grungeisdead - "project muppet another mk1 joins the flock"

[grungeisdead]

well exams are nearly over 1 left wooop.

sun has been out in force this week but instead of playing with the car i've been immersed in gta 4 haha.

anyway messed about with the inlet manifold again took some more off it with the angle grinder and it'll almost go on fully, but got bored at that job so started with the wheels







got a few more coats to do over the week, not sure if I'm going to detail the inner bits black now cos I'm liking them all white but i'll see when I'm done

[grungeisdead]

swapped over the brakes and got a new brake line made up from the master cylinder to the drivers side wheel so i could bend it out of the path of the carbs without kinking it

239mm jobbies back on


angle grinded the flexi pipe and fitted the centre section, needs a larger sized tube placing over ideally and welding, will get the pat the mot'r to do that for me woot

finally got the inlet manifold after much fannying about with an angle grinder



 pressure gauge (ive got a blanking screw for after ive set the pressure



carbs all fitted and plumbed in, just got to fit the pedal back on, connect the throttle cables and wire up the fuelling loom






 and got a couple more coats done on the wheels too woopagio

off to stanford hall show tomorrow with my mate rob and picking up my yokos woo

[grungeisdead]

well updates

managed to get the carbs spitting and stuttering but not firing up, fuel pressure guage was broken and i didnt have a balancer for hand but new FPG is  on the way and a friend is letting me try out his balancer that he picked up for setting up his twin 45s on a 2L 16v.

also will check timing is correct by whipping spark number one out, turning the head by hand and checking teh piston height with a screwdriver.

fuel pressure was at 2psi before the gauge broke so i dont want to mess about adjusting the fuel pressure without a working gauge to check and i dont want too much fuel pressure in the carbs. also got some fresh petrol today cos the car was left garaged for the last year so the petrol probably lost all its octane level

and went down to my local tyre fitters and got the yokos on the routays, got them balanced then stuck em on the car, bled the brakes while i changed the wheels for ease of convenience so i finally have a brake pedal that works woo!

some piccies cos the day was still warm (check out my 3.75 bhp grass cutting skillz)









so all that needs doing pre mot is getting the carbs up and running and once thats done i can set the gear linkage ensuring all gears are correctly selecting, refit backbox and get it down to pat the friendly mot man

[grungeisdead]

had to completely setup the timing from scratch as it was mega out, lined up all the pulleys, just need a timing gun to make sure its bob on and a balancer to sync the carbs

but she lives

happy days ps. sound quality is gash cos it was on me phone

[grungeisdead]

rip muppet

errr driving to the mot station for 10, was running late due to a flat battery but my housemates girlfriend sorted me out with her getz, jump start it, get 5 minutes down the road and the idle creeped up to 3k, pull over in the park rather than going onto the main road, open the bonnet and was greeted with some flaming heatwrap.

my guess is the carbs didnt burn off all the fuel, some leaked out and caught fire. luckily i managed to get out unscathed but the car is rather poorly to say the least sad.gif

ahhh well win some lose some, and this was a massive fail.

edit: spare battery was in the passenger footwell, managed to grab the battery, my wallet and turn the fuel pump off before doing one sharpish

[grungeisdead]

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

[grungeisdead]

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

[grungeisdead]

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 :lol:

[grungeisdead]

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

[grungeisdead]

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