Motors Random adventures of a spanner! (Pic heavy!)

Model: X Reg 1981 Mk1 Polo

Engine:

42k 1598cc 1.6 16V (Lupo GTI - 123bhp)
5-Speed Box

Suspension:

Fully Adjustable Front Wishbones
Rose jointed Camber adjusting top mounts
Strengthened strut tops
Lupo Gti Front Shocks and Springs
Mk1 Polo Steering Arms
Lupo Stub Axles
Mk1 Polo Rear Suspension

Shell Modifications:

Bulkhead removed
Seam welded
Seat Runners Removed
Modified Gearbox Mount for Lupo Gearbox

Brakes: Lupo GTI 256mm Brakes

Wheels and Tyres: OZ Routes 14x7

Comments: Will be receiving delivery of this project in the next week, got some seat mountings to weld in, get the shell prepped for painting and then get some bike carbs and inlet manifold made up along with some aftermarket engine management to deal with it all.

Will update this thread with more details when i get my hands on the old girl





couple of updates,


I've managed to pick up an M-Tech Automotive Megasquirt V3 Ecu brand new for 175 quid, This comes with the following:

Megasquit V3 Ecu (With new case)
Wiring loom
Data cable
Software




The ECU is built to this Spec:

V3 ECU
4x COP Ignition drivers
GM Sensors
VR Crank Pickup

This is ideal for a Throttle bodies transplant for 8 Valve or 16 Valve non Turbo.

It can run any 4 Cylinder by wasted spark/ or any 4 cylinder COP engine such as GTi6 if it uses a trigger wheel (either 36-1 for 60-2) so pretty much any VW, Ford, Vauxhall, Pug, Citroen etc etc

I know the lupo has a 60-2 wheel so thats all good, will just need to go lop off all the connectors from a crash damaged loop or polo gti.

also managed to get some schroth harnesses with pre-tensioners for 82 squiddlers that shall be finding there way into the car, would take pics but cant be arsed. they are similar in colour for the first blue which makes me sex wee everytime.

and my potential colour choices







Woop, the polo is here, a friend kindly lent me a space in his workshop for a few months. what a legend

anyway some piccies

The polo tucked away in la garage





the engine, and loom with plugs for the various sensors





The bell housing is leaking, i think the rubber seal needs replacing but ill drain the gearbox oil and investigate



decat downpipe



throttle body has already been replaced from a fly by wire to a cable version



Adapted lupo driveshafts





lucas 54 calipers for 256mm brakes



cable shifter loosly in place, holes have been drilled




but this needs removing to allow it to lie flat, it shall meet mr angle grinder



various pictures of the wishbone conversion, thought id just take a fair few for any one thats interested










not quite what this is? rear gearbox mount maybe? or possibly,



and some of the various bits of seam welding








some bits rob was selling which i think ill be stickin in the car



Sifted through all the other parts to find out what wasnt needed and theres a fair bit



will eventually picture it all gand get it up for sale to clear teh sapce.

got loads of jobs to do, big and small, cant even be arsed to start listing them all now, and they say a picture tells a thousand words, well ive just wrote an essay with this laptop crashing post

 

That looks like its going to be a lot of fun,someones put a lot of work into the shell, you should put a log up on the Club Polo forums, they appreciate nutters with big plans for polos.

 

hahaha im a regular on there, mad about polos and golfs been on here for years though and still mess about with my pcs so like to keep people updated with what im up to

 

That's going to be completely sick. Keeping it looking sleeper-ish to torment Corsas and Saxos?

 

Got a few things done today,

Cut out the notchy bit on the transmission tunnel, so i can make a shifter template to make a base to attach it all up, nearly went deaf using the angle grinder in the car, ear muffs needed!

Got the Hocks off and popped the OZs on, temporarily as i want to put the hocks on my mk1 golf shell which ive sold, and put the black lorbers with near new 195/45/15 eagle f1s on the loop while i find some 14 inch tyres or sell the routes.






Also got a good gander at the hub setup, noticed there was an awful lot of play in the bearings inside the hub, it may be due to the fact theres no driveshaft in there, but im going to check the mk1 golf hubs tomorrow to check for thier movement inside the carrier. The mk1 Golf hubs will fit the lupo driveshafts, lupo struts and the wishbone ball joint. It will also allow me the hub carrier spacing to fit VWII Calipers, and a brand new vag mk1 polo master cylinder. Although i will only have 239mm brakes for the time being it means i can get the car running and mot'd and then find out if there is enough room to fit the mk1 golf servo and linkage with the engine installed.

If not i will have to invest in a remote servo before i can run the 256mm brakes as the larger pistoned calipers means the pedal would hit the floor long before your brakes had any real bit without the use of a servo

The balljoints look at a skewif angle which is in part due to it being jacked up at the time and i think with the engine installed more weight will be applied on them which will allow to sit true. hopefully

also while having a wee smoke i made a list of some things to do but theres loads ive probably missed out.






Stuff to do

Stuff to get

* Exhaust System
* Seats
* 14 inch Tyres

Stuff to do

Braking & Suspension

* Fit New Master Cylinder
* Fit Golf Mk1 Hubs
* Fit VWII Calipers & 239mm venteds
* Fit Braided Hoses
* Make new solid brake lines from mc to regulator and front caliper hoses

Body

* Rust treatment on a few areas
* Primer/Silver Paint
* Waxoyl
* Seat Runners

Engine

* Replace Bell Housing & Gasket
* Change Gearbox & Engine Oil
* Get a crane and fit

Shifter & Pedal Box

* Make Template for Shifter Base
* Mount

Fuelling

* Fit Fuel Pump & Accumulator
* Fit Fuel Lines

Megasquirt

* Read, read and read
* Set Initial ECU settings for specified settings
* Assemble Loom

Other Jobs

* Pedal Box Modifications - Cable Throttle, Push Pin Servo, Hydraulic Clutch (i think? )
* Relocate Battery to Boot
* Fit Harnesses & Pre-Tensioner Relays
* Fit Battery & Fuel Cut off Switches
* Uprated Headlight Loom
* Fit Ancillary Wiring Loom

Further Jobs

* Replace Bearings in Lupo Hubs
* Make Neccessary adaptations to Mk1 Golf Servo Assembly
to allow use of lupo calipers and rear disc conversion

 

will torment them no matter mate, but yep it stay moderately understated on the outside, not sure what overall feel in going for inside, nothing flashy by any accounts, cable tied clocks on non dashed Cheesecake, not sure whether to get a mk1 polo dash flocked or experiment with a lupo or mk5 polo dash.

after seeing a ppc magazin about building your own cars wiring loom i was tempted just to have a bank of switches for various things like lights, engine fan and other odds n sods, then just get various guages, a tacho and speedo.

 

looking good, keep the thread updated so we can see how your doing my first car was a polo many years ago so i def wana see how this turns out! good luck!

 

Had a bit of a chiller day at the unit, Rob was changing the hub over on his cabby for one from my red shell, which solved his humming niose thats plagued him for the last week or two.

I stuck the lorbers on the polo and while the wheels were off sprayed the arches with metal ready.

Plan for this week is to prep the interior, wire brushing it all and then getting some metal ready on it and lashing it all with por 15.

then nnce thats done i can get the inner arches and engine bay sprayed up, Robs trying to tempt me to spray the whole car there while we have the whole car stripped so i reckon i could be tempted now to save fannying about later.

Zee polo also met its younger sister too

 

christ do you have access to a full garage?

 

pretty much haha it was going to be a driveway project like the others but my mate is an absolute legend and is sorting me out space and man hours too while he waits for his mk1 to come back, i said i would help him rebuild it as he cant remember how they go back together and im forever taking them apart

 

The wheelbearings need to be compressed by the castle nut on the CV joint in order to work properly. Without the proper tension there will be play in them.

 

sound man, thats what my polo bible uncle steve said, another mate told me that with the engine in and no driveshafts in the bearings can crush, however at 675kilos kerb weight, without an engine and fully stripped the car weighs as much as a feather so shouldnt have any problems like that

ta for in the info

 

NP.

They can crush, but if you're only pushing it about by hand you should be OK. What I'd do though is take the shafts out of the outer CV's, Ducktape some plastic over the open ends of the CV's then fit them to the hubs and torque them up. Safe then .

 

Me and walsh started on the floor today, got a fair bit done, also s iifted thru a few more of the spare parts

couple of pics after a hoover

 

*sniff* I miss my polo...



ontopic: I remember how light they are, one of my mates would lift the arse end and turn it so i'd have to mess about getting out was funny the first couple of times...

 

Another awesome polo log, great stuff. I'd love to get myself a project car someday and just sort it out, learn some mechanical skills. Keep it up!

 

hahaha yeh people used to do the same to my old mini, what polo did you have?

you should deffo give it a crack mate, well worth it!

somre more done on the floor pan and transmission tunnel, made a bit of a start on the firewall





wire brushed the seam welds to get rif of some of the surface rust

 

The engine is too far forward.

 

nice observation skills, whats the problem?

 

Twas a C reg 1.3 i had (think i may have linked to it before), wasn't in too bad condition if i say so myself... When I got her she still had the original tape deck in her, whilst I was waiting on my new head unit coming I had only one tape and that was from the same yeah the car was made... The Top Gun Soundtrack!! was awesome listening to that and bombing around the back roads!!