard that too but i don't think they are, you could maybe try modify a 9n mount to fit the 6n2 but nothings a straight swap on this which is what makes it a challenge

Little update, whilst the engine was all out i took the gearbox home to paint it a smart satin black, changed the timing belt and got some parts for the build :) went for a full ko4 setup, forge FMIC, BAM inlet, Forge charge pipe, VR6 Radiator , even won a forge TIP on ebay

Edited 29 December, 201510 yr by JoshyDubs

Right back to the mounts! so i decided to start with the engine mount first i would only tack weld this in before making a gearbox and dogbone mount so that i can make adjustments should the engine sit to high, to low, to far forward, to far back, to tilted or completely pissed... yeah it was allot to align properly... anyway first i made 2 plates that the mk4 engine mount could sit on, i would tack them in place, then tack the mk4 golf mount piece on the plates, then bolt the mk4 golf engine mount to the engine and mount and see how it all sat before making a gearbox mount

To make the gearbox mount i cut the cylinder shape mount off the original polo gearbox mount and welded that to a piece of angle iron which i bolted to the 1.8t gearbox so that the passenger side of the engine bay didn't need any modification atoll and i could use the original polo mount point, the reason i done it this simpler way is because i have future plans of fitting a 6 speed gearbox which will require a new gearbox mount to be fabricated anyway... after both engine an gearbox mounts were tacked in i did some serious staring and measuring to make sure everything was bang on straight! i was happy with my plates so they were fully welded in and i made 4 more plates/walls for them so they became little box type platforms, i also found the mk4 engine mount had to sit quite far to the right of the bar and it over hung the chassis rail so a small platform was made for it to be welded onto... (pictures speak a thousand words) i also put some filler on the bay basically making a start to some minor smoothing

the mk4 was slowly getting cannibalized! some pics of it getting stripped for its goods

Excellent thread this. Proper cool. :-)

What kind of power you expecting out of this with the k04 setup?

Nice work! I'd have the front number plate in the centre, but each to their own! That'll be one quick car!

WOW!! what a thread!! absolutely great work mate!!

Very impressive work bud. To do all that work at your age is a great accomplishment. I'm planing on a conversion from my 6n2 1.4tdi to a mk 4 golf 130 or 150 tdi engine. Waiting to see how the mounting is going to be done. Though I'm handy with the welder lol. Did you have any trouble with the drive shafts?

cheers guys I'm hoping about 280HP summin like that then i can get a ko4 hybrid in the future when this turbo goes, and yeah only reason for putting the plate there was that someone hit my front bumper and made a nasty filler crack appear so that was just to cover it up

Now that i had a engine and a gearbox mount tacked in it was time to tackle the dogbone mount! i could have modified the polo mount but theres no upgraded polybushes for that mount so i decided to use the mk4 golf 1.8T dog bone, for this i cut out the polo mount and then cut the section of the mk4 golf subframe that the dog bone bolts onto, i then trimmed this down and welded it to the bottom of the polo subframe...

after the section of the mk4 subframe had been welded to the polo subframe i made some walls around it to create a box section for strength, unfortunately my lower OMP strut brace got right in the way of the dogbone so instead of removing it i mounted the dog bone much further back so that it didn't hit the brace, however this meant that the rear wall of the box section was too close to the ARB... so to miss the ARB and allow some tolerance for when it twists during high speed cornering i had to make a slight bend in the wall so that the ARB was not effected, below are some pictures of the wall being mocked up with cardboard, you can see from the pictures the small tolerances of space there were and the bend that had to be made for the ARB. (pictures also show the reinforcement bar i welded to the 2nd bracket that comes with the dogbone mounts which i then painted red), the second problem i had with the box section is it didn't allow enough room for a 3" exhaust to go through so the grinder came out again to cut out an arch to make room for the exhaust, i then made an arch shape wall to weld in aswell, this completed the box sectone fabrication for the dog bone mount!

Now that ths dog bone and gearbox mounts were fully welded up it was time to weld up the engine mount so that all mounts were 100% it was good to see the weld penetrating through the engine bay into the inner arch in the 2nd picture, this showed that the mount was solidly welded to the side of the bay! I also got a VR6 sachs clutch and G60 flywheel for the gearbox this would be able to cope with about 300 BHP

Slowly worked my way through your build thread while at work today, absolutely crazy :P

How much did your insurance rocket with the 1.6 lump conversion?

cheers mate, the 1.6 was never registered simply because i couldn't... no one would even insure me on it so it was impossible, however now I'm older the 1.8t will be able to be registered and insured properly lol

So now that all the mounts were done and welded up 100% it was time to reinforce and weld up all the cut outs that were made... I first made some plates to weld in either side of the subframe to give it extra strength, I then also grinded back and seam welded the turrets that the subframe bolt onto as these are only spot welded from factory, an finally for the cut out in the subframe which was made for diff clearance i cut and solidly welded in 3 steel rebar's then made 3 plates to close up and finish off that cut out...

After that the chassis notch made for the gearbox clearance was welded up buy re-welding the inner wheel arch wall in, making an arch to fill the gap in the chissis leg and some more rebaring... all the welds were then seam sealed and ready for paint!