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Eskey

Greetings to all, my name is Oleg, I am from Russia.
  In our country, second-generation polos are not very popular due to the small number of such cars, and so I decided to look for communities outside my own country.
   And so about my baby:
   1992 release, engine AAV, coupe, well, or a hatchback, 4-speed gearbox.

 I bought it in 2013, it has a lot that worked badly, there was a lot of putty on the body, but I was happy to move from car with carburetor on car with injector, I was most attracted by the work of the engine, it worked like a clock even at an air temperature of -30°C, and I was not scared by the puffed putty on the body.
First of all, the technical part was brought to an acceptable condition and it became my daily car.

Here is a photo of how it looked after the purchase:

32d46c8s-960.jpg.f8b749e6fd271cf68a2200191dd021f5.jpg

It looks pretty good on the back, but the front look was not as whole as I thought...
As it turned out - this body was in an accident, there was a head-on collision, and the left spar was curved, and the hood with front fenders needed to be replaced.
Some time later, I managed to find the front fenders and hood in excellent condition.

I don’t have a photo with an old hood, but there is a photo with old fenders and a new hood:

9e6b818s-960.jpg.dc0491f1366355714ce3fcde1fb98e74.jpg

Then I replaced the front fenders, and also installed the missing part of the front panel:456b818s-960.jpg.01e70c46cb601b0fc953af6a190927b1.jpg

The grille was also replaced:

d76b818s-960.jpg.66baa40d20ea78e2dccaa7abfeb72947.jpg

For comparison, posted a photo as it was and as it became:

4ceb818s-960.jpg.b48b4acb208af64fb9e8df4ed0fa4368.jpg84eb818s-960.jpg.ed962f5933bb5c89ae9c59fe40255b57.jpg

At that time I was very pleased with my work, however - it was 2013.

He lived with me in this config until 2015, then I had an accident, because of the lack of a bumper amplifier, all my work was destroyed.

4379f5as-960.jpg.15e9dea8107af6527f9059b110887533.jpg

After that, I ordered new body parts: bumper, bumper amplifier, front panel and grille with headlights.

8679f5as-960.jpg.b3c89d5decda04f543d1d66d1a153fd0.jpg

a679f5as-960.jpg.140c8eab1d9404f5bbc7649dd79ce4b8.jpg

I decided to complete the work before the new year (it was in December)

bf9f5as-960.jpg.f127e435e46e8d262fcc0e92d379f74d.jpg

Here I got to the front panel:

9bf9f5as-960.jpg.aec0a66c0ab764cd3efaa1929120db8a.jpg

Instead of a normal amp bumper was bolted unknown origin design. All of this has naturally been removed from the body:39f9f5as-960.jpg.c5f99bfe10f56044b3796811b234a14b.jpg 

All new parts were installed in place without difficulty.

I don't know how you call the front panel, but we call it TV:

69f9f5as-960.jpg.43b7d0921ffa5bb4939375652c100549.jpg

And everything is in order...

b9f9f5as-960.jpg.4ad1ddb5362f6cbc5d9ba055f94e1d18.jpg

 

I will continue the next days, see you soon!

 

 

Edited by Eskey
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kiran_182

We call it a front pannel, the bumper part is a cross member, should have been fitted as standard 

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Eskey
19 hours ago, kiran_182 said:

We call it a front pannel, the bumper part is a cross member, should have been fitted as standard 

Oh thank you very much, now I will know how this part is called correctly.

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Eskey

After installing the bumper, we have this look:

79f9f5as-960.jpg.1d620481d20fb085a6bd473af213e521.jpg

In the same winter I changed the rims on winter wheels and set the taillights Hella redblack

fc6843as-960.jpg.d99b6847d1cf4085d542a7d3ed5a0f34.jpg

And for summer time I bought a set of VW motorsport rims on Yokohama S-drive tires

cecf666s-960.jpg.e73ec5be5bee6d15b6136523636b9206.jpg

In the middle of the spring season, a 4-speed gearbox broke down.

I found a 5-speed gearbox with an index of 8P:

4.jpg.3880d0bce9e5ceeee87af6f5c3b6a041.jpg

 

Cover of fifth gear was in rust:

5.thumb.jpg.39d25a22fdc51c258012573176de107d.jpg

This has been fixed:

6.thumb.jpg.f8755fef21e02ef0ceb1f782a2e4488c.jpg

7.thumb.jpg.ec5889ce3fcd17914acd0e8f82f65cb1.jpg

The gearbox was not completely disassembled and washed:

8.jpg.9de54fe72cf9d46fb29cb53aacc3931c.jpg9.jpg.673287289c79b97284a0f0521b982e96.jpg

All seals have been replaced. And also added a dust-coat on the gear selection shaft.

10.jpg.74b8684dee50b1694ac6e5139020903b.jpg

Now a few words about the gearbox bracket:

11.jpg.7d4debad60f0e2766370d9358f5ae13c.jpg

It is not suitable for 085 gearbox, and I couldn't find a factory bracket...

Using the angle grinder, I cut off all the excess metal from the bracket and attached on the right place:

12.jpg.93c64a61add04c25f549dbd889a91a3b.jpg

to be continued...

 

Edited by Eskey
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kiran_182

Think 8p is the g40 box and will give the car some better pace, thats a good find 

 

Youll need a 5speed anti roll bar too. 5speed gearbox mounts are aroud

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steveo3002

g40 is atv....8p is just a stock 5 speed with a nice cruise speed

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Eskey
19 hours ago, kiran_182 said:

Think 8p is the g40 box and will give the car some better pace, thats a good find 

 

Youll need a 5speed anti roll bar too. 5speed gearbox mounts are aroud

 

19 hours ago, steveo3002 said:

g40 is atv....8p is just a stock 5 speed with a nice cruise speed

There is such a chart that shows the gear ratios of the boxes.
In general, my 4-speed gear ratios were exactly the same as the 5-speed, but there was no 5 gear.

The old gearbox had the index AKY.

284301264_.jpg.e3fb160d2932cc16508004e01b6daf88.jpg

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Eskey
19 hours ago, kiran_182 said:

Youll need a 5speed anti roll bar too

Can you show a photo of thing about what you talking, please.

Edited by Eskey
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steveo3002

mk2f should have the correct arb...its the bar that ties the the lower arms to the car 

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Eskey
16 minutes ago, steveo3002 said:

mk2f should have the correct arb...its the bar that ties the the lower arms to the car 

speech is going about non stock details?

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Eskey
22 minutes ago, steveo3002 said:

mk2f should have the correct arb...its the bar that ties the the lower arms to the car 

I apologize for the misunderstanding, I think I understood what you are sayed, I highlighted this detail red

478240669_.jpg.7f75951e3e147fe49ee3db8356d3dc8a.jpg

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steveo3002

Image result for polo mk2 anti roll bar

this part here...some early cars had what we call a 4 speed one , later cars all 5 speed bars regardless of what gearbox was fitted

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Eskey

Now I have a 100% understanding of which part we are talking about, we call it the stabilizer

1036242018_.JPG.7503c8640379ed6b49ab7fc5818f3d7a.JPG

Which diameter of arb on 5speed body?

Edited by Eskey
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steveo3002

same diameter , differant shape to clear a 5 speed 

 

i dont have a picture to compare them , im confident your car has the correct one

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Eskey
5 minutes ago, steveo3002 said:

same diameter , differant shape to clear a 5 speed 

 

i dont have a picture to compare them , im confident your car has the correct one

And I already thought that at the 5speed it is more powerful, but most likely I have the right one installed, because nothing hinders the box

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Eskey

Hi, I continue my story about the Smurf.

  After sawing off unnecessary metal from the bracket, I have bended  the edges inward:

13.jpg.dd05f9ca4132c1fe20350633060dec53.jpg

Then I cut metal plates and made a holes for mounting bolts in them:

14.jpg.17972846bd35d37ec837b7229a48d15e.jpg

 

I was needed one more plate, and cutting it out, I prepared all of them to assemble the bracket:

15.jpg.36a6058d6dcf62b66859522f5a79a9dd.jpg

Then it was all assembled in one element and welded off:

16.jpg.769fceaf55adc03883831c4014ef9591.jpg

It was my first experience in welding.
So don't kicking me so strong)) (Joke, of course kicking))))

17.jpg.c1ef1f557544f2d5cbc848d2b16cff7f.jpg

18.jpg.2665b61474a8c7d79508d69a00516872.jpg

Now i need to go sleep.
 Bye bye!!!

 

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dvderlm

That's ugly but not at all bad for first welding. It has to hold the weight of 1/3 of engine and gearbox.

 

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Eskey
17 hours ago, dvderlm said:

That's ugly but not at all bad for first welding. It has to hold the weight of 1/3 of engine and gearbox.

 

I took the metal of the same thickness, like the bracket, it has been used for more than two years, likely all not so bad, if nothing broke off

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Eskey

Hi all.
The following works were performed in the cabin, in particular with the high beam and turn signal switcher, I apologize in advance if something is not correctly named, we calling it a dragonfly or guitar or helicopter:

1.jpg.6bef8030ba4106903a7536247e45a40c.jpg

The high beam didn't turn on with correct switcher, but by a separate toggle switch, and the turn signals did not turn off automatically after turning the steering wheel to the straight position.

Here is a toggle switch:

2.thumb.jpg.c0a384af0a0c360d6ac915588aff58a8.jpg

This toggle switch was working even with the ignition off.

I bought a dragonfly from golf 3:

3.jpg.7287d6254dcdf59d3bd2cebf3be767ba.jpg

 and before installing I decided to look inside:

4.1.jpg.0d4ba3d408e510c34cc74ab4d7a97c78.jpg

Then I blanched the contacts and smeared with plastic silicone grease, because dust does not stick to it...

4.thumb.jpg.2346923fc6f9770ba5f068a9d68842d9.jpg

assembled it, and installed on right place

5.jpg.0c4757a3a42341a473ae0ae9b21c7080.jpg

it's new design looks pretty good and not bad blended with interior of cabin.

That's all for today, i hope you will understand my words, and if something will be unclear or was not correct translated, please correct me, this way I can learn English faster.

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kiran_182

English is pretty good, on minor errors in grammar

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Eskey
52 minutes ago, kiran_182 said:

English is pretty good, on minor errors in grammar

That's good that you understanding me, errors in grammar even in our country are making a russian people in russian language

Edited by Eskey

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dvderlm

"Dragonfly" is much more poetic than "indicator and wiper stalks".

 

But "blanch" is odd for electrical  contacts. It is usually cooking term for put something in boiling water for a short period before doing different cooking method like roast or fry.

Maybe "rub clean" or "degrease" or "sand down" or "abrade"?

 

 

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Eskey
10 hours ago, dvderlm said:

But "blanch" is odd for electrical  contacts. It is usually cooking term for put something in boiling water for a short period before doing different cooking method like roast or fry.

Maybe "rub clean" or "degrease" or "sand down" or "abrade"?

Yes, this is important information for me, I think a more proper word is abrade.

11 hours ago, dvderlm said:

"Dragonfly" is much more poetic than "indicator and wiper stalks"

We always simplify complex part names.

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steveo3002

abrade would be correct ...or just say 'cleaned up ' 

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Eskey
1 minute ago, steveo3002 said:

abrade would be correct ...or just say 'cleaned up ' 

I only managed to clean them with a screwdriver. It was resistant dirt.

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