Het Polo86c Register
Algemeen forum => Techniek => Topic gestart door: polo_td op di, 11 jan 2011, 20:54:51
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Hi
I have been around for a while now and i am deeply impressed with the knowledge u guys have. -thumbsup-
So when i now start a new phase of the polo 1WTD´s life some things needs to be sorted.
so!
This week i´ve started a new project, my turbo converted polo diesel will now be updated.
The engine will produce approx. 170bhp and 230Nm.
Now i really need this forums help.
Clutch, what can i use? 200mm?? or even bigger with mods?
Can i use the G40 clutch with my flywheel?
Gearbox is there ant thing u can do to increase the stiffness and strength?
Do i have to do any thing at all??
Gearbox is 8p, ratios, can i change any thing to get the revs down and increase topspeed?
The difference between the gearboxes like che, ceg i.a? i know the ratios are diffrent but is there any thing to gain material wise?
please help is needed fast in this so please help me out here??
thomas
Sweden
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Hello Thomas,
Welcome on this forum! i hope you can read all the treads in Dutch -uitlachen-
We are very curious how you made the turbo on the diesel engine. -foto- The free space in the front is rather small to place a decent turbo close to the exhaust manifold.
AFAIK the only option is to place a 200mm clutch with a sintered disc (for handling the power) and a strengthened pressure plate (pressure group?! -gert-).
For the gearbox i don't know any mods, only the oil passage of the 5th gear can be modified (to be found on this forum). This increases the lifespan of the gearbox.
I think the "longest" gearbox is the original G40 gearbox (AJV?) i think they can handle the power for a while.
There are guys here with a lot more experience with this kind of tuning material.
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pics comming up now.
(http://forumbilder.se/images/de201024950PMaad0.jpg) (http://forumbilder.se)
(http://forumbilder.se/images/b3920091207047fa5.jpg) (http://forumbilder.se)
This time the manifold will be better and the pump will be special made etc etc.
thomas
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Nice ride -thumbsup-
Original place for your carjack :)
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Thanx
When the airbox was gone it was so empty in that area.
So i thougth why shall i allways have to pic everything out of the trunk if i´ve got a flat tire(it always happens when u fully loaded u know)...
thomas
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nice polo, strange place for the carjack, but i understand the reason for it. And truely, you will need the tools more under the hood than in the trunk, where it originally belongs.
but you said about flat tire, yes, but you still need to take the spare wheel out of the trunk then. Or did you placed that somewhere else?
I just want to say one thing: its not an audi you know -nana- But i like the foglamps in the grill.
About the gearbox: 8p is commenly used in polo 1990-1994, but because its a 5speed, the fifth gear can cause troubles (its just a 4speed gearbox with an 5th gear glued on)
Maybe you can search for a g40 gearbox, also 5speed, but stronger because of the increased HP of the car.
Clutch: 200mm? i dont think that will fit. Just use a g40 flywheel and clutch. You can decrease the wheight of the flywheel, there are some people who have done that. Just search arround on the forum.
If you dont understand something (because of bad translation or something. I think some of the people here, can translate and explain it to you.
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This update is something beyond the ordinary.
Now the pump is modified into a monster just for this engine.
You can read what is done and see a clip of the test run on the flow bench.
Many thanks to Göran "diesel mech" Lindgren.
************************************************** *****************************
OK, then it was time for the 2nd upgrade of the pump, Edition R
Do not miss the movie clip I have made for the sake of you readers, further down the topic.
The following was the first performance upgrade.
Replacing rotors 80-10 mm
Change the direction from right to left using wire EDM, among other things ;-)
Then the pump is delivering about 230% more fuel than stock, ended up on about 80 cc of fuel.
(http://forumbilder.se/images/f13201132956Pd8ac.jpg) (http://forumbilder.se)
Edition R is reworked like this:
Modified RPM controller weights, it was not enough speed first round, now it will be sufficient.
(http://forumbilder.se/images/5d3201134203P92d9.jpg) (http://forumbilder.se)
LDA, cover with specially sharpened stick to get more fuel at full turbo boost pressure and eliminate smoke in large quantities, it will probably smoke a bit anyway, but not as bloody as before
(http://forumbilder.se/images/853201134252P07c4.jpg) (http://forumbilder.se)
Regulator Spring, changed from a separate idle spring into an integrated spring-in controller package (VAG 2.4 d)
(http://forumbilder.se/images/8c3201134338Pe96d.jpg) (http://forumbilder.se)
Modified controller bridge for longer travel of LDA = more fuel around 100cc @ 1500 rpm
Test run of the bench and shot.
(http://forumbilder.se/images/8c3201134533Ped66.jpg) (http://forumbilder.se)
Movie Link here http://www.youtube.com/watch?v=aXl8x9dOC9k
Happy Midsummers eve wishes Göran "diesel mech" Lindgren
************************************************** ******************************
Thomas
Sweden
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Cool! -wanker-
Are you open for production-orders? -naughty-
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impressive!
Bye Bye firewall?
I'm interested to see the LDA lumpy bit fitted inside the enginebay!!
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Me too but i´l get it sorted.
Will mount it next week, pics comming up then.
Jaap
How´s your Giesel going?
Thomas
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Hello!
Now I come back.
I've lived in the garage this weekend.
Worked constant from Saturday 08.00 until Sunday 19.00 without sleep, when we really needed to be done.
We have set up some odd ideas about this project.
One of these was to do a metal widening on a car in a weekend:)
And that, without having done it before.
Can say that it went well!
Plus that we grinded and adjusted all dents etc
My early ideas with urquaattro etc was thrown in the bin and scrapped because I had a couple of new thoughts and ideas.
Finally Me and Martin had a "new" way.
We take the hourglass broadening, racing, bergcup, DTM, and 90's design throw it down in the blender and what do you get?
see in this sequence:
(http://forumbilder.se/images/031201181201A7a4f.jpg) (http://forumbilder.se)
Work in progress!!!
(http://forumbilder.se/images/1a1201182325Abc58.jpg) (http://forumbilder.se)
Front wing with wheelarc extensions!
(http://forumbilder.se/images/fe1201182408A312f.jpg) (http://forumbilder.se)
Blurred image, but an idea with wheelarc extensions.
(http://forumbilder.se/images/931201182914A2758.jpg) (http://forumbilder.se)
Ready for transport, without wheelarc extensions.
I will add a pics rear wiew later ther you realy can se the total with over the "ass" :)
Thomas
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Now the car is assembled and pump performance in the beginning.
A very difficult period, I can promise, but now you can drive the car in the rain, This update has been hard,working around the clock more or less.
But just wanted to show how the car looks now.
Please enjoy !!!!!!
First car last summer.
(http://forumbilder.se/images/de201024950PMaad0.jpg) (http://forumbilder.se)
(http://forumbilder.se/images/c99201160447P2e85.jpg) (http://forumbilder.se)
(http://forumbilder.se/images/e89201155118P7a64.jpg) (http://forumbilder.se)
(http://forumbilder.se/images/a59201155227Pc798.jpg) (http://forumbilder.se)
What do you think?
Will all the work be visible !? : thumbup:: D
thomas
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Wow, looks sick! -thumbsup-
Very well done, widened with the right proportions
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Nice job, "last summer"-edition was a .... erm ... disaster imo :)
This summer edition: prize magnet! -thumbsup-
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i liked it more in black, but the wheels are looking good!
what kind of foglights are that? not original, but they fit well i see. Thats why i ask
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Agreed...with those rims this thing would look pretty "sick" in flat black, bumper to bumper. -ja-
Edit: Almost forgot... -goodjob- on the Diesel engine -thumbsup-
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A small clip from dyno-day.
IC blown and exhaust pressure problems.
Not the best result, but a start, anyway here it is.
http://www.youtube.com/watch?v=LAHUlf4e9ks
The real clip will be presented as soon as i get it.
thomas
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Some pics.
(http://forumbilder.se/images/5e2201112303971b2.jpg) (http://forumbilder.se)
(http://forumbilder.se/images/00220111231107608.jpg) (http://forumbilder.se)
(http://forumbilder.se/images/67220111231348ccd.jpg) (http://forumbilder.se)
(http://forumbilder.se/images/4722011123221195c.jpg) (http://forumbilder.se)
(http://forumbilder.se/images/9122011123245ee5d.jpg) (http://forumbilder.se)
(http://forumbilder.se/images/b6220111233422999.jpg) (http://forumbilder.se)
Thomas
Sweden
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At least it is getting enough fuel :)
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Oh yes.
And it was no problem to fit the LDA against the firewall either.
3cm clearence.
thomas
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I think that will fail any soot emissions test. (I hope for you that they don't have that test in Sweden) But the smoking seems to only be in the middle of the rev range if I interpret the dyno run video correctly, some more tinkering will probably fix that.
Have you thought about using a 1.6 block with the diesel head?
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We still have alot to do in this car.
We will add a intercooler and tweek the engine evenmore.
Waterinjection will be added etc.
Yes i´ve heard about this 1.6 block but so far we will take this 1.4 engine to its maximum just to see what its capable of.
thomas
Sweden
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Jaap, hows your Giesel going???
Havent seen it for some time.
Thomas
Sweden
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hi.
Need some suggestions for color.
racing inspired.
Does anyone have mounted dubble radiators and have some input regarding this?
thomas
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Very special car, -thumbsup-
Wrong model but crazy colors, give's it an awesome look.
(http://www.mijnalbum.nl/Foto-URD8GWKR-D.jpg)
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Massive!!!
realy like the art and the devided feilds on this drawing/scetch.
Is it gold, black and sand colour?
thomas
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Looks like it. When you know it's a poster size and airbrushed you go -wtf2-
I read somewhere that only the wheels took him 16 hours to make them like this.
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http://www.steilheck.nl/cpg/albums/userpics/subbed.jpg ? :)
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Hi
A late update to this subject at night.
Today I will take down the front and begin to modify this so that I can fit an intercooler model "big" to this car.
Likewise, the radiator will be replaced with a larger and an extra waterpump must be added on.
Will take down the manifold and wrap this due to thermal radiation.
Then, the generator have a review and an additional tachometer output is taken out from the coils inside.
A lot of effort that will definitely have an effect.
The turbo is now in the hands of turboservice.se in the hunt for more effect and power, is up to them to find the solutions.
Perhaps these will come onboard as sponsors of this project aswell, which I would think is great when it obviously need a massive modification, we'll see.
What this will give, we shall see, but it is quite clear that it will get better.
What color is concerned, it is now leaning to a white pearl for those of you who are wondering.
thomas
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-thumbsup- Although it doesn't seem racy to me, a lot of cool cars come in that color!.
(http://www.mijnalbum.nl/Foto-WK4ACBUL-D.jpg)
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Hi
Some new pics!!!!
(http://forumbilder.se/images/a62201110203414f2.jpg) (http://forumbilder.se)
(http://forumbilder.se/images/63220111022502591.jpg) (http://forumbilder.se)
(http://forumbilder.se/images/eb22011102408dcfa.jpg) (http://forumbilder.se)
Thomas
Sweden
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Any on-road on-board movie-clips? -naughty-
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-thumbsup-
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-goodjob-
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very nice project you have there -love-
how much horsepower do the engine produce?
-goodjob-
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thanx wery much for all the comments.
The engine produces 130bhp and 210Nm on the wheels without IC and a crap turbo....
We had a powerloss of 13% in the drivetrain so this means apprx 145bhp in the engine so to say
We will update these during this week and week 36-38 somewere we will put the car on the dyno once again.
Hopefully we will reach the goal of 155-160bhp on the wheels = 180bhp enginepower and somewhere round 250Nm then.
Turbopressure is today peaking at 2.9bar with very poor efficiency in the turbo.
Thomas
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massive! -notworthy- -klappen-
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-thumbsup- I am impressed as well.. nice ride
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Thanx!
Very nice to here.
Some pics of the front /ic mounting.
(http://forumbilder.se/images/cc5201162829Ad1c2.jpg) (http://forumbilder.se)
(http://forumbilder.se/images/265201162936A3734.jpg) (http://forumbilder.se)
(http://forumbilder.se/images/b15201162541Af1af.jpg) (http://forumbilder.se)
thomas
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pfff superb i'm in love :)
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(http://forumbilder.se/images/eb22011102408dcfa.jpg) (http://forumbilder.se)
I like those round rear wheel arches
I thought on it before to do this on my own steilheck but it takes a long time to do it right
you can now fit bigger wheels than on a standerd steilheck
and this is a real nice job -thumbsup-
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Thanx for the comment.
Yea, ican fit wheels up to 18" but over 16! i don´t like the look.
Thomas
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withstupid it kills the proportions, the flow of the lines.
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Ok, but what kills what??
18" wheels or the bodywork with rounded wheelarcs?
Thomas
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The 18" wheels of course in comparison with the size of the car. :)
Just to big for a polo.
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To big???
Yes waaaaaay to big.
In my point of wiew the limmit is 16"
Thomas
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Same as putting 13" on a Touareg -gert- . Or these 20"
-gumuz-
(http://www.mijnalbum.nl/Foto-Q3WMX8PO-D.jpg)
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Looks terrible!!!!!
thomas
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Some new pics.
(http://forumbilder.se/images/8d201180613AM280b.jpg) (http://forumbilder.se)
(http://forumbilder.se/images/9c201182121AM50e1.jpg) (http://forumbilder.se)
Was thinking of using these, but i changed my mind...... ;)
(http://forumbilder.se/images/4c201182634AMf2bf.jpg) (http://forumbilder.se)
Thomas
Sweden
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:), I hope the ones on the right didn't make it either.....So the original stuff is working on the front?
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offtopic,
Most people put a Golf III spoiler below the FRONT bumper (http://lh4.ggpht.com/_0Zowa055UZk/TMPsy33B2DI/AAAAAAAAEJU/cetkz0cwGXk/s640/2010_10240006.JPG) -uitlachen- But on the rear it's also -thumbsup-
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Hi all.
Yes i was thinking of adding the org rear peice from golf III but i wanted somting diffrent.
So therefor i took the front piece and i´m satisfied with how it turned out.
Thomas
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To big???
Yes waaaaaay to big.
In my point of wiew the limmit is 16"
15'' is for my limmit but the 175/50R13 I have under my steilheck touches the wheel arcs already on a bumpy road.
maybe de ET rating is wrong
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Hi
Now I have spoken to my new sponsor Swedish turbo service again who said that the turbo was ready for pic up.
They had apparently turned inside out of everything in this job.
They had spoken to pro´s in England and Germany to get more information about what's to be done and what would be good, whats fun to hear is that they had never heard anything like this during his years in the industry, either here in Sweden or abroad.
It´s fun that the car makes such interest from the most experienced people in the industry.
I must say I really like everyone´s engagement to get involved in the project.
The turbo is now in base an Schwitzer (Borg-Wagner) units, but we have retained the exhaust housing from the previous Garret aggrigatet becuase we wanted to see how much a special processing of this would bring.
Exhaust house has now been modified significantly.
The shaft has been replaced and the diameter of the turbine wheels changed, the turbine wheel has trimed wings on them for increased flow and power.
Happily it is now turbo good for 200 diesel horses and more ..... :)
See pictures below:
(http://forumbilder.se/images/c5201172246AMacc2.jpg) (http://forumbilder.se)
(http://forumbilder.se/images/2f201172342AM6047.jpg) (http://forumbilder.se)
(http://forumbilder.se/images/39201172417AM8c46.jpg) (http://forumbilder.se)
(http://forumbilder.se/images/d8201172456AM4821.jpg) (http://forumbilder.se)
(http://forumbilder.se/images/ff201172533AM5dc6.jpg) (http://forumbilder.se)
(http://forumbilder.se/images/45201172607AM903d.jpg) (http://forumbilder.se)
(http://forumbilder.se/images/31201172647AMae4e.jpg) (http://forumbilder.se)
(http://forumbilder.se/images/51201172724AMeaa1.jpg) (http://forumbilder.se)
(http://forumbilder.se/images/73201172801AM0767.jpg) (http://forumbilder.se)
You can see that it's right clever processed in the exhaust housing and the compressor side.
Today, i will get a new return piping from the turbo as we now have a different connection than before.
After that a tachometer goes in the car with a shift etc.
We'll see where I put this, there's not really much space in the cabin as you probably know already. :)
Thomas
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Have you thought about adding a G40/G60 or other supercharger and making it twin-charged? -naughty-
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Hi
Twin charged is an interesting path, but i cant find the space for it.
BUT, maybe 2 stage turbo set up will work.
We´ll see if its needed..... :)
Thomas
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Nice! I like the pictures. It will sound even better -naughty-
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Hello again.
Now it has happened stuff i think you should know.
We have been on Kinnekulle raceway and with the help of a talented driver who now works as a driver instuctor within just racing i belive we couldent get a better tryout on the car.
Peter had fixed the ring completely to ourselves, which is an incredible feeling just that.
Think about it, we got at a race track all to ourselves ... ;D
Many thanks Peter.
Peter Lundrgen from Götene Motorclub has thus been the one driving the car.
The car behaves consistently and very well on a track according to Peter.
Peter ran around the ring as the best at 1,10:52.
Which I think is good.
For reference, I can say that it is faster than orginalcup Volvo's cars run on the ring, and when they're built to run on racingtrac with weigth reductions and tuned chassis, etc.
We have a std car more or less, this is Very impressive in my eyes.
But something was wrong with the car, the effect did not occur so it could not bring better times.
This was on Friday and on Saturday, I talked with my filter provider.
Guess my suprise when he says that the filter attached to the car "just now" leave X liters of air / minute, it takes more than twice as much air .....
The filter povided was for a petrol instalation NOT Diesel.....WTF
This worked then as a restriction and we could only get maximum 1.2 bar then filter imploded
together and as they say put the lid on it.
The effect were about 80bhp measured by G-Tech on Saturday morning.
No wonder the car smoked, the car was so black in the ass so we had to wash the car before driving home.
Take it away, i will send the correct filter to you next week.
Said and done.
I did it and Holy shit ...............
Sure the car was good before but now it is a monster.
The effect is brutal.
It's just so that tires can keep the power down on third and fourth gear.
Turbo charger keeps going on with ease throughout the registry and the increase in speed is more or less linear.
No turbo dip at all under free acceleration.
I guess that the effect now is 160-180 hp.
This is now to be confirmed on the dyno again.
Temp problems are blown away both the exhaust and water and oil temp is laying still.
Will come back with a real report later.
With this effect, and a minor update to front so I can say that the car is probably running around the ring in under a minute. And it's fast
This is an incredible car.
Peter will write a report later this week about how he feels the car.
He is, however, independent and used to run cars on trac.
See you soon then with pictures and some video if you want .......
Thomas
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Can you post a picture of your own face while driving it? :)
Video is wanted to. Nice story!
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Wow!
@Tomas: way not a vnt turbo?
And what type of gearbox are you using?
Jan
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Vnt means more problems than gain at the moment due to to the control it needs.
Gear box is a CHL box from golf mkIII.
Thomas
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Isnt youre gearbox a litle short?
I drive with a VNT on my Mtdi, it works well.
The actuator works on pressure.(http://i237.photobucket.com/albums/ff278/JanNieuwenburg/burnrubber.gif)
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Hi.
Yes its a little short but the market up here in sweden arent axactly over flooded with 085 boxes.
But do uot have any other suggestions of gearboxes, please let me know.
the topspeed today is 220km/h.
Interesting with the vane controle, any scematics over how youmade this work????
Pics or anything?
Thomas
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-off- Loved the movie of the bmw on you tube -thumbsup-
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220?dont you over rev youre engine?
I can suply you an other final drive with bolts and nuts.
I will send later some pictures, dont have them on the moment.
Jan
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The situation is like this.
The topspeed is tested on the dyno so it´s calculated to be this.
But, it can´t be to far of though, becuase i drove it in 210+ yesterday. :)
Interesting with this finaldrive thing.
And please send pics.
Thomas
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Thomas I do in the weekend.
Jan
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Here is some new pics.
Some of them from kinnekulle raceway.
(http://forumbilder.se/images/9e9201172030A29a2.jpg) (http://forumbilder.se)
(http://forumbilder.se/images/a39201172102Aa18f.jpg) (http://forumbilder.se)
(http://forumbilder.se/images/4b9201172130A8962.jpg) (http://forumbilder.se)
(http://forumbilder.se/images/e19201172155A2529.jpg) (http://forumbilder.se)
(http://forumbilder.se/images/a09201172345A53f0.jpg) (http://forumbilder.se)
(http://forumbilder.se/images/b99201172444A948e.jpg) (http://forumbilder.se)
(http://forumbilder.se/images/e39201172532Aa8ac.jpg) (http://forumbilder.se)
(http://forumbilder.se/images/ee9201172644A92ab.jpg) (http://forumbilder.se)
(http://forumbilder.se/images/3f9201172709A40e0.jpg) (http://forumbilder.se)
(http://forumbilder.se/images/709201172753Afb1b.jpg) (http://forumbilder.se)
Thomas
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-kewl- -wanker- -love-
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Thats one mint lookin' polo you have there mate -thumbsup-
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thanx!!
Nice to hear.
Thomas
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Wow! :D
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Hi.
today we were up on the dyno again.
(http://forumbilder.se/images/2342011105932a88b.jpg) (http://forumbilder.se)
Only 2.7bar boost pressure.
and i know it holds up to 2.9 bar boost.
That would have give us approx 174bhp.
So the 250% power increase project have reached its goal. :)
Thomas
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-notworthy- -goodjob- -wtf2-
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-thumbsup-
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hello!!
A new pic, just want your reactions.
(http://forumbilder.se/images/8812011104632d650.jpg) (http://forumbilder.se)
Thomas
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-wanker- :)
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hi
Got some new pics uploaded on Garaget.org
http://www.garaget.org/?car=152336&image=2517148 (http://www.garaget.org/?car=152336&image=2517148)
And
A new video.
http://www.youtube.com/watch?v=XmrbH7qFVg0
Thomas
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Cool! -thumbsup-
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hi and thanxs!
A new pic from the day on the race track.
(http://forumbilder.se/images/bf3201111081239ad.jpg) (http://forumbilder.se)
another pic.
(http://forumbilder.se/images/e032011111007545d.jpg) (http://forumbilder.se)
Thomas
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-wanker- -love-
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withstupid
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hi again.
2 new videos from dynoday... :)
http://www.garaget.org/?car=152336
Thomas
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Links shows pictures -dunno-
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Sorry just go down abit and to the left you se a botton with the text "videoklipp".
Press there and you se all of my clips.
Sorry for the inconvinience.
Thomas
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the good link
http://www.garaget.org/?car=152336&videos
smokes a lot -klappen- -klappen- -klappen- -klappen- -klappen-
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Hey if anyone is reading.
I now have an outside report regarding the car from Peter Lundgren.
Peter has many years experience in racing and today is the driving instructor in racing gave us the chance to get a test drive and evaluation of the car.
Here's his little story about his part of the story Polo 250% project.
************************************************** *********************************
Last winter rang a Thomas Knutsson to me and told me he was working on a project. Building on a VW Polo D Kombi to something more advanced than the original. And it was urgent because the car is visible on the car show in Elmia at Easter. He is neither the first nor last to have ideas about building a car, but I listened to what he had to say. He had some issues that we talked about. He called several times and we talked some more. And over time i began to understand that he really was doing something. So at one point he asked also if I could think of to test drive the car. If I had the time I could think of doing this. And here I sit now with a new experience.
I had arranged a date at Kinnekulle raceway for testing.
A little late Thomas came to an end. We got started just after lunch.
I ran some laps with Thomas as a passenger. The perception I had was that it felt very insecure. How much should you dare to push this car?
But, out with Thomas, and add about 10 laps. The feeling that the car was unbalanced remained, especially the rear end that was not as it should.
We discussed it and I also got the information that the car is not built as a race car. We adjusted the tire pressure as the only option. Drove another 10 laps. Checked the temp, tested braking, throttle and so on. I started to get me some more feeling of the car behavior. The feeling of understeering was there all the time. Prior to Run No. 3, I felt that it is time to push the car, see what it can do. But with understeer in the head, regular street tires on, a gearbox that does not want to rough handeling I still had to take it a bit "careful". Tested to hit the throttle earlier in curves, correcting understeer and now it started to go much better. I also began to get warm in “my clothes”, better temperature in the tires and the lap times fell,
Now that i knew where i had the car I could begin run it in a different way. Begin to reflect on what I'm driving. And little by little, I got the feeling that the car can "become something".
What I think of as the main action's to be taken is due to the handling. It is being understerred, but still feels very stable. But with other struts and so on. this should not be a problem. The next thing to work with the engine power. It is smooth o fine but with a little high exhaust temp at the end of the straight. Output Register is far too short. It came nicely at 4500-5500 revolutions but nothing more.
Later it turned out that it sat quite wrong air filter in your car, which explain a lot.
So overall, having been told the whole story of this project, I think you managed to build a surprisingly good car. Thomas is enthusiastic and energetic with his project, and it is also what it takes things like this. There is every opportunity to get this car to a potent and competitive race car in the appropriate regulations, if you like. It is interesting to follow the development of this project and it has definitely given a taste to participate and test the car while it develops.
Peter Lundgren - Test Pilot
************************************************** ******************************
Must say it feels quite strange to read this for me.
We have built a car, we have done something extraordinary that you know who have read the thread.
When I talked to Peter about how we wanted to do so where he's quite "off" at first.
When one is so up in the project are easily biased and do not always see the reality.
We must be open to others' experiences, etc. Therefore, I stood on me.
But the car was ready and tested.
Had time been available before the test drive on Kinnekulle I had found the error but unfortunately it became as it were.
Motor supplied only 80bhp most and then in a register at 1000rpm´s.
Despite this, he run the car.
Now that the engine performs 160bhp such an assessment is made to the car to get around the Ring of around 1min.
It is very good. It was so good thanks to the sponsors' contribution.
But ...
Now we have built this car ready for road use with std articles regarding handling, etc.
Soon we are taking the step towards this and start with "Step 2".
Now we will optimize it for the track and racing.
Now there is no requirement for std stuff anymore, but now we take a deeper step into the world of racing.
Then it's gold with Peter's experience.
Watch this space for thoughts on this.
How good can a polo diesel from 1993 realy be???
There is great potential as Peter writes to get to a really good car.
Thomas
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Love the story, keeping in mind the man never drove a tuned polo -naughty-. Respect for trying to be nutral and at the end he even gave advice -thumbsup- . It shows you've got a great street legal car!
-
New videoclip.
http://www.youtube.com/watch?v=PF1WgCkAOtI
One more:
http://www.youtube.com/watch?v=mtiv8o6yzS4
Thomas
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-gert- In the dark? Not afraid of life stock?
-thumbsup- Great, it doesn't rev high, but U can feel the torque from behind my screen.
Ps what's your location? When i'm for my job over there i'd love to visit and testdrive.........! -naughty- -sturen-
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Yhea in the dark...... live stock, yes they are there but jist had to.... stupid? yes!!!
Outside gothenburg, just send an pm before you leave and we´ll see.
Thomas
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-thumbsup- ( -off- last time was Öland, between Sweden and Finland, was great overthere!)
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oh, just 350km away -thumbsup-
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-uitlachen- Dänmark is closer, I know....
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Damnit in June I was around Gothenburg -boehoe- :)
Would love to see that Polo with my own eyes after al the stories you told and videos you've posted -thumbsup-
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(http://forumbilder.se/images/a89201110352604dc.jpg) (http://forumbilder.se)
(http://forumbilder.se/images/f5920111042082959.jpg) (http://forumbilder.se)
thomas
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You've enjoyed the weather -thumbsup-
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Absolutly.
Thomas
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Would be great if you could and would take it to Holland and come to the international Polo (1974-1994) meeting in Cuijck.
It will be held on sunday April 15th... Friends with Polo's are more than welcome too, ofcourse?!
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Hi.
Sorry for the late reply.
Very flattering, i will mark this in the calendar.
We´ll se what the future brings.
Thomas
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Hi again.
long time sins last time.
Does any one know of any other turbodiesel then jaap´s and mine?
Could be fun to take a look at.
thomas
Sweden
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Did a quick search:
http://www.youtube.com/watch?v=r3V78-x8uuo (http://www.youtube.com/watch?v=r3V78-x8uuo)
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Hi.
Now the car has got a new inner ceiling in black pics later.
The rear wing/spoiler is on the makeing and i´ve got a link for you to look at if any intrest.
Its gonna be made in carbonfibre...
Alot of work to do this....
http://madcamcnc.blogspot.com/2012/01/foam...ed-milling.html
thomas
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That looks interesting, So that is how they make a negative mold for the carbon-fibre. I made molds for polyester a couple of years back. I hope you can show us more of making the parts. -thumbsup- for the black ceiling.
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hi there!
Yes its a rather time consuming job to do this thou.
I will try to get more info on how the work progress.
Thomas
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new pic.
(http://forumbilder.se/images/a17201214940P1a55.jpg) (http://forumbilder.se)
Thomas
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JEAhhh -thumbsup-
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I like the mirrors!
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Thanx for the comments.
I to like the mirrors.
Thomas
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Hello.
Some new pics of the inner headlining.
(http://forumbilder.se/images/3e4201291051A7e84.jpg) (http://forumbilder.se)
(http://forumbilder.se/images/094201291122A8b69.jpg) (http://forumbilder.se)
(http://forumbilder.se/images/214201291153Ad5e2.jpg) (http://forumbilder.se)
(http://forumbilder.se/images/fd4201291351Ad098.jpg) (http://forumbilder.se)
Thomas
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Nice! The only thing that cought my eye was the grey mountings of the sunvisors. ;)
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Hi
Yes i know, these will be painted black, but havent had the time yet... :)
Thomas
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hmm... just wondering:
I think i have a set of original polo 86c GT sunvisors.
I think the mountings are black.
(could look into it this evening)
If they are. They are collecting dust at the moment so.....
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hi.
Please do.
Thomas
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Now i´m proud to say that the car is in swedens most popular and largest auto news paper.
Next for the car is the largest autoshow in sweden during easter, approx. 75000 visitor over 4 days.
Thomas
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Now i´m proud to say that the car is in swedens most popular and largest auto news paper.
Next for the car is the largest autoshow in sweden during easter, approx. 75000 visitor over 4 days.
Thomas
-thumbsup-
there is no greater compliment then that :)
BTW: i found the sun-visors.
They're complete and completely black.
If you want them just let me know trough a personal mail (PM)
I'm open for an offer (and i know they arent made of gold :) )
-
Now i´m proud to say that the car is in swedens most popular and largest auto news paper.
Next for the car is the largest autoshow in sweden during easter, approx. 75000 visitor over 4 days.
Thomas
-thumbsup-
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Damn, sorry... Fantastic! Don't forget the pictures!
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Looks very nice inside!
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Thanx i´m rely satisfied with it.
Thomas
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Nice job thomas -goodjob- -thumbsup-
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Thanx.
Thomas
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Hi long time sins last .
Is there any one that have maked there own rear axle?
thinking of making one ala polo s2000.
need some ideas or more information about diffrent ways to go.
The car will be used on track.
Thomas
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I would say keep the original design and just make adjustments that help to improve the performance of it. Like welding extra corners, maybe adding some weight for better handling/weight distribution.
Better to ask, Why do you want to change it? The are a lot of people who drove rally's and or races with polo's and not one of them build themselves an own axle. Just look at the bergrenners like Peter Naumann or Gerhard Moser......
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no idea where, but i have seen highly modified rear axles on polo's in the past (pictures on the web)
most of which i think was for
- finding the balance between stifness and weight
- giving the care more options for adjustment
(mostly polo mk1 by the way as i recall)
is it worth the effort? I have no idea.
-
Look in this (http://www.volksforum.com/forum/showthread.php?t=46037&page=56&pp=20) topic on volksforum.com.
This guy modded his rear axel om his MK1 Golf.
He also posted the explanation:
(http://i899.photobucket.com/albums/ac193/daved96/toe003.jpg)
(http://i899.photobucket.com/albums/ac193/daved96/toe004.jpg)
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First thanx for reading this.
I´ts been a while sins the last update but better late then never ... :)
Hello
Now, the chassi update has begun.
first we dissmounted all at the rear, beam wishbone etc.
(http://forumbilder.se/images/242720121129279be9.jpg) (http://forumbilder.se)
Empty...
(http://forumbilder.se/images/66272012113055f1dd.jpg) (http://forumbilder.se)
(http://forumbilder.se/images/fa272012113301aa2f.jpg) (http://forumbilder.se)
It´s always more work..
(http://forumbilder.se/images/ff2720121134164174.jpg) (http://forumbilder.se)
On this pic, you can see two other taction arms that we was thingking of using but no, we will make a new set with unibolts... :)
time to start up the lathe, had to produce this..
(http://forumbilder.se/images/6b27201211355865b4.jpg) (http://forumbilder.se)
Can anyone see what this is?
(http://forumbilder.se/images/fa2720121137199718.jpg) (http://forumbilder.se)
When we found the rigth pivot point for the rear beam, I could start with the front end.
(http://forumbilder.se/images/6f272012113934ae1c.jpg) (http://forumbilder.se)
Then to the fun parts. :)Rear beam modification.
We will build a trailingarm setup.
Man in action....:)
(http://forumbilder.se/images/4e272012122637e867.jpg) (http://forumbilder.se)
(http://forumbilder.se/images/fa27201211422186d1.jpg) (http://forumbilder.se)
One done .
Did make a new set of shorter steering arms.
These will give us quicker steering respons.
(http://forumbilder.se/images/7d2720121146195e1c.jpg) (http://forumbilder.se)
Thomas
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-thumbsup-
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Damn, that's no one night sleep modification. -thumbsup-
It's seems to me that the pieces of metal/bolts are brackets for the bushes?
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bushings spacers for in between brackets and ' arms ' for sufficient play? Nice work!
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Polo 86cs? 's' for super? Wow. -thumbsup-
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serieus high tech modifications -thumbsup-
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Hi.
Mk1-madness you re so right, the picture shows the center line pivot point bracket for the rear beam.
IRS on a Polo 86c is far beyond the normal mods.
The front and rear beam are now done and mounted.
Fully adjustable in front and rear.
Today we will start with the front hub angle.We want the wheel to dive in more when we turn the steering wheel.
IRS is a far bit "overkill" but i like the idea of having a Advanced rear beam.
i also want to have control over the toe-travel, have the possibilities to adjust camber , caster and toe.
So far the setup has changed the wheelbase with ~50mm in length and the track width by 60mm.
Caster in front 3deg. so we will see what we end up with but it will definite mean that we have a better situation then before.
pics coming up.
stay tuned.... :)
-
-love- can't wait :)
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Hi
Now comes the pictures.
After a whole lot of work during the Christmas and New Year eve, now the car is down on its own wheels again.
First a picture of the modified section of the section toward the torpedowall to handle the increased load.
(http://forumbilder.se/images/c92013113912A13cb.jpg) (http://forumbilder.se)
Then comes a picture of the rear axle mount in the middle.
(http://forumbilder.se/images/ae2013114010A5a77.jpg) (http://forumbilder.se)
Wishbones have been modified.
The spring plate is moved up 20mm, a stabilizer bracket is welded and steering arm has a new position. The angle of the hub modified to provide more angle in the hub that little sloppy expressed as more camber angle and better precipitation of the wheel when steering.
(http://forumbilder.se/images/27201310007PM8b18.jpg) (http://forumbilder.se)
(http://forumbilder.se/images/202013125536Pf70a.jpg) (http://forumbilder.se)
Finally a picture of what the front end looks now :)
(http://forumbilder.se/images/252013114105A61aa.jpg) (http://forumbilder.se)
Thomas
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-hitit- Respect!
I've only got one question. Is this gonna be street legal?
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Yes it will be.... :)
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-hitit- -klappen- -love-
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-goodjob-
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Hey.
Now it has taken off again ....
Got a problem when I realized that I have not blasting cabinet that is big enough.
Has a small table cabinet that works great most of the time but when it comes to such intake, cylinder head or cylinder block then I am totally screwed.
Thought I could not keep on struggling with this little box more, everything takes so much longer so I decided to spend some time and build a cabinet.
Will upload some pictures today on how to do, so please come with advice and comments, it is always fun.
Have collected some parts etc so it should go fast.
Thomas
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Hello again.
Yes it was time to show what last week went to. This post is long.
Well as you have gathered, I got tired of leaving away any blasting job that was larger than type 20x20cm.
So with all the work that was suffering for it, not to mention all the cost of money for the job and travel costs, etc., plus you always have to wait for it to be done, I decided to build my own blasting cabinet at the absolute lowest cost.
Sat and thought about buying sheets of metal and fold up a cabinet but have no possibility to fold that large pieces so there is a little problem directly ...
no, I thought, one more lap.
Got an idea that it has to work with refrigerators. :)
The problem is that these plastic inner side which will not last long.
If you remove this it will not be air tight so that idea went away.
But anyway, so I checked on the net and all other buy and sell sites.
2-500SEK(30£) it was ok to find to that cost but then it was an option to buy the sheet again .... fuck.
But what the fuck I was thinking a "freezer box" has the aluminum inside usually plus they're larger.
great!!but these were even more expensive.
But then the thought struck me that it is the freon in them, recycling of household goods is in our community to be free to get rid of.
Scrapyard next :)
Calling the scrapyard and talking to their boss whom showing a large interest in diesel cars ..... huh Oh well :)
After some talk, it is clear that I can come and look if there is any cabinet.
It does, fortune was made. The cabinet was already empty of gas, so it felt good.
You do not want to ruin the environment more than necessary.
This is what it looked like.
(http://www.forumbilder.se/CDMUQ/en-frysbox.JPG) (http://www.forumbilder.se/CDMUQ/en-frysbox)
Then I put the box on the stand.
Idea was that the door would be opened upwards, but because of the height it needed so it was not good.
I had marked out for the holes to put the hands in etc so it was probably the last second I checked the ceiling height in the garage.
Missing about 20cm for it to go free. It goes fast sometimes ... :)
Was to turn the cabinet.
i put a few locks jumpers from the local hardware store that I had lying around, believe they were the kind 1£ each or something.
Then it looked like this.
(http://www.forumbilder.se/CDMUQ/halmarkerade.JPG) (http://www.forumbilder.se/CDMUQ/halmarkerade)
But while I was on the scrapyard, I took the opportunity to pick a stove door.
Awesome resistant glass in these windows, they are not scratched for quite some time.
Another good thing with these stove lids is that they are in metal, and have a ready framework to cut out ..... :) Free is good.
(http://www.forumbilder.se/CDMUQ/ugnslucka.JPG) (http://www.forumbilder.se/CDMUQ/ugnslucka)
By far the hardest thing to sort out in blast cabinets, is visibility, you have to have a good situation for air to enter and exit efficiently.
Had a an old airfilter from a Volvo 850 laying around, perfect.
Was to cut out for this and make a frame that holds it in place.
Wanted easy access to be able to change it from the outside. On with 2 valve cover I had on the inside.
Took the opportunity to drill a hole for airfeeding into the cabinet, created an air connection and with water separator, becuase water we do not want in the cabinet. I have this already on my second box and is easy to move over.
I installed a quick release on the inside because I want to be able to put my old cabinet in this one to save space. Turned out like this.
(http://www.forumbilder.se/CDMUQ/luftfilter850.JPG) (http://www.forumbilder.se/CDMUQ/luftfilter850)
But the air must be filtered and everyone who has worked with a blasting cabinet know how fast all filters etc clogging. Vacuum cleaners are fighting like an idiots and pretty soon it has died.
Has this problem in the small cabinet.
No, now I build a cyclone filter.
But where shall I put this, course it also takes space.
But there is the place where the compressor is in the freezer ..... behind it perhaps there is space.
(http://www.forumbilder.se/CDMUQ/ventilationslucka.JPG) (http://www.forumbilder.se/CDMUQ/ventilationslucka)
Began to measure and soon i saw that it was quite possible to get a filter with good airflow capacity in there.
But it is not so easy to make a cone .... but after some counting and searching on the web, etc. I found a formula that could be used.
But now I had no sheets of metal ...... Damn, it becomes the next problem.
But then the thought struck me that one of my sponsors are working with sheet metal.
Went down to Piaab and had the possibility to take some waste pieces from their container., Free AGAIN .... :)
Drawn and cut, rolled and bent as best I could,
Found a pipe that was just the right size for connections and welding sheet metal is not my favorite.
Mounted the cyclone filter and then it became like this.
(http://www.forumbilder.se/CDMUQ/cyclonfilter.JPG) (http://www.forumbilder.se/CDMUQ/cyclonfilter)
Now it was to get a steelnet/mesch? or something , this was not easy, but down to the store in the village, and asked if they had a shelve that were broken, that they had ... :) Free again Fantastic!!
Now it was to fold a sheet metal square cone, and this was not so hard up with the spare pieces of sheet I received from Piaab and draw, cut and bend it.
Tried to see if it fit, and it did.
Before this, I cut out the bottom of the cabinet.
Glue and blind rivets so it was airtight.
Measure out where to put my arms, find the position for the window on the box and cut out for them.
Had two old floor-well connections I bought for the laundry room renovation.
Mounted these parts on the boxdoor.
Attached the rubber gloves that I bought.
(http://www.forumbilder.se/CDMUQ/skapetklart.JPG) (http://www.forumbilder.se/CDMUQ/skapetklart)
Underneth the cabinet you can see the nice yellow and black roof plates that became a cone in a blasting cabinets in there "second" life ..
Bought a blast nozzle and modified it where the connection to the sand.
If you buy a blast nozzle gun, do check all the races there is always burrs that cause malfunction.
Connect all hoses and in with the grid.
Turned on the vacum cleaner and put in a bit of old rusty parts from a vw golf.
A rear brake caliper bracket, a strut, everything with rust since 1983 ....
Closing the door on with the air and try.
Sweet jesus it worked :): Thumbup:
(http://www.forumbilder.se/CDMUQ/skapet-in-action.JPG) (http://www.forumbilder.se/CDMUQ/skapet-in-action)
Inner dimensions are for the interested is 85cm deep, 95cm wide and 65cm high.
Believe the cost ended up with glue and screws etc about 80£. : D
There's some adjustments to be made, but on the whole ... : Thumbup:
Exceeded expectations ...
Thanks to me for this time.
Thomas
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-notworthy-
Good job -thumbsup-
-
Respect -thumbsup- very creative
-
Nice and creative -thumbsup-
-
Great job! When can we start sending you stuff? :D
-
withstupid -naughty-
-
thanx.
It´s working like a dream.
And the facts that its so easy to do i do hope more will build there own cabinet like this.
will upload some pics later over yesterdays work.
Thomas
-
Started with the golf again.
This weekends work was the sillarea.
Did som blasting and painting first.
some pics..
(http://www.forumbilder.se/CDUIF/blastrat-och-lackat.JPG) (http://www.forumbilder.se/CDUIF/blastrat-och-lackat)
(http://www.forumbilder.se/CDUIF/troskel-hoger-klar1.JPG) (http://www.forumbilder.se/CDUIF/troskel-hoger-klar1)
(http://www.forumbilder.se/CDUIF/troskel-hoger-klar2.JPG) (http://www.forumbilder.se/CDUIF/troskel-hoger-klar2)
The other side done aswell. :)
(http://www.forumbilder.se/CDUIF/troskel-hoger-klar3.JPG) (http://www.forumbilder.se/CDUIF/troskel-hoger-klar3)
(http://www.forumbilder.se/CDUIF/troskel-vanster-klar1.JPG) (http://www.forumbilder.se/CDUIF/troskel-vanster-klar1)
Thats all for now.
ps. i know its not a polo so let me know if you want it removed..... :)ds
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In my opinion: It's your topic -thumbsup-
It's gonna be wide! Why not polyester? This ads a lot of weight.
-
Hi
Well,plastic may be lighter but not my way to go. :)
Polo_td question:
But now i have a question.
What can i do with the camshaft on the diesel engine 1w.
It seems to clogging up and drop the power significant after 3500rpm.
Is there any other cam to use?
Does someone know the duration etc on the original cam?
Thomas
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Can't help you....
Already more pic's of the golf?
-
Now in the new edition of the VW Scene magazin.
A little story of this white polo diesel.
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Wow, that's a nice compliment! Pictures?
-
Hello.
Now I've finally got the roof job done.
There is a big difference in the curvature of a polo and golf mk1 roof.
Overall, it is 3cm difference in the roof at the front and rear 2cm.
Front
(http://forumbilder.se/EA2J8/tak-byte-1.JPG) (http://forumbilder.se/EA2J8/tak-byte-1)
rear
(http://forumbilder.se/EA2J8/takbyt-bak2-bra.JPG) (http://forumbilder.se/EA2J8/takbyt-bak2-bra)
Anyone who thinks that the polo open air roof is easy to get there are SO wrong.
The Twingo roof is very easy to install.
If you do not have access to a weld and want a large sunroof etc should choose the Twingo roof.
After a lot of measuring and adjusting it became like this after 8 hours of work.
(http://forumbilder.se/EA2J8/takbyte-kurvatur-fram.JPG) (http://forumbilder.se/EA2J8/takbyte-kurvatur-fram)
(http://forumbilder.se/EA2J8/takbyte-sidan-kurvatur1.JPG) (http://forumbilder.se/EA2J8/takbyte-sidan-kurvatur1)
Along the side
(http://forumbilder.se/EA2J8/takbyte-sidan.JPG) (http://forumbilder.se/EA2J8/takbyte-sidan)
Now this shall be welded, etc.
Could not do this yesterday but restored my fuelfiller pipe that was shitty.
Dull image, but think you have seen such before. :)
(http://forumbilder.se/EA2J8/tankror-fixat.JPG) (http://forumbilder.se/EA2J8/tankror-fixat)
New plate at the top, changing some tube sections and weld, grind and paint as usual.
But I'm happy with the result.
The all for today.
Thomas
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-thumbsup-
-
Looks good!
Twingo roof -thumbsup- some here have done the same.