project polo mk1 -old skool/racetrack car

[Gallagher]

Well, since the derby is mostly done, I am now beginning my other project on the polo. the car is a 76 polo l with 0,9l engine and 40hp :redface:

My plans:

exterior- original. the same look as my derby. lots of chrome :)
interior- just the plain steel painted, 2 race bucket seats and 4point harnesses, and a cage.
engine- 3f engine with tuning cam and motorcycle carbs. (90-100hp)
old skool 13X6-7" wheels and 80-100mm lowering.

there is extremely little rust on this car luckily. almost just the front and the door, but I have got a new one in store.

should get the weight down to 550-600kg when it is done.. that is a lot of fun with 100hp ;)
Me and a friend who is the owner of www.raceland.no is going on a trip to ast suspension in valkenswaard, holland and further down to raceland in belgium in the beginning of july. On this trip I will also stop in dortmund and pick up an 3f engine. Just have to get a passport. I thought one could travel between schengen countries without showing passports, but holland seems to have changed theese rules lately :( btw: a passport costs 125 euros in norway..

started with stripping the car today and scraping the floor for padding and glue.. more updates to come.


http://i4.tinypic.com/15cmu78.jpg

http://i5.tinypic.com/15cmuk2.jpg

http://i5.tinypic.com/15cmv4n.jpg

[Berserker]

super cool, why don' you come by for a cup of coffee, i live between Valkenswaard and Dortmund...

so this is the idea?:
http://www.msc-sophienthal.de/img_1u1/hans-anton-Dateinen/audi50_2.JPG

nice project but why don't you think of widening like the "berg-cup" cars???

would be cool too and some 13" 8j rims :cool:

http://daten.ws-mack.de/Bild.asp?P=E:\mack\freigabe\berg-cup\Kategorie-Eingabe\Videos\Dateien\Kat8\17.Show\KIF_3271+Kopie.jpg

[Gallagher]

funny :) well, our time schedual is pretty tight as it is.. If it was just me, I would have stopped ;) No, both of theese cars are too racing-look for me.. I want to keep that original old skool look on the outside, pretty much the same as the derby.. the interior and angine will be all racing on the other side...

[Berserker]

the 1st one is pretty old skool, the rims and not widened and all, ok forget the paint-job...

[Gallagher]

well, if you give it a better paint job, it would look similar :)

berserker: how is it with passports to get into holland now ? do not think I will get a new one in time..

[Berserker]

where are you from again? EU country? if so than you only need an ID/identity card and not a passport, but you know since the EU that we have open borders so no-one will check you, only if the police pulls you over...

you can risk to go without, but you also have to go to germany and since the world championship is going on, there are a lot of boarder controls (just slipped my mind)

[PerL]

where are you from again? EU country? if so than you only need an ID/identity card and not a passport, but you know since the EU that we have open borders so no-one will check you, only if the police pulls you over...

you can risk to go without, but you also have to go to germany and since the world championship is going on, there are a lot of boarder controls (just slipped my mind)

He's from Norway like me, we are not within the EU, but we are following most EU rules (including the Schengen agreement) as we are a part of the EEC.

[Gallagher]

yeah.. the problem is that in norway, the only valid identification papers abroad is our passports.. got the engine today on ebay.. 100 euros.. damn thats cheap..

[Berserker]

the only thing to remember is with the World championship that the Germans are really controlling their boarders for terrorists....

so I wouldn't risk it without a passport

[Gallagher]

just came back from my trip to eindhoven / Valkenswarg and nijmegen now.. brougt back 4 ats classic rims, a engine and a gearbox.. pics will come.. I am planning a days work on the car tomorrow..

[Gallagher]

well, here are the pics I promised you.. the 3f engine, my "new" garage, the ats rims and the inside of the car.. also how the rear wheelarches look now reydu to be welded back in place.. I have already welded the battery box together as you can se.. Also had a hard time removing the glue from the inside of the car, but I am getting there :)

things are atleast moving forward :)

http://i6.tinypic.com/1zvq4b4.jpg

http://i2.tinypic.com/1zvq4xh.jpg

http://i2.tinypic.com/1zvq552.jpg

http://i2.tinypic.com/1zvqpuq.jpg

[Gallagher]

well, the work is progressing slowly since I just bought a 93- polo fox also, but I have got some welding done, and the engine is assembled, washed, sandblasted and painted..

http://i7.tinypic.com/21jyhzq.jpg

[Berserker]

how did you get the gearbox so clean? also sandblasted? with some clear paint?

[Gallagher]

how did you get the gearbox so clean? also sandblasted? with some clear paint?

yepp.. first steaming, then sandblasting and at the end som silver hotpaint.. will last atleast a month ;) Of maybe I have some luck.. this car is only meant for tracks, so it wont be driven that much..

[Gallagher]

bought some bushings today from germany.. payed 161 euros delivered to me in norway, hope theese will help on the track. Pics. are borrowd from thomas78 here on the forum when he mounted them on.

http://www.volksforum.com/albums/files/2/2/2/3/PICT0069Small.JPG

http://www.volksforum.com/albums/files/2/2/2/3/PICT0100Small.JPG

http://www.volksforum.com/albums/files/2/2/2/3/PICT0112Small.JPG

[Berserker]

bought some bushings today from germany.. payed 161 euros delivered to me in norway, hope theese will help on the track. Pics. are borrowd from thomas78 here on the forum when he mounted them on.

http://www.volksforum.com/albums/files/2/2/2/3/PICT0069Small.JPG

http://www.volksforum.com/albums/files/2/2/2/3/PICT0100Small.JPG

http://www.volksforum.com/albums/files/2/2/2/3/PICT0112Small.JPG

Ey you're still alive, cool I also need those, I just find 161 euro a little bit much for some legos..

What did you do to your brakes??

[Gallagher]

hello berserker :) I havent don eanything with it yet, but I am going to do the same as I did on mye old skool derby. VwII 239mm vented brakes from golf 2 in front and golf 2 drumbrakes in the rear. more than enough and brakes like hell :)
the VW II calippers fit perfectly with the g40 calipper carrier, but you can also use carriers from a golf 1 with VWII calippers. have to work a little with them, but not much.. easy with a grinder..

[Berserker]

hello berserker :) I havent don eanything with it yet, but I am going to do the same as I did on mye old skool derby. VwII 239mm vented brakes from golf 2 in front and golf 2 drumbrakes in the rear. more than enough and brakes like hell :)
the VW II calippers fit perfectly with the g40 calipper carrier, but you can also use carriers from a golf 1 with VWII calippers. have to work a little with them, but not much.. easy with a grinder..

VW2 calipers are also used on polo g40's and fit on later model polo's carriers+front legs...

Like I did:
http://www.volksforum.com/albums/files/1/8/0/4/IMG_3075.JPG

Polo 2f legs with vw2 calippers with Brembo Max discs and ferodo ds2500 blocks..
http://www.volksforum.com/albums/files/1/8/0/4/IMG_3078.JPG

[Gallagher]

yes, my brakes will be similar to this. the 2f legs and the mk1 legs are the same i think. the only thing I need is the carrier you have on theese legs. drilled and grooved vented discs and greenstuff og other blocks also help a lot yes.. what did you do to your master cylinder and brake servo ? nothing ? I dont know what fits here..

[Berserker]

yes, my brakes will be similar to this. the 2f legs and the mk1 legs are the same i think. the only thing I need is the carrier you have on theese legs. drilled and grooved vented discs and greenstuff og other blocks also help a lot yes.. what did you do to your master cylinder and brake servo ? nothing ? I dont know what fits here..

No polo 1 legs are different from polo 2 and 2f legs, you need the legs with half moon shaped braking blocks and not the square ones, The discs from the square ones have a different offset and do not fit..

If you get legs with the half moon shaped blocks, you just need to replace the callipers for the vw2 ones and the rests will fit perfectly..

I don't change my master cilinder because it will make no difference because the cilinders of the callipers are the same, and my Audi already has brake servo..

[Gallagher]

No polo 1 legs are different from polo 2 and 2f legs, you need the legs with half moon shaped braking blocks and not the square ones, The discs from the square ones have a different offset and do not fit..

If you get legs with the half moon shaped blocks, you just need to replace the callipers for the vw2 ones and the rests will fit perfectly..

I don't change my master cilinder because it will make no difference because the cilinders of the callipers are the same, and my Audi already has brake servo..

well, I made it fit with mk1 legs, caliper carriers for mk1 golf with VWII calipers and the calipers.. but I will give your version a try if i do not have the parts for my one.

I also use the original master cylinder and brake servo on my derby.. works perfectly.

[berendd]

the half moon shaped brakes are allready much better than the square ones...

been to Eindhoven? liked it?

[Gallagher]

yes, I think they are, but I am mounting VWII calippers anyhow. the smaller brakes will get overheated on track. Yes I liked einhoven :) got drunk, allthough all the bars closed at 10 in the evening. I work as a bartender and planned on having a drink, but none of the bartenders there could mix a longdrink. You guys have shitty bartenders :) otherwise I liked it a lot ;)

[Berserker]

yes, I think they are, but I am mounting VWII calippers anyhow. the smaller brakes will get overheated on track. Yes I liked einhoven :) got drunk, allthough all the bars closed at 10 in the evening. I work as a bartender and planned on having a drink, but none of the bartenders there could mix a longdrink. You guys have shitty bartenders :) otherwise I liked it a lot ;)

I think you went to a different Eindhoven than me :tongue: ....

The vw2 calipers were on a polo g40 so they do fit easily, but the calliper carriers for a g40 are different, they have an extra bracket which causes 13" rims to fit very hard...

[Gallagher]

I know :) if you have the right offset on the rims, 13" fits :) I have got a shit load of parts, so I'll just try different combinations til i find one that seem ok ;)

[berendd]

10 o clock? maybe youre watch was on asian time? :tongue:

[serge pot]

replied the mail

[Gallagher]

thanks serge pot.. the carbs are for the other car, my racetrack polo :) Pretty sure the clock was on GMT +1 :)

[berendd]

thanks serge pot.. the carbs are for the other car, my racetrack polo :) Pretty sure the clock was on GMT +1 :)

mmh strange... but hey you found serge!

dont let him crawl before me serge... unless he pay's mine too off course :tongue:

[Gallagher]

he, he.. dont worry berendd.. I already have the carbs, I just need some info on how to set hem up.. And after a long time I have finally found someone that knows how ;)

[berendd]

he, he.. dont worry berendd.. I already have the carbs, I just need some info on how to set hem up.. And after a long time I have finally found someone that knows how ;)

just kidding, I think Serge can be helpfull with that..

my carbs are waiting in the shed too, I need him to make an inlet, unfortunately I'm not a welding champion myself.

[serge pot]

so someone has got information which his ears are still flappering :D

[Gallagher]

had a very good discussion with serge yesterday, hoping for a smaller follow-up today ;)

[Gallagher]

just bought another car for parts.. thing are beginning to happend now and I have used about 1000 euros on parts just the last two months :) just have to wait until the summer so I can get the chassis welded and painted.. well this is the car I got for about 120 euros..



http://i175.photobucket.com/albums/w140/thor_inge_hansen/DSC_0438Small.jpg

http://i175.photobucket.com/albums/w140/thor_inge_hansen/DSC_0440Small.jpg

http://i175.photobucket.com/albums/w140/thor_inge_hansen/DSC_0442Small.jpg

http://i175.photobucket.com/albums/w140/thor_inge_hansen/DSC_0445Small.jpg

http://i175.photobucket.com/albums/w140/thor_inge_hansen/DSC_0448Small.jpg

[steven16v]

Nice car for 120 euros. Nice colour. And I like the interior of the car! Very sweet!

The roof, is that original?

[Gallagher]

nah.. the redneck dit not get the car threw mot control, and found out that chopping of the roof seemed like fun :) I also have to add that this car has got an extremely rare HC engine with 1100ccm and 60hp.

[berendd]

looks pretty good though..

shame that they cut the roof out, but a good excuse to make a ragtop polo!

[Gallagher]

he, he.. well, you are welcome to have a try at getting that approved by the department of motorized vehicles :)

[steven16v]

he, he.. well, you are welcome to have a try at getting that approved by the department of motorized vehicles :)

We don't say anything to them. :D ;)

[Berserker]

I also have a HC in my audi, actually on first sight the polo doesn't look that bad at all, but don't they all.. :rolleyes:

[Tjaap]

nice, why didn't i ever notice this topic before?

[Gallagher]

dont ask me ;) I am in the quiet foreign part of the forum :) thats why i guess.. Well, I am doing some jobs on my derby now to make it ready for track.. I guess I will start on the polo again in the beginning of june.

[PerL]

Well, I am doing some jobs on my derby now to make it ready for track..

I hope you have a passenger seat available? I'd like to join you for a round or two (ballast :D )

[Gallagher]

I just mounted in two seats yes.. they are a bit small for you I would think, but we'll squeeze you in ;)

[Tjaap]

Perl, you're a big bloke? i don't think i've ever seen you in a pic,

[Gallagher]

He is not a especially big bloke, its me that is especially petite :)

[PerL]

Perl, you're a big bloke? i don't think i've ever seen you in a pic,

I'm not big, I just have a sturdy frame ;)

(180 cm, 103 kg)

[Gallagher]

175cm, 75 kg ;)

[Tjaap]

Lol

[Gallagher]

broke mye hand the other day, so dont know if I'll be any good on racetrack, but I'll give it a try :)

[Gallagher]

I need one thing now that I have started building again: has anyone of you any pics of anyone that has mounted the battery in the rear (spare wheel placing) ? I have got my one idea of how I am going to do it, but would be nice to see anyone elses work :)

[Tjaap]

how about in the spare tire well. they sell those plastic containers for mounting batteries in the car. and i've heard (only heard never felt the need to look into it) the E30 BMW's had the battery in the back and the wiring is perfect for a swap and easy to remove if you find one in the junkyard

[PerL]

The plastic containers are made for boats and readily available around here (Biltema). For wiring, just use a phat car stereo wire, better than old, used wires out of a bimmer.

BTW; cant believe I forgot to post this .gif here, it's Gallagher from VW-Audi Club's summer meet two weeks ago... (I shot the pics and made the .gif)

http://images24.fotki.com/v770/photos/2/26836/141582/Gallagher-vi.gif

More of my pics from this event here! (http://www.fourtitude.com/gallery/gallery2.php?mode=album&album=/Events/VW-Audi%20Club%20Norwegen=Show%20and%20Track%20Event/2007)

[Gallagher]

things are finally happening.. Ill just give you the pics.. only some rust left on the front plate now.


http://i175.photobucket.com/albums/w140/thor_inge_hansen/Bilde066Small.jpg

http://i175.photobucket.com/albums/w140/thor_inge_hansen/Bilde085Small.jpg

things welded theese last few days:

http://i175.photobucket.com/albums/w140/thor_inge_hansen/Bilde075Small.jpg

http://i175.photobucket.com/albums/w140/thor_inge_hansen/Bilde074Small.jpg

http://i175.photobucket.com/albums/w140/thor_inge_hansen/Bilde076Small.jpg

http://i175.photobucket.com/albums/w140/thor_inge_hansen/Bilde099Small.jpg

And some ideas for some mods I am going to do..

http://i175.photobucket.com/albums/w140/thor_inge_hansen/Bilde073Small.jpg

http://i175.photobucket.com/albums/w140/thor_inge_hansen/Bilde067Small.jpg

http://i175.photobucket.com/albums/w140/thor_inge_hansen/Bilde077Small.jpg

[Berserker]

Why didn;t you leave the rear plate out, and placed a diffuser??

http://www.volksforum.com/albums/files/1/8/0/4/IMG_4184k.JPG

Not only looks dope, will create extra downforce as well....

[Gallagher]

first of all, because I am not looking for that gruppe H look with the plastic spoilers.. I want pure steel and a real old skool look on the outside, whilst the inside will be pure racing..

[Berserker]

Ah yes, sorry then, u told me already.. :tongue:

[Gallagher]

things are moving forward.. I'll just let the pictures do the talking :)

http://i175.photobucket.com/albums/w140/thor_inge_hansen/P6210002Small.jpg

http://i175.photobucket.com/albums/w140/thor_inge_hansen/P6210006Small.jpg

http://i175.photobucket.com/albums/w140/thor_inge_hansen/P6210003Small.jpg

[sjampoo]

you did put something underneath that plate that seals off the 'spare-wheel-tyre-removed-round-thingy' didn't you?

The 'spare-wheel-cup' gives the rear (some/alot) of stiffness,. and it's attached to the rear panel, and mid-section traverse. But more important: Without any further strengthening, in case off a crash with a rear-impact (pole, car, tree) in the rear.. you won't believe how easy the rear will bend inward.

[Berserker]

Strange to seem someone welding and cutting on the grass....

You shouldn' try that here in the Netherlands ;)

[Gallagher]

you did put something underneath that plate that seals off the 'spare-wheel-tyre-removed-round-thingy' didn't you?

The 'spare-wheel-cup' gives the rear (some/alot) of stiffness,. and it's attached to the rear panel, and mid-section traverse. But more important: Without any further strengthening, in case off a crash with a rear-impact (pole, car, tree) in the rear.. you won't believe how easy the rear will bend inward.

I understand, but I dont agree :) there will be a well made in the plate to fit the battery into.. this will attached to the rear panel andr the mid-section traverse.. but the metal used for the spare wheel cup, was a sorry excuse of metal (probably 0,75mm), whilst I am using 1,5mm steel.. hard as hell :)

[sjampoo]

.8 is standard car-sheet-metal.

The shape of 'things' should give it it's strength. The funny shapes in the bottom wheren't there just for fun :)

If you'r using thinker metal ofcourse, you won't need that kind of strenghtening, and while your putting in a (battery?) well, with attachments towards the rear panel and mid section traverse, I don't foresee any problems. :)

Way to go!

[Gallagher]

I know all the shapes and bends are there to give it its strength, but in a collision it would not have been worth much.. the worst thing now is that the bottow of the rear plate is not attached to anything in the center, so it a bit "wobly" :)

[Gallagher]

well, the battery tray is complete.. became fucking good :)

http://i175.photobucket.com/albums/w140/thor_inge_hansen/P7180030Small.jpg

http://i175.photobucket.com/albums/w140/thor_inge_hansen/P7180029Small.jpg

http://i175.photobucket.com/albums/w140/thor_inge_hansen/P7180028Small.jpg

[Gallagher]

the last pictures of my polo before being put away before the winter.. sandblasted and ground coat is on.. looking forward til next summer.


http://i175.photobucket.com/albums/w140/thor_inge_hansen/P8150010Medium.jpg

http://i175.photobucket.com/albums/w140/thor_inge_hansen/P8150009Medium.jpg

http://i175.photobucket.com/albums/w140/thor_inge_hansen/P8150007Medium.jpg

[Gallagher]

Got something in the mail from wiechers.de today :) I just love german perfectionism..

http://i175.photobucket.com/albums/w140/thor_inge_hansen/S73F0011Small.jpg

http://i175.photobucket.com/albums/w140/thor_inge_hansen/S73F0012Small.jpg

http://i175.photobucket.com/albums/w140/thor_inge_hansen/S73F0013Small.jpg

[Berserker]

That's one great looking cage, steel or alu???

[Gallagher]

steel of course.. with TÜv.. It not only meant for show, was hoping that it would save if i went off of the track someday :)

[Berserker]

steel of course.. with TÜv.. It not only meant for show, was hoping that it would save if i went off of the track someday :)
I know, I would also only buy steel, but most people use it for show, already didn't think u would..

[Gallagher]

well, some things have happened.. not too much, but just enough :)

I'll let let pictures do the talking :) Well, I have to tell you that the front wings are glassfiber.. to reduce some weight in the front..

http://i175.photobucket.com/albums/w140/thor_inge_hansen/S73F0147Small.jpg


http://i175.photobucket.com/albums/w140/thor_inge_hansen/S73F0146Medium.jpg

http://i175.photobucket.com/albums/w140/thor_inge_hansen/S73F0145Medium.jpg

http://i175.photobucket.com/albums/w140/thor_inge_hansen/S73F0144Medium.jpg

http://i175.photobucket.com/albums/w140/thor_inge_hansen/S73F0143Medium.jpg

[Tjaap]

such a great project... do you, by any chance have an inside view of the battery tray you made?

[sjampoo]

Green dials and red fingers...

OLD!

[Gallagher]

old it is :) about 32 years..

here are some pics:

http://i175.photobucket.com/albums/w140/thor_inge_hansen/P7250015Small.jpg

http://i175.photobucket.com/albums/w140/thor_inge_hansen/P7250013Small.jpg

http://i175.photobucket.com/albums/w140/thor_inge_hansen/P7250012Small.jpg

[appie]

no more pic`s ?