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kwijibo_coupe

White AFH converted coupe A.K.A. The White shed of Excellence

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kwijibo_coupe

Model: 1992 Polo CL Coupe

Engine: 1390cc AFH on standard 6n injection

Suspension: TBC

 

Brakes: Standard

 

Wheels and Tyres: BMW E30 Bottle Tops 14 x 6 ET35

Exterior Styling: Standard, rusty, bit of a state

Interior Styling: Corrado seats, GT clocks
 

To Do List: Too much to list...

 

Better late than never for a build thread I suppose.

 

I bought this Polo at the Polo Social 2017. Within 5 minutes of being on site at the Social it was affectionately nicknamed "The White Shed of Excellence" thanks to @jonPDpolo. The reasons for which I'll not go into, if you know...you know.

 

The thing was a state, had been sitting for a while since the previous owner had moved abroad. However it had been converted a few years ago to an AFH and had been looked after at some point. So as a result it drove back to the camp site and then back home to Scotland the next day pretty much flawlessly.

 

This is how I picked it up.

 

 

IMG-20170702-WA0031

 

IMG-20170702-WA0029

 

IMG-20170702-WA0032

 

Unfortunately lost the 'L' from this windscreen sticker :lol:

 

IMG-20170702-WA0030

 

IMG-20170705-WA0003

 

Got it home and desperately had to do something to it right away. First thing I thought of was swapping the old clocks out for a set with a rev counter.

 

20170704_164744

 

20170704_172000

 

A few days later it went up to visit the 'Death Van' which was sitting up at my mates house.

We agreed on a deal for him to buy the van off me so long as I could take "a few" parts off the car...

 

20170708_173103

 

I may have taken a little bit more than I made out...

 

20170708_195532

 

Anyway the front end of the car went from this.

20170708_180620

 

To this.

20170708_211528

 

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Much better I thought.

 

Over the next few weeks when time allowed it was just a case of cleaning things up when I could. Starting with the state of the engine bay.

 

20170805_113850

 

I do love the look of an AFH in these.

20170805_124540

 

Also sorted something that had been annoying me from a safety point of view. The Corrado seats have a really tall seatbelt clip. Me being a skinny chap meant the lap belt didn't actually contact me at all. Just went over the seat and flopped about. So to try and avoid submarining in the event of an accident I swapped the Corrado seatbelt clip for one off a G40 seat.

20170805_131845

 

Success, the lap belt now contacts me as it should with a bit of room in the belt to spare before the stopping pin thing.

20170805_132129

 

Onto a cosmetic annoyance was the colour coded bumpers. As I'd changed the front for a none colour coded item I set about changing the rear.

20170805_161451

 

The best one I had in my collection was a 'race spec' one that had been drilled a bit :lol:

Looks better than the colour coded one anyway.

20170805_163909

 

A few more bits and pieces were sorted then it was time to put it on a complete set of wheels. Went for a set of 14" BBS RAs at first which I think looked alright.

20170806_14165120170806_141703DSC_4038DSC_4042DSC_4052

 

I then got my hands on a set of BMW E30 bottle tops. I think they looked a little better.

20170923_10032620170923_151320DSC_4079

 

That was pretty much that for a while.

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kiran_182

Nice recovery, always wanted to see how a mk2f goes with an afh

 

Is the death van on the road

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kwijibo_coupe

Grown up things like buying a house, work, family and other commitments meant pretty much all car activity halted for me until Christmas.

 

20171209_125635

 

Got the new garage all cleared, tidied and ready to accept The White Shed of Excellence.

 

20171213_15283520171213_204803

 

Once I get time to work I try not to hang about.

20171213_21152120171213_22071220171214_171254

 

On removing the suspension I found the reason for the poor ride and handling. The rear springs had been swapped for really short 275lb springs. That's stiffer than what I run on the front of my GT!

20171214_171120

 

With it all stripped I've got a collection of parts to sort out and a shopping list to make up.

Included on that list will be an H&R cup suspension kit and 256mm brake conversion parts.

I already have parts like a rear disc conversion, braided brake lines etc. ready to go on the car.

So more updates should come soon.

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kwijibo_coupe
7 minutes ago, kiran_182 said:

Nice recovery, always wanted to see how a mk2f goes with an afh

 

Is the death van on the road

It goes alright, it is a bit dulled down with the 8P gearbox (never understood why people do that) but even so it feels a lot more refined compared to a GT. Hopefully a GT gearbox will liven it up a little and along with my suspension and brake plans make it a nice fun B road blaster.

 

The Death Van is now in the hands of my mate who plans on doing a long term restoration on it. His first car was a Mk2f breadvan so I think he wants to relive his youth.

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residentmelon

Nice work 

 

I have a set of bottle cap for my MK2 they look really nice out of interest what tyre size you running?

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kwijibo_coupe
5 minutes ago, residentmelon said:

Nice work 

 

I have a set of bottle cap for my MK2 they look really nice out of interest what tyre size you running?

Thanks :)

 

Just now they are 165/65/14 which is a bit big. When funds allow I'll be swapping to a set of 185/50/14.

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residentmelon

5a4f4eebb514d_Wheels1.thumb.jpg.16e315b5d751bdcb7977300609564bd2.jpg

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residentmelon
1 minute ago, kwijibo_coupe said:

Thanks :)

 

Just now they are 165/65/14 which is a bit big. When funds allow I'll be swapping to a set of 185/50/14.

 

Take it you looking at the Yokohama A539

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kwijibo_coupe
55 minutes ago, residentmelon said:

 

Take it you looking at the Yokohama A539

 

Exactly what I'll be getting. Run that tyre on my GT and absolutely love it.

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McCann

Good to see some afh loving on here for a change lol.

 

Nice turnaround on the car. It is looking much better. Bet its fun to drive

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mbusby993

Always quite liked this one, glad you’ve got a thread up. I need to sort out a daily so I can take mine off the road and do the AFH swap and all the bits I fancy. What’s it like on standard injection? 

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kwijibo_coupe

It is honestly great on standard injection. Reliable as you like, gives great fuel economy and more than enough power to have fun with. 

Like I say it feels a bit dulled down with the 8P gearbox especially from 3rd onwards. But I reckon with a GT gearbox it will be a right laugh. 

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kwijibo_coupe

Some updates on this.

 

Went out to the garage on Saturday night and the engine looked like this.

20180217_180525

 

Just over an hour and a half later with the help of @Ross36 we had done a little engine raise...

20180217_194649

 

Then out the car completely ready to be worked on.

20180217_195008

 

Leaving one rather dirty but bare engine bay behind.

20180217_195037

 

The plan is basically to tidy up everything and do a bit of preventative maintenance along the way.

First item on the remove and throw out list is this, actually can't believe how many still have these fitted.

20180218_201239

 

I had a quick look at the wiring after that and thought I'd tackle that another day. Looks like sections of it run from the engine bay, into the scuttle then into the cabin with no plugs to split it up. Obviously making removal a bit of a PITA, but I'll figure it out and probably install a plug to insure it is easier to do in the future.

 

So with that onto the engine teardown, gearbox off first.

20180218_212455

 

This is where I discover it is actually a CWX gearbox on it, not the 8P like I thought.

20180218_212504

 

The CWX was the standard 6n 16v gearbox and has almost identical ratios to the GT gearbox, however it has a 3.8 final drive instead of the 4.063 of the GT. I never thought this would make much of a difference, but it didn't feel very well suited in this car. Not sure if it's because of the difference in tyre size between the 6n and 86c or maybe the gearbox was on it's way out (it was making noises) but 3rd onwards seemed a bit slow which is why I thought it had an 8P.

Regardless the plan was to fit a CEH I have laying around so that will be going on it see.

After some ratio comparisons though, I might look into getting this gearbox reconditioned and sticking it in my turbo. Might be a little better than the CEG I currently run.

 

Anyway enough gearbox talk, clutch and flywheel came off next. It was still running the 6n flywheel, so that will be replaced with an 86c unit so a bit of weight saving.

 

20180218_213223

 

That's pretty much it for now, currently all sitting like this until I get chance to work on it again.

20180218_213416

 

 

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nige8021
kwijibo_coupe

Some goodies arrived for this during the week.

 

So I now have a nice, shiny H&R 60/40 kit for this. Should be a big improvement over the cheapy TA Technix coilovers that were on there.

20180222_195145

 

Also ordered some de-greaser, a pressure spray bottle and a bag of rags to clean the engine bay.

Finally on top of the bag of rags there is a pair of handbrake cable adaptors for the pending rear discs conversion :)

(Ignore the 30 year old, granny spec carpet...)

20180224_122000

 

Got started on the engine clean at the weekend, this is before.

20180224_122722

 

This is after. Still some work to do, but nice to know everything so far is nice and clean under the sludge.

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Continuing the tidy up it was time to pull the wiring loom for the AFH.

20180224_142713

 

Here it is in all its messy glory on the granny spec carpet.

20180224_150948

 

Here is the engine side of the loom.

20180224_155021

 

The eagle eyed may spot right away the issue that concerned me the most.

I hate these things and personally think they belong nowhere near a car.

20180224_155005

 

Anyway, I swapped those for some proper crimped connections, insulated them and loom taped everything that was exposed to the elements.

20180224_16101720180224_154234

 

The three plugs that connect inside the car I've left alone for now, as I plan on buying some of the connectors Nige linked to above and tidying them up that way.

 

While I was under the dash I noticed some messages from a previous owner...

20180225_09311020180224_141613

 

Before I put the loom back into the car I had to fix yet another bit of bodgery, seems all I do on cars I buy is fix other people bodges :lol:

So I had to somehow make this badly cut out, sort of rectangle shaped hole into a more circular one so the rubber boot will fit nicely.

20180224_181647

 

Firstly a piece of scrap metal was riveted on to give the hole saw pilot drill something to go into.

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Like so...

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And we now have a nice round, more OEM looking hole.

IMG-20180224-WA0036

 

The hole saw wasn't too happy about it though. Top tip o the day....don't buy cheap hole saws.

IMG-20180224-WA0031

 

Anyway the hole is drilled and the rubber boot fits nicely, so it's a bit more OEM looking which is the look I'm going for.

20180224_191330

 

One last little thing to tidy up after that. Taking off the final bit of colour coding.

20180225_115338

 

I personally thing it looks much better with the black boot trim. Just the rust to try and sort now...

20180225_121758

 

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kwijibo_coupe

Didn't realise it was February when I last worked on this. Just laziness more than anything else.

 

Anyway I've got a load of parts sitting so decided it is time to stop making excuses and get to work.

Started off with a set of front struts that I cleaned and gave a quick lick of black paint.

41437727231_e4ceb8653f_k.jpg20180413_155302 by Steven Thomson, on Flickr

 

One last look at the inserts before they are hidden forever, just to prove it is H&Rs going in not some cheap rubbish.

40542902335_2784b1adf3_k.jpg20180413_160954 by Steven Thomson, on Flickr

 

All built up with the spring and top mount. Looks pretty much standard, more aftermarket lowering kits should come with black springs.

40723107454_0634fe9075_k.jpg20180413_173322 by Steven Thomson, on Flickr

 

And the matching pair. Also cleaned up the hub faces with a wire wheel and chased the threads for the wheel bolts since these have been sitting a while. I did consider chucking in new bearings and hubs but there is nothing wrong with these and I'm not looking to do a full on restoration here. :lol:

27565337758_042094dbc5_k.jpg20180413_174255 by Steven Thomson, on Flickr

 

Stuck the passenger side one on the car and stuck a nice shiny VW11 disc on too.

41395103152_4a93990455_k.jpg20180413_211927 by Steven Thomson, on Flickr

 

Then put on a VW11 carrier I found.

39628456600_505ce05d4f_k.jpg20180413_212453 by Steven Thomson, on Flickr

 

That's all for now. Next step is to fit all the suspension, fit the stage 2 subframe and all the other goodies I have then work on getting the engine back in.

The plan just now (until I change my mind next week) is to get this back on the road sometime in May and use it as a daily/rolling project. 

Thanks to a new job I recently cut my commute down from 70+ miles a day to just 2. So really, I don't need a super reliable, comfortable or sensible daily. Plus I'll have extra time to work on my cars again. Hopefully get one of them ready for the Social :lol:

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kwijibo_coupe

Rear suspension time, I don't know what it is but I just love the look of these shocks. I think it might be the fact they are so subtle.

41566323351_09d8586579_k.jpg20180418_143137 by Steven Thomson, on Flickr

 

All fitted...but nowhere near sticking the wheels back on yet.

41525292902_03590cf488_k.jpg20180418_213628 by Steven Thomson, on Flickr

 

Now a chance to kill two birds with one stone. A previous owner had welded this sump up for a reason I'm yet to figure out. If it was to fix an oil leak it didn't work as it leaked like a sieve. But also if I'm fitting a subframe then this sump is too deep and it will foul. So a mk2/3 sump conversion is the fix for both of these issues.

41525264532_775ba15e51_k.jpg20180419_124633 by Steven Thomson, on Flickr

 

Old sump off, notice the deep skirt on the oil pump pickup. This is the mean reason the sump is deeper on these.

26697530057_f0fb2bf2f7_k.jpg20180419_131309 by Steven Thomson, on Flickr

 

Also the difference in length between a 6n dipstick and a mk3 dipstick.

39757813150_d439d0961d_k.jpg20180419_132834 by Steven Thomson, on Flickr

 

Bit of modification required to attach the top of the mk3 dipstick tube to the head, so I cut the bracket off the 6n tube and lined it up again the mk3 tube.

26697507077_710a5bd9d2_k.jpg20180419_134142]

 

Then a couple tacks with the welder and all is good. This isn't exactly going to be seen and its not going to see any forces so didn't see the point in making it tidy.

39757771320_1b9d7c5ebf_k.jpg20180419_171601 by Steven Thomson, on Flickr

 

Then it was time to find a mk3 oil pickup...I did not steal this from a G40 lump I have laying around...honest.

41566496661_3e1f83b5a8_h.jpgIMG-20180419-WA0023 by Steven Thomson, on Flickr

 

That's the G40...ummm I mean mk3 pickup fitted.

40673425485_e96a368fa3_k.jpg20180419_173855 by Steven Thomson, on Flickr

 

And the mk3 sump fitted, just waiting on a gasket arriving in the post and I'll get it fitted up properly. 

40673424915_1dfd069465_k.jpg20180419_174407 by Steven Thomson, on Flickr

 

I do love how VW used the same basic short block for the AFH so modifications like this are just a straight forward bolt on. 

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kwijibo_coupe

Next up some exhaust mods, the exhaust on the car looks to be made from stainless of decent quality but has a bit of a home made look about it, especially the welds.

Anyway the tailpipe was routed to dip down below the rear bumper and stuck out a fair bit. These photos are of it in my bench vice but hopefully you get the idea.

26697566837_79d6119e2d_k.jpg20180418_212523 by Steven Thomson, on Flickr

41525301702_4afa1e509c_k.jpg20180418_212546 by Steven Thomson, on Flickr

 

So what I wanted to do was to tuck it in a bit and have it come out at more of an angle rather than straight back.

Choppy choppy.

41525272372_3d9e6656ef_k.jpg20180419_103629 by Steven Thomson, on Flickr

 

 This is just me showing off my welding 'skills', I cut off a hanger that was welded to the tailpipe. The hole that resulted was about an inch wide and I managed to fill it with just weld. I was quite pleased with myself.

39757832490_390f6b4832_k.jpg20180419_105644 by Steven Thomson, on Flickr

 

Then some more cutting.

40877806144_8ad211b46c_k.jpg20180420_143121 by Steven Thomson, on Flickr

 

Tailpipe lined up how I wanted it.

41588885091_0099c6ea59_k.jpg20180420_143608 by Steven Thomson, on Flickr

 

All welded up and after the death of a few flap discs it didn't look half bad.

41548268422_0e101d9385_k.jpg20180420_145748 by Steven Thomson, on Flickr

 

And the end result. Sits a little further in than I wanted but it is just the right angle that I was after.

26720649637_b92f3743e5_k.jpgIMG-20180420-WA0014 by Steven Thomson, on Flickr

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MartinB

Good work, Steven :)

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MonsterL35YFP

Looks awesome, how did you make that loom? 

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Black dog

I really like your build. I've got a 92 coupe, it's a clean and tidy genesis one and I'm now in the market for a 1.4 16v conversion for it. Could you confirm what car and engine code to be on the look out for as a doner? I'm looking for the 100 bhp version and wish to run on standard vw set up not bike carbs! Thanks in advance.

look forward to seeing your subframe set up sounds interesting.

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nige8021
28 minutes ago, Black dog said:

Could you confirm what car and engine code to be on the look out for as a doner? I'm looking for the 100 bhp version

 

97~99 6N1 AFH engine code

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Black dog

Is that engine fitted to any of the saloon versions, there's a saloon 1.4 for sale about 50 miles away from me but the seller has no idea what engine it has, just its a 1.4 petrol

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nige8021

I think it was only in the hatchback models ie the 6N1's not the 6K models, it was also fitted to the Seat Ibiza 93~99 models

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