Frankie

Whilst we had some aluminium to play with we set about making a dash pod to house all the dials, kill switch etc. First a cardboard and gaffa tape moc up Then the measurements were transferred to 6mm ply and pinned together to get a more accurate scribe of the windscreen etc Once the ply box was complete we could then take sum accurate measurements/template from it to make the aluminium item. This now just needs its seems welding up like the selector box

I got hold of a golf original downpipe that I could use the end of that bolts to the turbo. We sectioned the pipe and welded it to fabricate the tight bend required to turn the pipe before the bulkhead Tacked up before seamed Time for a little break Then we needed to address gear selection. We had the gear selector unit from the golf and just needed to get it suitable mounted. We made up an aluminium box to house it on the tunnel. As it stands it just now needs its seems welding up by an aluminium welder.

Got some new progress pics of a few bits we've been playing with. Jobs aren't necessarily getting done in an order of priority, just a matter of what we fancy, whats fun and what's affordable (this has to be the tightest budget 1.8t going!) Original crash bar, we decided to make one that covers only the centre of the legs to leave stacks of space on the inner wings for intercooler pipe work etc. it is also lighter and better for airflow than the original. The number plate recess has been cut out to allow the airflow. The 'top trim' or headlamp surround trim that normally clips into the wing ends and sits on top of the bumper is now bolted to the bumper itself for easy removal of both in one piece. The idea is to make the front end as easy to remove and work on as possible, the bumper will be attached with bonnet pins and side straps. The radiator now mounts to the new crash bar rather than the original big plastic panel Meaning that all of the old panel can be cut away, leaving only the headlamp holding part

It's been dusted off and brought back into the unit today for a bit more of a play so wel see what the next few weeks bring.

made some progress with the clutch pedal tonight. The golf clutch pedal assembly bolts straight in. If you remove the lupo clutch pedal from the pedal box you are left with (as you mentioned when changing for gti kit) the perfect gromit and the studs to bolt it all in. The only modification to be made is to remove the lever point for the old cable pedal (the bit that fails on the pedal boxes)and the bracket for the clutch press sensor (this is built into golf assembly so no need for it there) Jona should have some more pics to post. I will look up the two andys and see what they can do for us. It would be nice to be able to just plug it all up!

i notice the clutch assembly seperates, thats why im hoping it will be reasonably straightforward. I should think safety will be no problem, the assembly bolts direct to golf bulkhead and thats how it will be fitted to the lupo. I'l keep you posted though. My aim is to use as much golf equipment as possible and keep cost down. The lupo was free so trying to keep the end cost as low as possible. what did you do for wiring? I have the entire golf loom and original lupo loom. I havnt began to look yet but im thinking il be able to just pretty much use the entire golf loom with modification for lights. Do you have a build thread on yours?

i intend to try using the golf clutch assembly as i have it all and its free but if i cant make it fit easily then il make good use of your advice there. Same goes for the selector, i shall be using the unit from the golf as a whole. although ive not had a proper look it seems as though i can just fit the whole lot as it is. Is that yours in the pics?

It shudnt need an iva test as the chassis won't have been changed enough and the car itself is already approved,ie not a one off body with sharp bits etc.Insurance company will want an engineers report. If engine was to go up back then thatd be iva territory.

Well most of it is trial and error and havnt really taken note of time but its taken quite a few evenings of tinkering.

oh and another thing, did it by any chance blow up on the limiter in 5th? That seemed to be the trend

if u had it of gin then I believe we met outside the betting shop. My girlfriend was telling me off for getting rid of the yaris when she saw it parked there lol. Drop me a pm when were at a stage when u wana meet up. dont take any addvice untill mine wrks though

The yaris was mine originally. Had over a years happy boostin out of it but then once it startd sanppin rods I think it claimed 4 engines in total. If I had to hazard a guess in hind site I rekon a bearing must have been on way out in charger an stressin number 1 rod. That thing did punch well above its weight tho, used to make me smile at hams hall. All about the torque to weight ratio and almost peak torque anywhere in rev range. Can u tell I miss it too lol

certainly sounds like we all share similar interests, our friend has a c20let corsa in the unit too.his lump goes away for 400hp rebuild on sat. Jona bona has a spiffin cossie you'd prob appreciate too

Were about a ten min drive from showcase island. More than welcome to take a nosey when it rolls under its own steam for the first time Were about a ten min drive from showcase island. More than welcome to take a nosey when it rolls under its own steam for the first time

If u mean the original 1.4 box i sold that a while back, sorry.