Good read so far! Not been on this forum for years since moving to a golf 1.8t. My golf was recently in a collision (not my fault) and it's not looking good for it. Mine was running milltek turbo back (resonated box with sports cat), sfs super size TIP, a k&n panel filter and stage 1 map at r-tech and ran 222bhp and 247ftlb. That was nippy enough so sure you'll be buzzing in your polo.

Currently on with getting a 6n2 polo from work and I'll have a spare 1.8t.. This thread has tempted me.

Yeah should be man :)

So now that all the mounts were made, the chassis strengthened and the cut outs all solidly welded up it was time to get busy with the filler and paint to make it all look good! id never done any fillering before and only painted small things so it was a bit of a step into the unknown... however i think I'm pretty happy with the result considering it was just done by myself with rattle cans... the colour i went for was mercedes obsidian black

Edited 24 March, 201610 yr by JoshyDubs

Nice job pal. Like the blue mounts and splash on the brake servo and master cylinder. Nothing better than being original

cheers man heres some pics of all the parts i painted before going back on the engine an car before putting the engine back in... all was done by spray cans in my garden lol

picture of the engine all back in :) some further measurements were made making sure everything was bang on straight before moving onto all the other bits an bobs involved in an engine conversion!

now the engine was in an bay painted up was time to start concentrating on making everything else work/fit as theres not much thats just gonna bolt on an go with an engine conversion like this, i made my first job the gear selector as it was a relatively simple task, just had to cut off original brackets and make my own for the mk4 golf selector to fit... the cables snagged slightly against the top of the floor pan so a bit of hammering gave us some more clearance

As the standard polo fuel pump probably wouldn't be up to the job of the much more powerful 1.8t engine that would have to be changed, so i went for a S3 pump the only problem was some parts of the sender unit were slightly different and the float arm was on the wrong side aswell... so i stripped both units down and swapped bits from the polo one to the S3 one, basically to make a hybrid S3 polo pump :)

Small update, got 2x 12" slim spal cooling fans to keep temps down... had to make some brackets up for them to fit but looked good when the were in       

next step was the pedal box, the pedal box in the polo had a FBW (FLY BY WIRE) throttle pedal and a cable clutch pedal which was the opposite of what i needed... after some research i found that polo 6n2 1.4TDI's have hydraulic clutch pedal boxes which would be a direct swap! however i needed a cable operated throttle as the 1.8t agu lump is a cable throttle, so in the end i used a TDI hydraulic clutch pedal box and we welded a polo 6n cable throttle pedal to the pivot point of the original 6n2 FBW pedal if that makes sense? this allowed us to have the hydraulic clutch and cable operated throttle :) , the reason we had to weld the polo 6n cable throttle pedal to the original 6n2 pivot point rather then just bolting it on is because the pivot point of the polo 6n pedal was a different setup from the 6n2's nut and bolt setup, hopefully pictures will show the difference... after the pedal box had was finished we fully seem welded the whole thing as its a common fault of the polo's pedal boxes to break from there tack welds...                             

sorry about the no updates recently! need to try upload more pics to my photobucket as this thread i useless without pictures

Any update? :P

lots of updates to come but been having trouble uploading pictures hopefully get round to it soon :/

This thread is amazing!

Wish I was capable of doing such awesome custom work myself.. can change the wheels?? 

Is it all finished yet?

I bought a 6n2 GTI to do up as a track car when i come back from New Zealand in Autumn, and have literally been toying with the idea of this swap since i bought it! Your build thread is next level, props to you man. I may well get in touch for advice and pointers if I do go ahead with it 

any updates ?

 

This is a great post. I just bought a 1.4 mpi aswell and also want to do a 1.8t conversion . So this as alot of info.