Cheers all- final push now, getting married in 5 weeks, and really want it as my wedding car. Got a trackday booked a few weeks after that too...
My first problem was the flywheel/starter interface. I had made a few assumptions:
- Polo crank palm geometry was the same as a Golf in relation to the block/gearbox mounting face
- Added an adapter plate into the mix (moving gearbox 10mm further from the crank palm)
- Starter and clutch engagement would be fine
So, once mocked up the starter did not have enough throw to engage, it was 12mm short (about the thickness of that adapter plate then...!)
With that in mind I was concerned about needing a bespoke flywheel- I've tried to retain OEM or off the shelf parts as much as possible. Handy for spares in the future, and often alternatives are available, such as engine mounts, with can be swapped for softer items should they be required.
Whilst doing some internet geeking, I came across Epytec, a German company- who offered a very light G60 esque flywheel, and an adapter ring (14mm) for a 02M conversion whilst maintaining the lighter fly I believe. Anyway, parts duly ordered, CAD station shutdown, and brews consumed.
Parts arrived:
So, onto the scales with you lot:
Polo G40 PY Lightened flywheel:
Polo G40 Helix Paddle Clutch:
Golf G60 Lightened Flywheel:
Golf VR6 Clutch:
EPYTEC Golf G60 Flywheel:
So, totals look like this:
Polo G40 Lightened Flywheel & Helix Clutch: 8.38kg
Golf G60 Lightened Flywheel & VR6 Clutch: 13.37kg
EPYTEC Flywheel & VR6 Clutch: 9.87kg
So 1490g on the mass of flywheel/clutch - which is still lighter than a stock G40 setup I believe, inertia clearly different as Golf components are larger. But for now, I'm happy it's ballpark. Engine response and characteristics shouldn't change drastically.
I have also cracked on and painted the bay with Halfrauds paint and 2k lacquer, although I think I've sprayed the car in too low an ambient, the lacquer hasn't gone off properly and can be marred easily. No biggie, but frustrating.
I also cut and shut the downpipe and exhaust to accommodate the new engine angle, this took a full day (10hrs) of mocking up, tacking, removing, and then finally fully welding. My stainless MIG isn't pretty, but it'll be covered in exhaust wrap. Also remade the rear hanger, so that's another few big jobs off the list.
And for me the most satisfying part, bolting things on that aren't designed for a Polo, win!
Cheers
Pete