robbig Posted July 25, 2011 Report Share Posted July 25, 2011 (edited) So I've started on the car.My car (Zak) is a 2002 Lupo with a 1.4 75bhp engine (soon to be changed to a 1.4 sport 100bhp). I've had the car for over 7 years now and I've been itching to do something to it. Last year I got the rally bug while helping out on a rally team as a mechanic and asked myself how hard it could be? We shall see. I want to stay within the 1.4 class so I cant put in a turbo, diesel or a supercharger.You can also follow it here - Lupo Rally Car BlogI'll try to keep this as upto date as possible and also add a few "how to's" aswellI'd like to say thanks to TruCido and also Awesome_Al who have given me a little help through the forum and emails already Edited July 26, 2011 by robbig Quote Link to comment Share on other sites More sharing options...
robbig Posted July 25, 2011 Author Report Share Posted July 25, 2011 (edited) So I've been busy buying new parts for the car including front GTI hubs, rear brake conversion (which I still can't believe how much I paid on Ebay if you are on clublupo I assure you I'm still feeling guilty but thats the way Ebay works), rear drilled and grooved discs and a rear anti-roll bar from Awesome GTI.The GTI hubs travelled back from Germany in my suitcase a bit excessive but I only paid 30 Euros for each so I made a saving (I work in Germany).I'll be fitting the rear brakes and sway bar as soon as I have my bushes (next week) but the front hubs will have to wait for the brakes which I'm hoping will be Wilwood G60's.I'll try and put a little how to together for each item I get. Edited July 25, 2011 by robbig Quote Link to comment Share on other sites More sharing options...
scotty_82 Posted July 25, 2011 Report Share Posted July 25, 2011 Cool thread, when's the stripping starting to get rid of all that weight ? Quote Link to comment Share on other sites More sharing options...
truCido Posted July 25, 2011 Report Share Posted July 25, 2011 at last a post up good stuff! Quote Link to comment Share on other sites More sharing options...
vpolo Posted July 25, 2011 Report Share Posted July 25, 2011 what sort of rally are you going to be entering ? road rally ?matt Quote Link to comment Share on other sites More sharing options...
Bikerz Posted July 25, 2011 Report Share Posted July 25, 2011 (edited) I will have to get pics of our rally lupo up. (We as in Swansea Uni).Its a 1.0! Edited July 25, 2011 by Bikerz Quote Link to comment Share on other sites More sharing options...
robbig Posted July 25, 2011 Author Report Share Posted July 25, 2011 Cheers guys,I want to enter into maybe three stages a year. so Rockingham Stages and Promenade stages (Wallasey) not so sure on the third one my mate does the North West Stages but its a car killer. I'm at the Promenade Stages on the 8th September. I want the car to be easily changeable between asphalt and gravel.I'm going to enter into class 1 hence why I need a 1.4 sport engine and try and squeeze as much power out as I can so probably looking at a throttle body setup with cams. If I went for the 1.8T engine I'd be penalised by having my displacement doubled, not good.I'll try and get the strip done as soon as I can but it'll be my daily driver until I can get a replacement car.Bikerz - I've seen the Swansea Uni Lupo before its pretty sweet. What suspension did you use?I've been qouted £900 from AVO and £1500 from H&R both are the same system so I'll probably go for the AVO's, you can fine tune them more with the shocks and a range of springs Quote Link to comment Share on other sites More sharing options...
robbig Posted July 25, 2011 Author Report Share Posted July 25, 2011 (edited) I will have to get pics of our rally lupo up. (We as in Swansea Uni).Its a 1.0!I'd be interested in seeing the pics for some tips Post them on here if you want or let me know if you are starting a new threadBTW is anybody going to the Tatton park show?Tatton Park VW NWPretty cool video Edited July 25, 2011 by robbig Quote Link to comment Share on other sites More sharing options...
Defcon5 Posted July 29, 2011 Report Share Posted July 29, 2011 Do you work at the university Bikerz? Quote Link to comment Share on other sites More sharing options...
Adam R4 Posted July 29, 2011 Report Share Posted July 29, 2011 Awesome mate! I rally an F1000 Suzuki Swift! Quote Link to comment Share on other sites More sharing options...
lupo1.0se Posted July 30, 2011 Report Share Posted July 30, 2011 Nice SE - should be a interesing project Quote Link to comment Share on other sites More sharing options...
Bikerz Posted August 8, 2011 Report Share Posted August 8, 2011 (edited) Do you work at the university Bikerz?Student. Im 24 and fed up with being an Electrical Engineer so doing a little move sideways for somthing I love! (Lifes too short and all that)Lupo runs AVO's Damp and rebound and height adjustable. Proper coilovers rather than srpings with adjusters. Will take you as many pics as you like when I go back in October. I have some of seat mountings (as I wanted them) Edited August 17, 2011 by Bikerz Quote Link to comment Share on other sites More sharing options...
robbig Posted August 13, 2011 Author Report Share Posted August 13, 2011 So I've had a broken week of work on the car this week. Got the rear beam off, stripped off the drum brakes and removed the bushes. Putting it all back together now but the hyd hoses off the new calipers don't seem to fit, Any ideas? I bought it as a full conversion kit but it seems the caliper hoses don't fit the rear beam? Do I need new ones?Pics are coming soon of the rebuild. Quote Link to comment Share on other sites More sharing options...
robbig Posted August 13, 2011 Author Report Share Posted August 13, 2011 So just figured out that I've been sold a Polo rear disc kit and not a "Lupo conversion kit" as was advertised on EBay!I need the hyd lines and brake cables so it's off to the dealers for me again.For info if you buy polo brakes you need the following parts to complete the conversion:Pipe-6x0611763cPipe-6x0611764d2 x Brake cables-6x0609721e Quote Link to comment Share on other sites More sharing options...
robbig Posted August 16, 2011 Author Report Share Posted August 16, 2011 (edited) Finally got cracking on the rear end of the car and took the rear beam off the car.I've replaced the beam bushes, swapped the rear drums for Polo disc brakes and added the rear anti-roll bar.It didn't go to plan! I first put the bushes in the wrong way and then spent a day looking for a press and then when I came to fit the rear brake lines and cables found that they were the wrong ones and weren't for a "Lupo conversion kit".Any way its off the axle stands and I'm just waiting for the hoses and cables to drive her.Heres some pictures from the rebuild. The bush going in the wrong way, doh!! Built up rear beam with bushes installed wrong, doh!!! Had to press them out and in again. Not fitted the front bushes yet, going to wait for either the front brakes or suspension, whichever comes first. Edited August 16, 2011 by robbig Quote Link to comment Share on other sites More sharing options...
Bikerz Posted August 17, 2011 Report Share Posted August 17, 2011 Watching this with intrest! Quote Link to comment Share on other sites More sharing options...
robbig Posted August 22, 2011 Author Report Share Posted August 22, 2011 (edited) Connected the brakes up this weekend with the hoses and cables from the dealers. Sorry no photos as I didn't have my camera but next week I am stripping the back of the body and losing some weight so I'll photo that.Everything on the rear brakes seem to work fine but the handbrake is practically on the last thread (the two threaded portions that attach to the back of the handbrake). I can't tighten it up anymore. It works but it doesn't seem right (too many clicks), the cables are lupo sport cables. Is there a self adjuster in the caliper? Anyone? Edited August 22, 2011 by robbig Quote Link to comment Share on other sites More sharing options...
Bikerz Posted August 22, 2011 Report Share Posted August 22, 2011 I did a GTI rear beam on a SDI and never had any handbrake problems. I used GTI cable lines into sdi handbrake Quote Link to comment Share on other sites More sharing options...
Little Green Giant Posted August 22, 2011 Report Share Posted August 22, 2011 this should get interesting!! Quote Link to comment Share on other sites More sharing options...
Cannonball Posted August 22, 2011 Report Share Posted August 22, 2011 Strange, as Lupo sport cables when I measured them were the same length as a standard 1.4, so not sure why your ratchet is like that. The 1.6 has them a bit longer at 1500mm youve not been given those have you ? Quote Link to comment Share on other sites More sharing options...
Bikerz Posted August 22, 2011 Report Share Posted August 22, 2011 Sorry mine was a petrol sport rear beam with disks and went straight on a SDI. Quote Link to comment Share on other sites More sharing options...
robbig Posted August 23, 2011 Author Report Share Posted August 23, 2011 Cheers for the responses.I knew it wouldn't be easy, They're definetly the sport cables I measured them aswell just to check. I can't get my look-up to work on my computer aswell so I can't check on there. I might have to space it out with washers no biggy.I'm gonna give it another bleed anyway this weekend as I wasn't fully happy with it so it may change. I'll keep you posted. Quote Link to comment Share on other sites More sharing options...
robbig Posted August 23, 2011 Author Report Share Posted August 23, 2011 Should there be springs on the rear calipers?For example like this:http://www.clubgti.com/forum/showthread.php?t=207880or is that over the top? Quote Link to comment Share on other sites More sharing options...
Bikerz Posted August 23, 2011 Report Share Posted August 23, 2011 (edited) Cant remember off my head mate. But I would have throught it should have springs. If its a rally car get the VW Shannon ones as they are heavy duty and ALOT stronger, perfect for those "ON DA BAR" moments! Edited August 23, 2011 by Bikerz Quote Link to comment Share on other sites More sharing options...
pieface Posted August 23, 2011 Report Share Posted August 23, 2011 If your looking for a well built cage, check out my mate Marc;http://www.huxleymotorsport.co.uk/He is a custom fabricator, and has recently done a lot of work for the BDC (British Drift Championship) including some custom work for Driftworks, and ProTuner.His work is second to none, and he is where I will be going when I buy my cage. Quote Link to comment Share on other sites More sharing options...
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