my mk4 polo. (engines in)

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mini_dub
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my mk4 polo. (engines in)

Post by mini_dub » Sun Apr 29, 2012 3:55 pm

just thorught i would stick a bit up of what i get up to when iam not messing with the passat

this was my first vw which i brought a few years ago now and fell in love with it within minutes of owning it even tho it was silly slow

not long after i brought it i had done the usual coiovers, polished p-slots 6n2 rear lights and had my self a pritty cool ride
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unfortunatly even tho it was mega slow i still managed to crash it :hyst
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fortunatly due to the fact it was so low it was all cosmetic damage done and was fix for a wooping £80 drove it around for a few months multi coloured until the gearbox started playing up and making some weird noises it came off the road
i wasnt to sure what to do with is as it wasnt worth anything as it was so i decieded to turn it in to a small project
when i say small iam sure it has been off the road for about 4-5 years now :D

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so theres a few pictures of what i have done body work wise smooth washer jets,jacking point arrows,seams under rear lights,badge and boot lock removed,top grills on front bumper and tow recess on the rear
next up it was on to paint
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full high build primer
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nice new coat of dragon green
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that brings us up to a few weeks ago where i decided i was going to do an engine conversion :| i decided that 20vt even tho they are a great engine and seem to make easy decent power i wanted to do somthing different and went off and brought a 2.0ltr 16v ABF from a mk3 golf been spending a lot of time trimming cutting moddign to get it to fit and heres where iam up to
notch needed
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notched
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master cylinder inside the cam pully [-x
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as iam sure you know the mounts from the polo were no good for the ABF so after a little thing i decided to mount it the same as the mk1 golf
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these still needed to be welded

here a few other shots of how tight it now is that i have it fitted better just enough room
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thats where iam up to today hopfully ill be welding the mounts in this week if i find the time then there is still alot of stuff to do to have it ready for me to smooth the bay and have the engine rebuilt

i will jusy add everything that has been done has been done by my hands no cheque book builds here :D

comments allways welcome

Chris
Last edited by mini_dub on Sun Aug 12, 2012 8:40 pm, edited 1 time in total.
{()()]==AIR Car of the month October 2010, March 2012. Car of the year 2012 Image
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torque777
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Re: my mk4 polo

Post by torque777 » Sun Apr 29, 2012 4:21 pm

Wow that's a labour of love ! Going to be good when done , fair play to you Chris
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Re: my mk4 polo

Post by mifkif » Sun Apr 29, 2012 4:53 pm

As you said at UD, this is not an instant gratification ride, but once it is done, you know it will afford you all the rewards. Putting in the time and effort now, will make it all the sweeter in the end.

Good luck with the rest of the build.

Matt
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mini_dub
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Re: my mk4 polo

Post by mini_dub » Sun Apr 29, 2012 5:06 pm

torque777 wrote:Wow that's a labour of love ! Going to be good when done , fair play to you Chris
cheers mate i have fell back in love recently now i have a proper place to work on it

mifkif wrote:As you said at UD, this is not an instant gratification ride, but once it is done, you know it will afford you all the rewards. Putting in the time and effort now, will make it all the sweeter in the end.

Good luck with the rest of the build.

Matt
cheers i think i will need luck. iam quite alot happier working on it atm knowing it wont be instant now that the passat is at a level iam happy with but still looking forward to getting this out for the first time, long way to go yet tho :???:
{()()]==AIR Car of the month October 2010, March 2012. Car of the year 2012 Image
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Wheaver
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Re: my mk4 polo

Post by Wheaver » Sun Apr 29, 2012 6:28 pm

I really like these polo's my mate had one has his first car in red was stunning till someone stuffed the rear of it I was gutted for him.

If the passat is anything go by this will be some motor :-bd

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Re: my mk4 polo

Post by redeye » Fri Jun 01, 2012 8:48 pm

WoW looking good keep it up :-bd
Who did the drive shafts?
Thinking of an engine swap in a blownup 1.0 lupo I just bought for the wife. I'd like to fit a rover K, but think an 8v 1.4 just to get it up and running.
I've said it before and I'll say it again.
"I'm never buying another Volkswagen"

mini_dub
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my mk4 polo

Post by mini_dub » Sat Jun 09, 2012 6:36 pm

Well made a bit more progress over the passed weeks
Started deleting unwanted holes and brackets
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Nearly finished the bay interms of smoothing but there is alot of tidying and little bits todo
Made up some chassis legs braces today saw this done on a mk1 golf at early edition and really liked it plus i should help support the extra weight and power of the new engine
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Parts have also been rolling in pritty fast
New front subframe with anti roll bar
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Polo 1.4-16v front hubs
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Golf mk2 g60 calipers and carriers to take the disc size to 280mm
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With regards to the drive shafts i havent had any made but have spoken to drove shafts uk and they will make basicly anything your after for about 250-300 depending on specs
{()()]==AIR Car of the month October 2010, March 2012. Car of the year 2012 Image
My Wagon: viewtopic.php?f=5&t=19734
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mini_dub
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my mk4 polo

Post by mini_dub » Wed Jun 20, 2012 10:51 pm

Done a bit more on it recently taking its time never want to smooth an engine bay again!
Smoothig wise is pritty much done just a lot of final fettling to get done before its painted!
Engine mounting wise is pritty much done with a small bit of fab work left
new engine mount design made
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Support bars welded and blended in
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Gusset piece welded and blended (for looks more than anything)
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Can see here the chassis leg is now boxed
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Thats all for now fokes
{()()]==AIR Car of the month October 2010, March 2012. Car of the year 2012 Image
My Wagon: viewtopic.php?f=5&t=19734
my mk4 polo: viewtopic.php?f=10&t=48182&p=372666#p372666

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mini_dub
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my mk4 polo

Post by mini_dub » Sun Jun 24, 2012 4:18 pm

Got a bit more done this weekend
Chassis leg fully box and support bar bended in
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Poped the front end on as i was bored of doing metal/body work in the bay
Can also see the wheels i have for it they are bbs rm 15" 6.5" wide they will be fully broken down and referbed before the go on the car will most likly put some wider rear rims on the back
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I totally for got when doing the support bars how much the rad support sits over the the chassis legs almost looks as tho i measured it perfect more like luck i think
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Cheers

Chris
{()()]==AIR Car of the month October 2010, March 2012. Car of the year 2012 Image
My Wagon: viewtopic.php?f=5&t=19734
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torque777
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Re: my mk4 polo

Post by torque777 » Sun Jun 24, 2012 6:12 pm

It's coming along nicely Chris

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Re: my mk4 polo

Post by mini_dub » Tue Aug 07, 2012 4:09 pm

Havent done a great deal in this over the last couple of weeks, even tho i spend alot of time up there i regualarly come away finding i havent really managed to complete anything! Gessing thats the way it goes with this type of trial and error project!

With that said i have finally managed to get my hands on a new pedal box to covert my cable clutch to a hydrolic one! I went for one off a 6n2 polo tdi which is pritty much a bolt on part with limited modding

I had to cut a pritty good size hole in the bulk head to allow room for the clutch master cylinder with that done i then made a new part for the bulk head
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Leaving just the inlet and outlet for the master cylinder! (quite neat if i do say so myself)
Next up (no pics of this) i had to cut a bracket off that was used to hold on the drive by wire set up on the tdi 6n2 then i was a case of a bit of chopping and welding on the throttle pedal converting it from drive by wire to cable!!
And it was finshed

See why i leave with the feeling i dont achive much??? That lot took the best part of a day to do but now have the right pedals to make it go,stop and change gear so wasnt a wasted day!!

Done a spot on the final engine mount today but more on that later

Chris
{()()]==AIR Car of the month October 2010, March 2012. Car of the year 2012 Image
My Wagon: viewtopic.php?f=5&t=19734
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torque777
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Re: my mk4 polo

Post by torque777 » Tue Aug 07, 2012 6:08 pm

Mate these kind of projects take a long time , especially when having to fabricate parts to fit , it will all of a sudden start to come together

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Re: my mk4 polo

Post by Das Booted » Tue Aug 07, 2012 6:23 pm

quality work and attention to detail

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Re: my mk4 polo

Post by mouse » Tue Aug 07, 2012 7:31 pm

Real nice read this mate and doing stuff yourself in the long run means so much more when she's done.

mini_dub
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Re: my mk4 polo

Post by mini_dub » Wed Aug 08, 2012 4:04 pm

Cheers it is slowly getting there list is still huge tho but slowly getting smaller


Problem is there is maybe 1or2 mk4 polo havig this engine conversion so i all gess work really altho i should have somthing quite special when its finished

Worse part is when you spend most of the day fabbing somthing up only to realise you have lost the plot and your original idea isnt going to work and start all over again ~x(

Bit stuck atm as iam currently waiting for some more material to complete the last engine mount
{()()]==AIR Car of the month October 2010, March 2012. Car of the year 2012 Image
My Wagon: viewtopic.php?f=5&t=19734
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Re: my mk4 polo

Post by mini_dub » Sun Aug 12, 2012 8:39 pm

Well after moaning like a girl the other day i fianlly feel like i have hit a massive point in the project!!
The engine finally sits in the bay on its own :) :) :) :) :) :) :)
The passenger mount isnt 100% completed but i have to say it was a good feeling when i let the engine craine down for the first time and it didnt just fall out

One it was in i refitted the front end and the bonnet!! To check clearances tight is the only way to discribe certain parts

I have to say i was very happy that the bonnet shut as i hadnt test fitted it at any point of the build so turns out luck was on my side on that part

Heres a few pics
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And last one of the donkey snug in its new home
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Still masses to finish in the bay yet hoping to get it in paint before the weather turns really poo for the winter other wise it will have to wait till next year which i wont be happy about :/


Thanks for looking

Chris
{()()]==AIR Car of the month October 2010, March 2012. Car of the year 2012 Image
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torque777
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Re: my mk4 polo. (engines in)

Post by torque777 » Sun Aug 12, 2012 9:00 pm

Well done Chris , must be a good feeling to get it sitting in there and getting the bonnet down too :grin:

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Re: my mk4 polo. (engines in)

Post by Eazi e » Sun Aug 12, 2012 9:08 pm

Talented fella ^:)^

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Re: my mk4 polo. (engines in)

Post by luvmydubs » Sun Aug 12, 2012 9:29 pm

Definitely. Boys got skills for sure.

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Re: my mk4 polo. (engines in)

Post by mini_dub » Wed Aug 15, 2012 10:51 am

Cheers lads :ymhug:
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Re: my mk4 polo. (engines in)

Post by stylin » Sat Sep 01, 2012 11:00 am

haven't looked at this for a while but well done on your fab work(see what i did there #-o )
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STYLIN
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mini_dub
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Re: my mk4 polo. (engines in)

Post by mini_dub » Wed Nov 21, 2012 2:25 pm

Few updates on this for those who care :)

Pritty much finished the engine bay now tiny bit of welding then some small prep work and then its time for some paint ( at last)
Before
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After
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General bay shots with the motor properly in
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Been having trouble recently with the power knocking out in the unit so today when it was off I decided to take the car off the stands and have a look at the sump clearance!
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There isn't massive clearance to the ground but a good 1.5-2" with on flat tyre so it's not too bad will fit a shallow sump as well to improve things

Got quite excited seeing it back on its wheels altho it got to dark to progress any further :(
{()()]==AIR Car of the month October 2010, March 2012. Car of the year 2012 Image
My Wagon: viewtopic.php?f=5&t=19734
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torque777
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Re: my mk4 polo. (engines in)

Post by torque777 » Wed Nov 21, 2012 2:51 pm

Nice to see some progress Chris :grin:

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Re: my mk4 polo. (engines in)

Post by mifkif » Wed Nov 21, 2012 3:52 pm

Biggup! Good show Chris, should be plain sailing from here :hyst

Keep the faith brother, she will be a beaut when done. I was going to say finished but builds like this are never truly finished, they constantly evolve.

Hope your bro is giving you a lift, he is a crazy Mo Fo too :ymhug:

Have fun,

Matt
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Re: my mk4 polo. (engines in)

Post by lcf13 » Tue Dec 18, 2012 11:08 am

wow!!!! MASSIVE RESPECT!!!!!!
i need to post something simillar, but not the Polo but the restauration of the 1980 Alfa Romeo Giulietta and the Opel Vectra! needs to find the spare time to post it! but definitive TO DO LIST!

Massive respect for the project!
Hell's Kitchen AVE 667
Passat B5.5 2001 1.9 TDI 74 KW

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