Hi all,

Been meaning to start a thread for a while now I'm currently making a road legal track car 6n2 using a 1.8 20vt from a mk4 golf gti.

I bought the car before i passed my test 18 months a go here's what she looked like when I bought her,

Didn't do alot to it just put those white alloys on and the usual 17 year old things.

I bought a 1.4 td polo to replace this as i was doing alot of commuting miles and it was never the best on fuel, this left me with a good clean polo which i did not want to get rid of but was far too slow for my liking...so this happened.

After getting this far i knew there was no turning back so i began chopping up the engine mount ready for a new one to be welded on.

Once i got this far i needed an engine, so i bought A mk4 golf gti as a doner car i got the shell with engine box wiring dashboard and back axle for a bargain £125

As i started to offer up the engine into the bay it became apparent that the gap wasn't wide enough...so i made it wide enough :p

I boxed everything back in and then began making some engine mounts

One for the drivers side

And one for the passenger side

Which meant i could now sit the engine in the bay

I then started painting up the new engine

Before

After

Then the last couple of days i have started tidying up the engine bay ready to paint.

I've plated off the channel on top of the chassis legs to create a smoother look

And thats as far as i got today so this thread is now up to date hope to get some more done this week and possibly get it in primer by Sunday will try and throw an update on tomorrow night, Thanks for looking

Nice work!!

Not much changed today spent 4 hours sanding filler on the driverside chassis leg still a couple more bits which need some filler.

But disaster has struck, set off to remove the front subframe and the captive nuts which the bolts holding the front of the subframe on broke so I'm going to have to cut open the mounting point and find a way of fixing them 😢 Will hopefully get that done tomorrow

Subframe bolts are pain where the sun doesn't shine!

Exactly the same happened with two of mine, I cut the side open and am now using two different nuts to mount it back....they have an odd thread, but it is the same as the thread on the nuts/bolts that hold the bottom of the suspension struts onto the swivels.

These and the little window I cut are getting welded in today in fact!

Nice work, be good to see another 1.8T 6n2!

So got some more done on it today,

Got both chassis legs smoothed to a point where I'm happy with them and started to reapply the seam sealer.

Also got the Subframe, struts, bottom arms, hubs and steering rack out today. Getting the subframe and bottom arms sandblasted so I can then finish making up the dog bone mounting point, paint and reassemble with poly bushes. Also putting bigger brakes on off the MK4 golf on so will paint them and the carriers up ready for reassembly.

Cut open the mounts for the subframe where the nuts broke off haven't got any pictures of them plan is to get some new nuts and bolts in the morning then weld them in and plate over the hole I've cut. Also tomorrow I'm going to sand down the seam sealer so that it leaves a smooth finish, rub the rest of the engine bay down and hopefully (fingers crossed) get it primed :)

Probably won't get chance to update tomorrow night, hope to get an update on when I get back from Elsecar at the races on Sunday anyone else going?

That's all for now

Looking good - wish I could weld like you!

Looking good - wish I could weld like you!

Haha are you joking looks like bird poo 1/2 the time I weld 😂

First one wasn't bad, but then I was looking at it on a phone with a cracked screen!

First one wasn't bad, but then I was looking at it on a phone with a cracked screen!

Haha it's all just practice as long as they all hold up I'm not bothered haha

Looks familiar  nice work mate, loving the colour scheme on the engine 

On 4/26/2016 at 19:19, thomas_6n2 said:

Looks familiar  nice work mate, loving the colour scheme on the engine 

Thanks mate looking forward to getting it up and running a lot of work to be done yet though  

 

Haven't really had much time for it lately bought yet another polo to add to the collection so just been tidying that up and getting everything from my daily swapped into it hahe engine bay is sat with the passenger side chassis leg and bulk head prepped for paint just need to prep the drivers side chassis leg and then the engine bay can be painted got the subframe back from being blasted so can get that finished and painted then new wish bones, ball joints, track rod ends and poly bushes to buy and fit and the engine can go in finally! 

 

Ill leave you with a picture of my new daily TDI

Finally got some work done on the polo this last week.

Got the engine sway mounting point fabricated up on the underside of the subframe looks rather industrial but will do the job.

 

And finally got the engine bay painted!

 

 

Then painted the subframe and put that back in. Put the old steering rack back in going to put a manual steering rack in when i get the money for one.

 

 

Next on the list is to clean up and paint the gearbox and a few last bits for the engine then get a manual steering rack put in and the engine and gearbox can hopefully go in and stop in. Now the engine bay is painted I don't want to be taking the engine in and out so I'm avoiding it at all costs :P.

Looks awesome that bay how did you get it so good looking

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On 9 June 2016 at 17:47, mad-dean said:

Looks awesome that bay how did you get it so good looking

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I think it just looks good in the photos it's not as clean as I could have made it but when I want to use it for track days I didn't see the point in spending hundreds of hours on the engine bay which will all be dirty as soon as I drive through a puddle haha 

Looks good and progress it happening. Nice to see a 20vt conversion :)

So been a while since i have updated i bought a new push bike so spent most my time riding that but this last week or so i started making progress.

The engine went back in so i could mock up a down pipe and other things i still have to buy

 

As you can see things are tight but it should all work i hope haha

So ordered the pipe for my downpipe just need to get round to welding it now. Once i had decided what pipe i was going to need for the intercooler pipe work it was back out with the engine so i could do some final bit of painting 

 

 

Hopefully get the gearbox painted this week and get the belt done on the engine then the engine can go back in for the last time... hopefully haha will update again after some more progress has been made.

First time reader...nice welding work.

 

Purple bay! I have a purple bay and a 20vt in my 6n...

 

Looking good though, but I do hope your not going to be running low with that dogbone mount also your engine seems to be sat really low. Mines as high as I could go and I have a shallow sump and I can struggle with clearance.

 

 

On 7/19/2016 at 05:53, Mattnaz said:

First time reader...nice welding work.

 

Purple bay! I have a purple bay and a 20vt in my 6n...

 

Looking good though, but I do hope your not going to be running low with that dogbone mount also your engine seems to be sat really low. Mines as high as I could go and I have a shallow sump and I can struggle with clearance.

 

 

I don't think its that low :/ i'm still going to have to chop some out of the bonnet to get it to shut :/. I don't want to run it low just a nice height slightly lower than standard i.e like 50-60mm. I'm also going to put a thick aluminium skid pan on the underside. Also with yours being a 6n i think the front end is slightly shorter than mine but i may be wrong. Thanks for reading.

 

Not a lot more has happened since the last update, painted my gearbox, welded the down pipe up, changed the timing belt water pump and alternator belt, put a new second hand alternator on (only 150 mile old!) and got my brake servo on.

 

Next on the list is the rest of the exhaust then most likely onto fabricating the front half of my roll cage. 

Don't worry people this project is still going just haven't had time to update will try and get some pictures up tomorrow night and a video (if it will let me). 

Had the car running, gearbox is painted, belts have been done, I've chopped the wiring so it is as simple as possible started making feet to weld into the car to bolt the roll cage for the downpipe is almost complete and the clutch and flywheel has come through the post will possibly get fitted this week.

Next on the list is:

Mount rear 1/2 of cage

make template for front 1/2 of cage with some cheap pipe and start making feet for the front cage

fit the clutch and flywheel

start wrapping up the wiring

make a switch panel for the dash board and fit the clocks into the dashboard.

 

That list should keep me going for a few weeks now show season is over I should get more done :)

Hi great build so far what driveshafts will u be using ? 

4 hours ago, Russellsprout said:

Hi great build so far what driveshafts will u be using ? 

Be either making some custom ones myself and sending them off to get balanced or i will get custom ones made up for it going to be another pain i think!

I've decided it's time for an update! Alot has happened since i last updated! Engine has been in and out i don't know how many times, been dropped on my foot leaving me with a broken foot and everything!

So everything in the engine bay is now painted and I'm pretty pleased with how the engine bay is looking now.

 

It's a very tight fit as some of you may well know. Still a few bits to be done yet. Had it running then set about stripping the looms down.

 

Stripped the engine looms down at home to remove some sensors and solenoids ect

 

Then set about removing everything i did not need to run the engine

 

 

The final loom looked similar to this this picture still has alot of things which i have now taken out.

 

 

This is the pile of scrap i have been left with!

 

Ive also got most of the downpipe made up.

 

 

Still need to chop the straight down to where i want and put the v-band clamp on so next will need to order some 2.5" pipe and a reducer to go from 3" to 2.5"

 

Also started work on the mounts for the rear cage feet.

 

 

Ive now decided to leave the inside unpainted and just put the rear half of the cage in to save some time and also want to get everything running perfect before i paint inside just incase i damage the paint trying to sort little niggles out.

 

 

I've also cut the bottom half of the dash off as i wont be using it still need to modify the hole so the clocks fit in and make some aluminium panels to mount my switch boards and fuse boxes ect.

 

Clutch and flywheel is now in.

 

Next on the list is:

 

Finish the cage mounts.

Start making switch panels, electrical parts for this are now ordered

Run the fuel lines in.

Underseal the underside of the car.

Mount new rear axle on polybushes.

Order radiator and piping so i can leave the car running longer than a few seconds.

 

That's all for now skint for the next couple of weeks but hopefully should start seeing some progress after payday!