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  #1  
Old 16-06-2006, 10:33
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Default Projekt 82 CL-D G40

Here's a little summary on my most-time-consuming project of the last months..

I bought this polo when I saw an add on our registers website ( www.polo86c.nl ). It's a 'real' 86c as it is a 1982 model with chassisnumberWVWZZZ86ZCW058310. I fancied the car because it has the 'one year only' flat rearview mirrors, and it looked like quite a undamaged car, in 'diamont-silver': It could be a panel-donor for my 1981 GL (same color), and with a primer finish be a replacement for my daily beater.

Here's how it looked like in the add:










Quite all-right. If does feature some minor dents on the front right wing and the bootlid (as visible on the second picture), but it did look ok overall. Since I do have a daytime job, I visited the seller and inspected the car.. in the evening. I'll tell you this: in the moonlight, every car looks good!

No seriously: The dent on the bootlid looked far worse then I expected, the 'top' of the car has been resprayed (professionally, but with some color-difference): Probably the result of serious hail. But overall it still is quite ok, not to say excellent for a 24 year old car.

First landmark was to get the car running PROPERLY. The ignition wasn't all to happy to rev above 3500 rpm,. accelerator-pump was completly off/non functional and the waterpump was leaking water... So we started to do some cosmetic surgery:

Bfore / After:



And finally I fitted a bigger unit



I've even sourced a 8 liter unit, but that'll come in later (if there's still room).

The ignition was fixed/swapped and the accelerator-pump has been adjusted to offcourse, but that doesn't look good in pictures

After this, I dug out an NOS rear hatch, since my damage-repair-skills did turn the original hatch from 'slightly-dented-not-to-bad' to 'cracked-paint-total-loss' in just 2 minutes..
Some loony did paint this hatch in diamont silver
n black trim, Opel/Vauxhall Corsa/Nova GSI style, but he crashed the rest off the car before he could fit it.



Looks quite awfull to me, with the black rearclusters and the missing mudflap. The other remaining mudflap went, the original lights came back in, and it isn't all that noxious.

Then, to get it MOT'ed the usual repairs followed: battery-floor, licenceplate lights, and some other minor things. Turned out the front brakes needed some inspection, and since time was a factor I had them fixed..

Some time went by. Did get the engine to run a bit more economical: it was doing 1 liter per 10 km (10liter every 100km's), and although it did consume like a porsche, it didn't feel drive one..

Summer arrived, and I finally sourced tyres to fit these NOS Centra Pepperpots: 175/50 R14 Pirelli P6000 on 6J-R14-ET48.










As you can see, it's not lowerred at the front.. but it's hanging to the back.. Did I only lower the rear? Nope. It's allready having it's new engine lying around in the back..

Because my daily needs to go, and I did drive that daily at 16 km / liter (6,25 liter/100) I wanted to get something REALLY economical..

I first planned to swap the petrol engine in my daily to a diesel, but the high-diesel-tax-rate killed that plan. This car is all-most 25 years off age, which means it will turn tax-free in the netherlands, it would be economical x 2.

Here's one diesel engine:



and here's another:


(Thanks Mark for stating it's all 'OKAY' but the engine wasn't anyways)

To get the diesel engine conversion through the conversion-test of the 'RDW', I need to get a Polo 2 Diesel engine in (engine code MN, 1300cc, 40BHP), but the later Polo 2f diesel engine is way more powerfull: code 1W, 1400 cc with 43 BHP...
Plan: swap to MN 30BHP, get it lincenced, that swap to 1W 43BHP.
The original petrol engine is a 1300cc HH block with 60BHP: The chassis will hold those enormous amounts of 43BHP easily, but to get it licenced 'the cheap way' I need to do it like this. Swapping it directly to a 1W engine would make the conversion test about 10 times as expensive.


Here's the first test, to see whatever is wrong with the 1.3 liter diesel engine (which came out of a breaker-car, which was being scraped since the engine died)



It turned out it was running on only 2 cilinders. Here's why:



And somewhere in it's horrible life the timing of the camshaft was off to:



Needless to say we fixed the headgasket, and got it up running on 3 and 4 cilinders: cilinder 1 is still a bit awkward.. maybe some injector problems?

Before I will fit the engine, the suspension needs to be updated: I fitted a 2f GT rear axle: 6mm thick and with stabilizer,. and i swapped the complete front to Diesel / 5 gear specs :


You can see the soundproofing that's allready waiting for the diesel to arrive.

When the speedo died (or better: the tacho did), i swapped to a mile-speedo, so even with the diesel engine in, I'll be using the whole scale (I hope).




Yesterday, we finally swapped the engine: Here's me checking out the enginebay from an unusual perspective:




And this is me, still smiling...




It turned out things where more complicated than we expected, so somewhere last night (or this morning) I finally drove home with an alternator giving 16 volts off power, and a speedo going to 70 miles TOPS..

Thanx to Marcel86c for all the help, work and coffee!

More to come, later on..
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  #2  
Old 16-06-2006, 10:40
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Jolly good english mate




fancy a cup of tea?
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  #3  
Old 16-06-2006, 11:25
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Just to boost activity in the international polo section abit..

Nothing wrong with that is there?
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Old 16-06-2006, 11:44
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Quote:
Originally Posted by sjampoo
Just to boost activity in the international polo section abit..

Nothing wrong with that is there?


of course not,

just complementing on your english
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  #5  
Old 16-06-2006, 16:13
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Cool project, I know all about the strange ways of RDW... But still a good way to get around the rules, although it is a lot of work


Nest step: 1W turbo?
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  #6  
Old 16-06-2006, 19:36
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Quote:
Originally Posted by sjampoo
Just to boost activity in the international polo section abit..

Nothing wrong with that is there?


Absolutely not, this place is too quiet, so anything is welcome.

The car looks to be in very decent condition, given its age. Do you dutch guys have taxes based on what kind of engine is in the car? No such thing here, only a flat-rate passenger car tax.

Oh, and please explain, why so much more difficult to just go for the newer engine directly? I mean, the volume (cc) is barely bigger, the hp also, and your still down almost 20 hp from your original engine! I simply dont get it!
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  #7  
Old 16-06-2006, 20:02
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Car taxes overhere are based on weight and fueltype.

So converting from gasoline/petrol to diesel means getting the registration changed.
But this can only be done cheaply ( this a low budget project afterall..) if you place an engine that was
originally available in the early Polo 2's ( the MN engine ).
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  #8  
Old 16-06-2006, 22:38
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Exactemundo..

If you fit another engine, which was originally sold as such in your model (but in another car), it's in there 'database' of 'known-good-setups'. So when I fit a MN engine the type will change from: 867 131 (Polo CL, 4 speed tranny, HH engine (60 horses petrol) to 867 194 (Polo CL, 5 speed tranny, MN engine (40 horses diesel).

There is no 'type' which states 'Polo CL, 5 speed tranny, 1W engine (43 horses diesel), so that would force a 'complete' testing: road-track testing, sound tests, etc etc: very expensive, for 3 horses moren.

IF it allready has got the 40 horses MN engine on the licence/registration, I can easily pop-in an 1W engine since there aint no big changes in horses or fuel. the usual MOT-guys won't notice, and no-one will care.

--
@ Stijn: Since I'm allready depressed on the power-output,. the 1.4 liter engine will swap straight in if the MOT-test goes ok next thursday,.. but in the end, that won't do the trick: Either I'll fit a G40 charger (expensive but original ) or build myself the 1.6 diesel block out of petrol+diesel blocks (data not available: probably a project to fail), or it'll get a turbo, or a combination of all these..
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Old 16-06-2006, 22:40
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BTW: drove it today.. (couldn't resist), but it does fume abit....

If it's warm, it does get better, but there's an oily cloud behind me...
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  #10  
Old 18-06-2006, 19:07
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Quote:
Originally Posted by sjampoo
There is no 'type' which states 'Polo CL, 5 speed tranny, 1W engine (43 horses diesel), so that would force a 'complete' testing: road-track testing, sound tests, etc etc: very expensive, for 3 horses moren.

IF it allready has got the 40 horses MN engine on the licence/registration, I can easily pop-in an 1W engine since there aint no big changes in horses or fuel. the usual MOT-guys won't notice, and no-one will care.


Ok, then I understand. Luckily not that difficult here in Norway.
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Old 18-06-2006, 23:01
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Quote:
Originally Posted by sjampoo
BTW: drove it today.. (couldn't resist), but it does fume abit....

If it's warm, it does get better, but there's an oily cloud behind me...


blue or black?
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  #12  
Old 20-06-2006, 10:34
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Blue,.. but it disappears when the engine gets warm/hot..



More news on the front:

Been to the RDW today,.. it's tested AND approved!
Emission-test: K-value 1.0 (2.5 allowed).

Wasn't that simple though: the car's of 1982, and the approval-specs are all dated 1987 and later.. But I could convince Mrs Bakker that it was all okay and stuff
His wife drives a 1983 Polo Classic, so he could appreciate my work on the car
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Old 22-06-2006, 08:31
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What did the mailman drag in to day? The paperwork! Wow! that's fastXL! Thumbsup for Hajee and his collegues
Tuesday -> Tested and approved
Thursday -> All paperwork has been done, and my freshly printed licencee has arrived in the mail.

Check the online specs: One capture of wednesday, and one of today:





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Old 22-06-2006, 19:35
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Aantal Zitplaatsen 0 - isnt that a bit unpractical?
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Old 22-06-2006, 23:27
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the dutch are obviously small people
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Old 10-07-2006, 18:56
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Just came back from the int. polo meeting in Denmark.

It did run well (93 mph max), but it's burning oil aswell.. Bigtime! 1 liter, every 300 km.


Didn't stop Marjolijn from taking some rolling shots:







Since it's running on oil (sort off), I'll change to the other (1.4) engine a bit quicker..
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Old 21-09-2006, 08:31
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Extremely small update:

- 1.3 liter engine is still in (vacation, no time, etc etc).
- It's still running, but takes up to 1 liter of oil per 250 km's.
- Installed a manometer to measure the pressure at the fuel-line.

pressure running diesel is about -0,2 bar
pressure on pure vegetable oil is about -0,8 bar. WAY to low.
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  #18  
Old 07-03-2007, 22:01
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Update

No matter how long I abuse the little 1.3 liter diesel engine, it keeps on running.. Yes, it even passed the MOT (APK) last month which includes a particle test..


Since my last update i've upgraded the fuel-lines to ID 10mm spec.. Some may call it 'garden hose spec'...

Oh well,. it is a hosepipe. Pressure on vegy oil: -0,2 bar max



It runs through the interiour to keep things nice warm and cosy. In the engine bay the oil flows through a heat-exchangers, electrical heater, diesel filter and feeds the engine at about 80 degrees celcius.

Top view:



The extra glass filter has only been there temporarily, just to keep large particles away, and it turned out to be one hell of an leaky **** causing all sorts of unexpected problems.

The fuellines in the end got some isolating stuff wrapped around and all works fine without air-leaks.

As it's kind-off a daily beater, things do need maintenance. Things tend to break.. like shock absorbers. And as it is a beater, on a tight budget.. I had to swap the complete suspension to -60mm.. as that's what I got laying around.. horrific.




Doesn't look that low, but trust me: it's satisfactory to me The rearwheels are allmost completely within the arches:




Will go nicely with the 14" summer rimms.

I purchased a G40 charger, and it's at 'Arno' to get the full revision treatment: Seals, bearings, the works. (no pics, it will get sandblasted )

In the meantime, been making some room, and fitted the famous G40 metal thingy to create room for the charger and it's hoses:



The enginemount fitting the 1.4 diesel engine arrived to day:


It's the three hole version, which fits the older engines:






With the engine mount delivered, and the complete G40 spec exhaust laying around I hope the swap to the 1.4 liter engine within a few months
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Last edited by sjampoo : 08-03-2007 at 21:06.
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  #19  
Old 07-03-2007, 22:27
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Looking good, hope you can get it to run properly with the G40!

P.S. I suppose you mean: tight?

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on a thing budget..

Last edited by RubenD : 08-03-2007 at 10:23.
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Old 07-03-2007, 22:36
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tight?
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