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Mk2 Polo Breadvan - G40 Trackday Build

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Most of you will already know me from the blue 2F breadvan in project threads.

This one is a Formel E mk2 which has been converted to a GT. I bought it for a bargain of £500 and ran it over 100 miles already without any issues. The temperature gauge didn't even quite get to half and I was driving quite "enthusiastically".

There are issues but small ones. The bad points are rust scabs on rear arches and a bit of rust on an A-pillar which will get sorted. There's a dent in a wing and a few scratches, the dent will come out easy as pie I reckon. Then daft stuff like the exhaust has a small rattle, the bulb has gone in the clocks so I can't see them at night, plus a vibration which sounds like it comes from the passenger seat rail area (probably a missing guide clip). One front wheel bearing may have started to sound a bit rough on the motorway or it could just been in my head! Lol

Ahh the name. I didn't choose it...the first owner called it Gloria and put a Gloria sticker on her etc, the name has stuck with all the owners apparently so the name is staying

Pictures from the advert for now until tomorrow! I also snapped the folder which contains history

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Plans now are undecided. It was going to give up its mpi for the 2F but it might stay with the mk2 now as I cook up alternative plans for the blue one.

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Looks a bit rough around the edges, but solid.

Looking forward to this mate! :-)

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Yeah it is a little bit mate, she's a bit of a fixer upper but will be looking nice in no time :)

Cheers mate

Lucky sod I would love a mk2 and a great price boss..

Pure sleeper, I like it a lot :)

I have some spare bulbs from the clocks if you want them. 10 min job to replace. Are they rev counter clocks?

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Well I will start this post to show the car in a bit more detail, First the interior, it has the black vinyl door cards which I love and I really like the seats even though the drivers bolster has a small tear...Is this a coupe s wheel or is the formel E wheel just similar?

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Now for the bad bits and I mean the rust that I need to sort, May need to hire dirtydubs for that one :tongue:

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The bad arch!

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And the worst

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Scatches too. Bonnet is worse but I didnt get a snap (rest of car is fine!)

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So anyway I gave it a quick wash and I heat gunned the bumpers black so they look a bit fresher!

Heres a picture to show the difference

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Result afterwards

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sleeper badge lol, unsure whether to keep it this way or take it off then put a neat little GT badge on the grille :unknw:

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Had this tacky gaitor

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Luckily it was hiding an original one :D

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Had this annoying dent

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panel off and not rusty :smile:

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Then beat it back to shape using a rubber mallet and some wood pieces to act like a dolly, used a flat edge of wood to follow the body line (crease or whatever) and it came out spot on! a little bit filler and paint then it will be like new again

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That was all for today, would have fitted the 4 branch but I forgot its still in the 6r's boot and that's parked up at work, I shall get it tonight at work though and maybe fit it tomorrow! Another issue is the windscreen wash pump isn't working at the moment so ill look into it

Would like to just say how fun this really is. In a few words I would say don't be put off by the numbers. Its so fun the way it revs lol I cant get enough of it!

Apart from a tidy up, keep the exterior as it is for that sleeper awesomeness :) really like this one, keep the badges. No one will suspect a thing

Good work so far boss and I am with keeping the rear badges on for me I think its a good look.. 4 branch I quite fancy one my gt ?? advice please ?

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I think I'm up with keeping the badges now lol, I have no experience of 4 branches on these myself, I bought a second hand one for 40 quid with a lambda and will let you know how it is once it's on, the one I got is an eBay one.

Just machine polished the car, looks a million times better and I promise this will be the last update today lol. I need sleep as I am working tonight!

Still need to hand polish the boot so I don't disturb the Gloria badge and I will give it another polish next week including the hard to reach places like behind door handles etc.

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Came up great dude! Wheels need some attention now and she'll look belting :-)

Heat gun worked a treat for you!

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Something...interesting happened today. I overheated like a bitch sitting in central London traffic and nowhere to go to pull over. Car steamed and cut out. Took about five attempts to start again holding flat on the throttle. I panicked like mad and kept on the accelerator using the handbrake at traffic lights to slowly brake. If the revs dropped it cut out. Eventually of course it cut out and I had no choice but to push it through traffic until I found a very unsuitable place to pull over. Red route for about 3 miles of road. Luckily a nice lass came and helped me push it. There are some decent folk even in london

So I ran to a shop as fast as I could to get some mineral water. Got back and it cooled down a bit so I topped it up. Couldn't start still and had 4 percent battery on my phone.

It was evident that my thermostat was stuck so I had to wait for 45 minutes till it was safe to drive again and find another rest stop.

Managed to get to where I was going and now I am back again. The fan is also not getting up to proper speed as it's catching the cowling. Plans are to give it a low temp thermostat I have in the garage and change for some good coolant then bend the cowling till the fan spins freely.

Worst day ever. And so so embarrassing. I may have also shouted at some guy in a van who said "your steaming mate you need to pull over"..." ah...you don't f*****g say you moron. Where the f**k should I pull over then?". Probably a bit far as he was only trying to help lol

Never mind

Edit. From now on. Tools in the car and any small parts in case of emergencies!

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Just met up with Nige and we quickly discovered much to our amusement that the diagnostics plugs were either removed during the conversion or hidden away somewhere. Next task for that is to remove the dash and cross my fingers that its all there and then route it how it should be!

For now I am going to temporarily remove the thermostat and replace the o ring as water now seeps from there.The car has ran okay up and down to meet Nige and idled on start up without issues. This morning's start up was a bit rough but not as bad as after the overheating. Perhaps the rough running could have been due to water on the coil and earth's after it lost coolant? who knows but a good clean up of the bay is in order and a full service.

The previous owner stated the oil was changed but I cant see that unless he done it without changing the oil filter because that has surface rust on it.

A big thanks to Nige for meeting up with me in his spare time! It is much appreciated!

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Ah a bodge...nevermind

ah another bodge..okay

another bodge

and another bodge bodgebodgebodgebodge.

Cars coming off the road for a couple days. Not going to bother explaining

Cant say I'm surprised, shame. A good going over will transform it

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Nor am I Kiran, It seemed golden on the first few drives so I had high hopes. I should have kept expecting to find dirt!

Bad luck dude be strong and one job at a time and I hope in no time you be good again..

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I'm in the process of swapping the cowling, fan, thermostat housing, couple hoses etc from my blue one as its all pretty new stuff.

Also just trying to trace all the engine loom back and figure out whats what. I couldn't really check all this in the dark when I got the car sadly. My own fault for not bringing a torch with me. I also am not familiar with the GT MPI so its all a learning curve. I think she will be good as new by tomorrow afternoon but it means working on my car when I should be sleeping before the nightshift

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and in all honesty I shouldnt have thought I could daily it right away lol

Its not massive problems or anything hard to fix, I just keep finding more and more shit lol

Found anything dangerous yet?

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Found anything dangerous yet?

hmm, sort of. If you imagine the whole cooling system being taped up, done with the wrong hose clips, fan bearing gone complete;y, bungs on the SPI thermostat housing which are just loose and leaking. One bolt used for the housing and the bottom section just tonnes of silicone sealing it.

I was fixing one leak and moving to the next all the time

I just came back in the house, used all the spring clips I could find, basically the hose clips weren't sealing the hose ends properly because of the flat edge as opposed to being completely round, (a couple hoses were split and I have replaced them) I've put the thermostat housing on from the blue one with a gen thermostat inside. Put the new fan on from the 2F with the cowling...bloody tight fit. For some reason the fan wont work with it atm but maybe i just have a plug on upside down or something daft

The blue temperature switch is snipped so to stop the revs dying and cutting the car out, temporarily I have had to advance the ignition timing almost as far as it will go. Its not overheating but its cold out so I need the fan to start engaging so it wont overheat in hotter weather. I will remove the pins from the blue connector and fit a new connector on then I should be able to revert iginition timing to standard again.

Its not hard stuff its just bloody annoying that the car is fighting back every time I fix something. The wiring is routed awkwardly and its quite a mess. couple unconnected wires here and there.

Oh mate, sounds like a shitter of a weekend!

Get yourself a new thermostat housing, you can also mitigate the bungs issue by looping a hose form one outlet to another - with nice tight clamps.

  • Author

Yeah its been a rough weekend since Friday. I've stuck a nearly new thermostat housing on there and all is well with the cooling system. Just need to stick my 3 pin thermoswitch in so the 2F fan works with it.

Just ordered a new plug and terminals for the blue temperature switch and they will be at TPS tomorrow morning so I can pick them up. I have a car I can drive now but the ignition timing is a bit wrong and its heating up quickly. Getting there though

Good idea for the bungs I will do that till I get a GT thermostat housing

Nothing i've got will help, i don't think - all the thermo stuff i've got is either 6n pattern or pre-86 pattern.

Oh, apart from a 2F thermostat housing i won't be needing. Pipes are a bit long though.

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All that's pretty much sorted now Mikey :) the cooling is spot on apart from the expansion tank having pin prick holes around the seam.

Yesterday I just wired a new blue temperature sender, couple updates soon..trying to figure something out first. Pretty sure the loom he used for the swap is not from a GT. The wire order is wrong in all the ecu plug pins if it is.

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Not an update but I thought this was quite funny.

Everyone is home tonight and this is what the house is like with all the cars parked up

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My 2 breadvans on the drive and the bluemotion on the street

Mx5 and the van on the street gfs dad's

Courtesy car (corsa) gfs mothers

Not so limited edition corsa gfs brothers

Suzuki swift: gfs grandads. He left it here until his insurance runs out on his other car

The silver vitara up the street is her brothers girlfriends too.

Neighbours must hate us lol a proper update coming soon but it's best to update all at once. Just swimming in wiring atm..

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