grungeisdead Posted February 24, 2010 Report Share Posted February 24, 2010 Model: X Reg 1981 Mk1 Polo LSEngine: 90k 1398cc 1.4 16v HeadSchrick Fast Road Cams42k 1598cc 1.6 16V Bottom EndLupo GTI 5-Speed Box with Cable Clutch ConversionSuspension:Fully Adjustable Front WishbonesRose jointed Camber adjusting top mountsStrengthened strut topsLupo Gti Front Shocks and SpringsMk1 Polo Steering ArmsLupo Stub AxlesPowdercoated Rear AxleMk1 Polo Rear Suspension - to be upgraded at some pointShell Modifications: Bulkhead removed Seam weldedModified Gearbox Mount for Lupo Gearbox & Retained Original Mount Blanked Rear Wiper HoleSpare holes welded up in firewallHeater matrix welded upBox Section Mounting Plates for Bucket SeatsInterior:Koenig Fixed Back Reclining Bucket SeatsSchroth 3 Point Harnesses with Safety Devices Pre-TensionersMotorsport Fire ExtinguisherExterior:Pre 78 Spec Polo Flat Grille & HeadlightsBrakes: NOS Mk1 Master Cylinder Lupo GTI 256mm BrakesNew Brake Lines200mm VW Rear ShoesWheels and Tyres: OZ Routes 14" x 7J195/45/14 Hankook Ventus K102Parts to get :-Rear Axle BushesLarger Master Cylinder200mm Rear DrumsHandbrake CableBraided HosesAll my welding was carried out by Gray & Dave from Retro Rides 07815 750 531 Based in Leigh. (Full resto, custom welding and mot work, basically anything) Really good pricesHere's the car back in the day, 2 formor owners ago, and the man who comissioned the conversion into lupo gti spec by AWTracksport, they are based up in lincoln way, which is where the car was born, it still has the original dealer stickers, and keyfob in good condition, since then its been to preston and manchesterI spotted it up for sale at &1500 quid on ebay with no bidders, full on sleeper spec as pics above with a full sd cage, emerald ecu and other goodies, however i bought this insteada year or two passed and i was finishing my last ever uni exams, and my side project (read: REAL disseratation =P ) was ready to go for its mot, maiden voyage was fine but the mot'rs were too busy to fit me in that day, so call back on monday.unfortunatly this happened on the way there =[devvoed at the loss of my baby, i was after another project and i saw the polo come up again for sale, this time as a rolling shell, most of the parts had been sold off.at 400 quid i wasnt going to let the little car get away again, and popped up to see Trooper25 off Clubpolo in Preston who had bought it privately from ebay.After chatting to him, he had wanted to use the car for rallycross, but the low lying sump meant the engine would need to be raised dramatically to be even viable, so he had stripped the motor completely and started seam welding the shell & removed the firewall as well as drilling out the spot welds on the seat runners and removing them but hadnt welded in seat rails with box section yet.anyway he took a ride in a 205 gti mi16 and decided to sack off the poor little polo for something with real rallycross potential.so i got the shell for 400 notes with the subframe and custom modificationsi then thought i should ask about the engine, is it still about, and his reply was you can have the engine and all the spares for 100 quid.SCORE!So I was a happy bunny, another project to sink my teeth into.I've done various bits on the car, wirebrushed and por-15d the interior, front and rear panels and engine bay on the hunt for rust and por-15d all the good metal after a dousing with metal ready, started building it the new rear axle to find some small holes under cracked underseal in the rear arches so I put a wanted up on RetroRides for some local weldersthese guys sorted me out a treatGray & Dave from Retro Rides 07815 750 531 Based in Leigh. (Full resto, custom welding and mot work, basically anything) Really good priceshttp://retrorides.proboards.com/index.cgi?action=display&board=pfsw&thread=73142anyway they carried out loads of bits for mebox section for bucket seatsrebuilding leading front edge of wingcouple of peppered small holes in inner rear aches - which was going to be the mot fail that set me off on wanting to get welding done on herre-welding in of a mk1 gb mount as it was cut out when the lupo box was usedsome various other holes around the bodyblanking off heater matrixwelded up the exhaust on my mk2 afh conversionmade a few other custom bits for the engine conversions, I would fully recommend the guysso while the mk1 was away i was free to think about the powerplant, i always wanted the Polo GTI full lump and was going to wire it up oem but needed to many parts and i didnt want to overcomplicate things for a little lightweight blat about car. so then i got hold of some R1 ITBs with an inlet manifold for the engine, but that warranted for aftermarket management and mapping = mega money!I have another car, a yellow mk2 and i converted that to a 1.4 16v AFH and was running it on bike carbs,full thread hereConversion FAQI wrote up to help collate all the knowledge i'd gained through reading on the net, friends and some experimentationbut i blew up the engine, bottom end was kaput, but the head and more importantly my shexy schrick cams were OK, so after reading about Jez's, Mitchells and others hybrid creations, i thought i want to retain the lupo block so i can call the car the lupolo, and by using an AFH head, i can use a set of bike carbs and a mk2 ignition setup which i have spare to get the engine up and running cheap and quickly in comparison to the steep start up costs of throttle bodies.anyway details of the new engineMk4 1.4 16v AFH HeadLupo 1.6 16v GTI Bottom EndCBR600 CarbsSchrick Fast Road CamsIt will be running the lupo 5 speed gearbox, running a cable clutch conversion with the cable operated 5 speed shifted in the carI used an afh headgasket, polo aex headbolts, afh relay roller(modified)Note, 6n 1.0 AER & Non AVY GTI lumps have the correct length headbolts6n Polo 1 Litre036103384Bbolt, with multi-spilne socket headM9X1,25X138 / AER,ALLLupo GTI036103384Bbolt, with multi-spilne socket headM9X1,25X138 / AHW,AKQ,APE, AUA,BBY,AFK, ANM,AQQ,AUBPolo GTI036103384Ebolt, with multi-spilne socket headM9X1,25X97 / AVYThe correct part from GSF is01163CYLINDER HEAD BOLTPO 1.4 AFK/AHW/APE/AUA/AUB Engines 99> & PO 1.0 AER Engine 96>99£2.00 each and you need 10. the relay roller part number 036109244the guys made me a bar threaded to 10mm at one end to fit into the block and 8mm to fit through the sleeve of the roller, it was impossible to drill through for guys with thousands of pounds worth of machinery so don't bother trying it at home, I'm glad I didnt bother!cambelt fitted and everything timed up, engine plate and alternator fittedmated to the 5 speed lupo gearboxdisclaimer :- I've not ran the engine yet, so it may all end in disaster but no harm if it does, as if it doesnt, its going to be a little screamerwill add some pics in a bit of the current state after welding when ive got the bloody bluetooth working on my laptop Quote Link to comment Share on other sites More sharing options...
dxg Posted February 24, 2010 Report Share Posted February 24, 2010 I've said it before about that Polo, but I'll say it again - it's nigh-on perfect! Quote Link to comment Share on other sites More sharing options...
grungeisdead Posted February 25, 2010 Author Report Share Posted February 25, 2010 I've said it before about that Polo, but I'll say it again - it's nigh-on perfect! cheers man, no where near perfect but i rag my cars haha well some updates on the shelli poked this bit of filler to reveal thiswhich when provoked more turned out to be a full rotton corner of the wing but all was done well by Gray.this was welded up but i couldnt get decent pics of it after in the darkWelded up heater matrixseat railspatched up some holes on the rear panelmk3 gearbox mount back indewipered bootlidmmmso need to get the bare metal cleaned up, skim of filler on the external bits and por15 on the seat rails, and get a lick of primer and paint on the fresh welded bits, i can deal with mismatched paint at the momentthen i need to get some 200mm drums and finish rebuilding the rear axle, and rest of brake lines, get all those plumbed up and bled and the engine can go back in along with the bucket seats and harnesses.inside in going to be bare as ****, just 2 buckets, harnesses and a fire extinguisher. Quote Link to comment Share on other sites More sharing options...
vworks41 Posted February 25, 2010 Report Share Posted February 25, 2010 Great stuff Quote Link to comment Share on other sites More sharing options...
grungeisdead Posted May 28, 2010 Author Report Share Posted May 28, 2010 well after another sabbatical, work continues on the mk1 this weekend,some goodies to fit200mm passat rear drums, back plates, stub axles and wheel cylinders, new vw shoes and bearings.256mm ebc x-drilled grooved discs, lucas 54 calipers and ferrodo ds3000 padsand the new lump is nearly done, just need to get a water pump, gearbox and clutch kit and woop.its now an 1.6 16v sporting Shrick Fast Road cams. laaarvly.will get pics after this weekends frolics Quote Link to comment Share on other sites More sharing options...
grungeisdead Posted May 30, 2010 Author Report Share Posted May 30, 2010 done todayundersealed rear inner arches after weldingundersealed welded engine bits sprayed and undersealed the bucket seat mountsremoved old 180mm drumsfitted 200mm back plates and stub axlesfitted bearing races into new 200mm drumsfitted handbrake lever and front part of handbrake cablefitted wiper mech - need the clips, nuts and grommets to attach the spindle bits tho if anyone can helpate donuts drank irn bru and got baked <3tomokeyscoupe s wheelget brake lines made upbuy - 2 rear flexis, 1 wheel cylinder,handbrake cablecirclip for brake/clutch pedal x 1cirlip for throttle cable x 2dremel rounded rear brake linefit rear drums, hb cable, brake linesfit front calipers/discs/flexisfit pedal box and pedalssteering column UJgear leverfit wiring loomstuds for seats and fit Quote Link to comment Share on other sites More sharing options...
grungeisdead Posted June 1, 2010 Author Report Share Posted June 1, 2010 got 28 days till the unit gets turned into a helicopter pad =/ so thats my deadline to get it running and out of there, if anyone wants to come grab some free/cheap parts to save them from mr scrapman, pop overwouldnt mind a helping hand too =Danyway engine loom found in the unit, main earths connected and fusebox screw in place, battery fitted.badly need the nuts and grommets for the wiper mechanism, anyone got any kicking about6,7,8 wiper locknut and washers and any plastic or rubber grometspics of seat mounted, pedal box and steering column fitted.although i broke the clevis pin, so if anyone has one?6a and 6b clevis pin12 cirlcipengines internals cleaned, sprayed down, drained and wd40'd up, sump bolted on to stop dirt getting in, but not cleaned up the mating surfaces or gasket pasted them up yet.just need a waterpump and i can get the tensioners fitted, head on and cambelt fitted. then i need to get hold of a 5 speed box, or just bolt ad's 4 speed in as a quick fix Quote Link to comment Share on other sites More sharing options...
grungeisdead Posted June 7, 2010 Author Report Share Posted June 7, 2010 finally found all my hub mounting bolts so the front brakes are on - lucas 54 calipers, ferodo ds3000 pads and ebc discs200mm rear drums and v dutty powdercoated rear axle, still awaiting my rear handbrake cable, when thats here i can get the bearings fitted. gotta order me wheel cylinder and brake lines tomo, but still desperatly need a clevis pin pedal pushrod thing for the master cylinder and the MC spacer. should also get hold of an uprated suspension kit for the rear as these shocks are truely pwned but should be mot'able for time beinggrille and lights fitted, bonnet just rested in place, got another black one but need to get the vent holes are the rear welded uptrial fitted top fill rad, unfortunatly its gonna require some slam panel butchery, i think rather than just messily cut it out, i've got various hole saws, so ill make a circular cut out big enough to pull the cap out from and notch the inner part of the panel so i can get some grippy action around das cap. id rather retain as much of the original slam in place for fear or it collapsing!note the grille cut out in this pic, im going drill the panel behind it, and fit an air scoop as fitted on GT's iirc and feed that over the carbs, eventually getting round to sorting out a plenum chamber for themrandom picsthen spent the rest of the time sorting out bits in the unit, getting rid of pap ill never need, and boxing up the rest ready for an ebay flex.heres what i uncovered from the house alone, its all gonna go on ebay at 99p starts when i get round to putting them up (next week or two)but if anyone wants owt gimme a shoutMk1 Golf GTI Magnecor KV65 Competition Leads Red with 2 Cable tidys GTI TSR Drilled AirboxGTI K&N Panel FilterGTI Warm Up Regulator 438 130 073GTI Cam Pulley - 056 109 111AGTI Lower Crank Alternator PulleyGTI Water Pump + Near new thermostat+housingGTI Near new Bosch Starter Motor 055 911 023BGTI Drivers Engine Mount - Rubber needs replacingGTI Rear Gearbox Mount + RubberGTI New Downpipe GasketGTI Complete Series 1 1600 Metering Head/Injectors/All Braided Lines/Fuel FilterGTI Semi Polished AlternatorGTI Oil Cooler / Hoses / Mounting BracketsGTI Series 1 Contact Breaker Dizzy - Near New Condensor & Contact Breaker 049 905 205EGTI Series 1 Parcel ShelfGTI Complete Series 1 1600 Head / Cam / Water Housing / Inlet Manifold / Throttle BodyGTI Short Driveshaft - Good condition, relatively new inner CVBosch Starter motor 055 911 023LGearbox Selector ShaftNew Tensioner StudNew Linkage Rod BushTintop 3Door Green Tint Glass Front Passenger/ Rear Drivers / Rear WindscreenTintop 3Door Clear Glass Rear Passenger PoloMk1-3 Lower Strut Brace - Adjustable but ONLY for cars up to -40mm. Mk2 Polo Coupe S Contact Breaker Dizzy - Near New Condensor & Contact Breaker 023 191 009 / 052 905 205Mk2 Polo Coupe S Airbox/Filter/ElbowMk2 Polo Coupe S Exhaust Flexi SectionMk2 Polo Coupe S Metal Cambelt CoverMk2 Polo Powdercoated Water Housing & Thermostat Housing 052 121 117 / 052 121 171CMk3 lower steering cowling cover 171 953 516BMk4 Polo 1.4 16v Power Steering Pump PulleyMk4 Polo 1.4 16v Power Steering Pump Pulley + PulleyMk4 Polo 1.4 16v Crankshaft Cambelt SprocketMk4 Polo 1.4 16v - Plastic Dizzy Cover & Lead Tidy 036 103 565AMk4 Polo 1.4 16v Power Steering Pump PulleyMk5 Polo GTI 1.6 16v Inlet ManifoldMk5 Polo GTI 1.6 16v Cylinder HeadMk5 Polo GTI 1.6 16v Red Rocker Cover / Cams / PulleysMk5 Polo GTI 1.6 16v Standard 4 Branch ManifoldMk5 Polo GTI 1.6 16v Decat DownpipeMk5 Polo GTI 1.6 16v FlywheelMk5 Polo GTI 1.6 16v Engine Wiring HarnessMk5 Polo GTI 1.6 16v HT Leads Red x 4LupoLupo GTI 1.6 16v Standard 4 Branch Manifold Lupo GTI 1.6 16v Decat DownpipeLupo GTI 1.6 16v Hydraulic Clutch Release Cylinder 600 721 261ALupo GTI 1.6 16v Engine Wiring HarnessOthersVW Cable Change Conversion for Hydraulic Clutch GearboxesCoil used in Emerald Setup - 089 04B 00104 - Leads from top left, clockwise are 14,32,27,41Audi 3 Pod 52mm Guage Facia - 812 863 321C2.5" NOS Veglia Borletti 8 Bar Oil Pressure GuageBMW Smaller, Lighter Power Steering Pump Pulley to fit Mk4 Polo 1.4 16v - 171576952mm VDO 150 degree Oil Pressure Guage12" Slimline FanOpel Manta GTE Tartan Recaros320mm Aftermarket Steering WheelSlimline Ali Rad 12"H 1.75"D 20.5"L 23.5" between mounting lugssaturdaywell productive day was had today,we put nays mk3 polo back together after he took apart to change the headgasket and a few other bits, and i got to pilpher some much needed bits for the mk1, muchos kudos to nayanyway bits done on the mk1* rear wheel cylinders fitted both sides* rear shoes fitted both sides* got a nos handbrake cable but its such a random design, need to fathom it then i can fit it tomorrow* new clevis pin fitted on the pedal box, all circlips in place and nos master cylinder fitted* interior loom fitted* dash fitted* clocks/speedo cable fitted* earthes fitted.* made cut out for top fill rad* mounted front number plate* mounted both front seats* fitted washers and locknuts for wiper mech and fitted wiper arms (well one, as the other has gone awol and they are mk1 polo specific!)* bonnet catch and release lever fitted* fitted new door sealsand the new oem shoes to keep with the lupo theme when i get hold of some tyres, if anyones got any 175/50 185/50 195/45 14 inch rubber lying around gimme a shoutpicked up a new water pump today and getting at gt 5 speed box from dubmania tomo, so the engine should be in the car one evening next week, proper buzzinglist for tomohorn + hornpushrear handbrake cablefull brakes lines + bleedingrelay - lightsharnessesignition wiring loom/coil/tcapower distribution block rear number plate light and heated rear windscreenlist for weekrear beam busheswater pump / cambeltoil pickup/sumpflywheel/clutchclutch release bearing/gearboxcranebonnet/bonnet stayparts listclutch release bearinggearshift baseafh starter motorthats enough to jog my memory for tomorrowcouple of crap picssundayfitted full new solid line and flexis, solid lines from rear are 15cm and 40cm too short so will get some extra lines made up in the weekfitted brake pedal return springwired up coil and ignition loomworking rear electrics, unfortunatly told the welder to weld up the hole for the numberplate light wiring DOH! so will drill that outfiited water pump / cambelt and timed up engine, will refit sump tomorrow and then the lump is ready to go to the unit.need to pick up das GT box from hoppys in the week and then chuck the engine in there woop Quote Link to comment Share on other sites More sharing options...
Recommended Posts
Join the conversation
You can post now and register later. If you have an account, sign in now to post with your account.