Club G40 Forum

Club G40 => Photos and videos => Ongoing Projects => Topic started by: PR23M3K on August 13, 2011, 12:50:14 am

Title: Vw Polo mk1 G60 - 196 Bhp / 228 Nm
Post by: PR23M3K on August 13, 2011, 12:50:14 am
Hello,

I would like to show you my baby ..... it is Vw Polo G40 '94. I bought it 3 years ago. It was fully stock.

Modifications done:
- polished G60 RS charger,
- german toothed pulleys (28 tooth charger pulley at the moment), additionally I have 22 and 24 teeth charger pulleys,
- custom charger bracket,
- custom chip,
- G60 injectors,
- Bosch W4DP0 spark plugs,
- ported head,
- aluminum air intake 77mm => 70 mm by the charger,
- air filter K&N,
- polished rocker,
- polished Polo GT inlet manifold,
- polished de-wedged throttle 48mm
- IC from Audi A3
- 4-2-1 exhaust manifold
- Jetex exhaust system – 2,5”

Suspension: Koni + H&R kit 80/60, front and rear brace bar

Wheels: PLS Hockenheim,
- front: 8,25" ET 6 – outside rim 3"
- rear: 9,25" ET 6 – outside rim 4"
- tires Continental 175/50/13

Body: removed rear wiper, smaller mirrors

Interior:
- 3 VDO gauges: oil temp and pressure, voltage
- AG SM Peak boost gauge
- modified clocks
- steering wheel: Raid HP 28 cm
- shift-light

Plans: new CatCams camshaft 267/281, 250kPa or 300kPa map-sensor, 24 or 22 teeth charger pulley and custom remap. After that I will search for a new body, I want the Polo mk1.

I bought the car in 2008, below photos:
(http://i1119.photobucket.com/albums/k622/PR23M3K/przod1.jpg)

(http://i1119.photobucket.com/albums/k622/PR23M3K/przod2.jpg)

(http://i1119.photobucket.com/albums/k622/PR23M3K/silnik.jpg)

(http://i1119.photobucket.com/albums/k622/PR23M3K/srodek.jpg)

(http://i1119.photobucket.com/albums/k622/PR23M3K/tyl1.jpg)

(http://i1119.photobucket.com/albums/k622/PR23M3K/tyl2.jpg)


Chart from the rollers. Stock car: 0,6 bar of boost:
Result: 106.6 HP, 153 NM
(http://i1119.photobucket.com/albums/k622/PR23M3K/wykresG40.jpg)

Next I have done following modifications:
- charger pulley 65 mm + SLS chip,
- FMIC from BMW
- de-cat
- Polo GT inlet manifold
- de-wedged throttle body (48 mm)
- rear and front brace bar

Unfortunately I did not measure power after these modifications. I sold the G40 charger in winter 2009 and it started .... :-)

Polishing:
(http://i1119.photobucket.com/albums/k622/PR23M3K/pokrywa1.jpg)

(http://i1119.photobucket.com/albums/k622/PR23M3K/ssacy1.jpg)

new charger ...
(http://i1119.photobucket.com/albums/k622/PR23M3K/G60charger.jpg)

Refreshed wheels:
(http://i1119.photobucket.com/albums/k622/PR23M3K/wheels.jpg)

Mounting the G60 charger:
(http://i1119.photobucket.com/albums/k622/PR23M3K/polog60-inprogress.jpg)

and it's ready for 2010 season:
(http://i1119.photobucket.com/albums/k622/PR23M3K/engine1.jpg)

(http://i1119.photobucket.com/albums/k622/PR23M3K/engine2.jpg)

(http://i1119.photobucket.com/albums/k622/PR23M3K/interior.jpg)

(http://i1119.photobucket.com/albums/k622/PR23M3K/at1.jpg)

(http://i1119.photobucket.com/albums/k622/PR23M3K/at2.jpg)

(http://i1119.photobucket.com/albums/k622/PR23M3K/at3.jpg)

(http://i1119.photobucket.com/albums/k622/PR23M3K/at6.jpg)

At the end of 2010 season I have added: toothed pulleys, 4-2-1 exhaust manifold and Jetex 2,5” exhaust system.

In 2011 I worked under the air inlet, new IC. I've wanted as much as possible of aluminum.
(http://i1119.photobucket.com/albums/k622/PR23M3K/inletpipes.jpg)

Pipe from the charger to IC
(http://i1119.photobucket.com/albums/k622/PR23M3K/inletpipes2.jpg)

Almost finished, you can see the new headlights, air inlet on the bonnet to the IC
(http://i1119.photobucket.com/albums/k622/PR23M3K/poloG60engine.jpg)

(http://i1119.photobucket.com/albums/k622/PR23M3K/front1.jpg)

Clocks at night, the red LED light below the VDO oil temp gauge is shift-light, useful thing ...
(http://i1119.photobucket.com/albums/k622/PR23M3K/interior-night.jpg)

It is not a full story, but the most important informations.
75 mm (28 teeth) charger pulley produces 1,35-1,4 bar of boost.
Next week I will check this setup on rollers.
Title: Re: PR23M3K's Vw Polo G60
Post by: djtez on August 13, 2011, 08:59:10 am
Eager to see results of the rollers!
This is how I'd like my car setup!!
Title: Re: PR23M3K's Vw Polo G60
Post by: PR23M3K on October 05, 2011, 10:10:38 pm
Chart from the rollers, setup as above, boost: 1,35 bar
180,7 Bhp, 226,5 Nm
(http://img528.imageshack.us/img528/8840/20111004164601.th.jpg) (http://imageshack.us/photo/my-images/528/20111004164601.jpg/)


Now I can modify the engine more and check it once more.

Parts to be mounted this weekend:
Title: Re: PR23M3K's Vw Polo G60
Post by: PR23M3K on December 04, 2011, 12:01:23 am
Result with the CatCams camshaft, 250kPa map-sensor, 28 teeth charger pulley and custom remap.
196,6 Bhp / 228 Nm
(http://i1119.photobucket.com/albums/k622/PR23M3K/PoloG60-catcams.jpg)

I need to change fuel injectors before I go with 24 teeth charger pulley.
Over 1,4 bar of boost it is to lean at the moment. I am looking for ~310 cc/min injectors.


I have also bought a new body, so there will be a lot of work through the winter
(http://i1119.photobucket.com/albums/k622/PR23M3K/Polomk1GT.jpg)

Title: Re: PR23M3K's Vw Polo G60 - 196 Bhp / 228 Nm
Post by: cheddarcheese on December 06, 2011, 05:00:17 pm
Nice Results and that will be one quick mk1  ;D ;D
Title: Re: PR23M3K's Vw Polo G60 - 196 Bhp / 228 Nm
Post by: Jezza-7 on December 09, 2011, 10:07:43 am
Do you use the standard g40 lader bracket to mount the g60 lader?
Title: Re: PR23M3K's Vw Polo G60 - 196 Bhp / 228 Nm
Post by: PR23M3K on December 09, 2011, 10:32:31 pm
At the beginning it was a modified standard G40 bracket, now I use a custom made bracket

G40 bracket:
(http://images50.fotosik.pl/342/0164ef7ee87b19d4med.jpg) (http://www.fotosik.pl)

Custom bracket
(http://images36.fotosik.pl/200/60e469b41e9f87b0med.jpg) (http://www.fotosik.pl)
Title: Re: PR23M3K's Vw Polo G60 - 196 Bhp / 228 Nm
Post by: djtez on January 15, 2012, 01:18:57 am
Wow cracking results!
Must be monstrously quick.

Any bottom end modifications ? Ie up rated Conrod or pistons?

I want to g60 my polo but value to opinion on here which is basically dont do it
Title: Re: PR23M3K's Vw Polo G60 - 196 Bhp / 228 Nm
Post by: PR23M3K on January 21, 2012, 01:51:02 pm
The bottom end is fully stock.

Engine is out and I am working on the mk1
(http://i1119.photobucket.com/albums/k622/PR23M3K/silnik-1.jpg)

(http://i1119.photobucket.com/albums/k622/PR23M3K/2012-01-20204532.jpg)

(http://i1119.photobucket.com/albums/k622/PR23M3K/2012-01-20204600.jpg)
Title: Re: PR23M3K's Vw Polo G60 - 196 Bhp / 228 Nm
Post by: djtez on January 21, 2012, 10:02:44 pm
Could you give me a little guidance on how a could sorta follow your set up..
Whhere can I find charger bracket? Do I need to buy another toothed pulley for charger?
What size of pulley can a run and still drive quite erratic..

Thank you in advance if you manage answer any questions
Title: Re: PR23M3K's Vw Polo G60 - 196 Bhp / 228 Nm
Post by: PR23M3K on January 21, 2012, 11:22:15 pm
To fit G60 you need to:
- modify stock charger bracket or buy special for example on ebay.de (30-50 euro), for special bracket  you may need longer oil return hose
- modify outlet dome as you can see above
- move a little bit a water cooler
 
Charger pulley is the same as for G40. 28 teeth (~75 mm) generates 1,3-1,4 bar of boost. It drives ok unless you have 175/50/13 or 195/45/13 tires but you can always put a bigger pulley.

What set-up are you currently running ?





Title: Re: PR23M3K's Vw Polo G60 - 196 Bhp / 228 Nm
Post by: ereeiz on January 22, 2012, 12:33:39 pm
Not seen a G60'd polo for a while. I was going to ask how you managed to drive it with the steel wheels on there, then noticed that was the original look for it, haha. Nice one!

Title: Re: PR23M3K's Vw Polo G60 - 196 Bhp / 228 Nm
Post by: djtez on January 22, 2012, 02:45:19 pm
Set up is quickly
Big valve head ported and polished on outlet
Piper high lift cam
R1 spec charger
Toothed belts 65mm
G60 injectors
Gt inlet.
Sns stage 5 generic chip
Full ppp exhaust including manifold.... Was hopin id not be far below 165flywheel,
Tyres size and compound are 195/45/14's on uniroyal rainsport 2

Title: Re: PR23M3K's Vw Polo G60 - 196 Bhp / 228 Nm
Post by: PR23M3K on March 20, 2012, 10:40:31 pm
djtez, yours setup will easily gain 200 bhp using G60 charger, bigger injectors and after remap of course.

Macadamia bronze on Mk1  :D:
(http://i1119.photobucket.com/albums/k622/PR23M3K/color2.jpg)

(http://i1119.photobucket.com/albums/k622/PR23M3K/color1.jpg)

(http://i1119.photobucket.com/albums/k622/PR23M3K/fender.jpg)
Title: Re: PR23M3K's Vw Polo G60 - 196 Bhp / 228 Nm
Post by: djtez on March 21, 2012, 12:29:58 am
im Thinking of a wossner 77mm piston set up  ( 1341cc )

now im still having some confusion on the G60 rs stages .
ive seen rs rs2 rs3 and also rs gt , which charger are you using ?
Title: Re: PR23M3K's Vw Polo G60 - 196 Bhp / 228 Nm
Post by: dub-disaster on March 21, 2012, 09:10:05 am
I lovd the colour realy old school! Whats rims are going on ig do you know yet?
Title: Re: PR23M3K's Vw Polo G60 - 196 Bhp / 228 Nm
Post by: PR23M3K on March 21, 2012, 04:19:41 pm
Quote from: djtez on March 21, 2012, 12:29:58 am
now im still having some confusion on the G60 rs stages .
ive seen rs rs2 rs3 and also rs gt , which charger are you using ?

I use RS2 below photos:
(http://i1119.photobucket.com/albums/k622/PR23M3K/th_charger2.jpg) (http://s1119.photobucket.com/albums/k622/PR23M3K/?action=view&current=charger2.jpg)   (http://i1119.photobucket.com/albums/k622/PR23M3K/th_charger1.jpg) (http://s1119.photobucket.com/albums/k622/PR23M3K/?action=view&current=charger1.jpg)

Quote from: dub-disaster on March 21, 2012, 09:10:05 am
I lovd the colour realy old school! Whats rims are going on ig do you know yet?
I have 2 sets of rims:
1st PLS Hockenheim from the black Mk3
2nd Maxx wheels 7x8x14 with Uniroyal Rainsport 195/45 tires
Title: Re: Vw Polo mk1 G60 - 196 Bhp / 228 Nm
Post by: djtez on March 21, 2012, 04:32:40 pm
This rs2 is this the same as stage 4?
Title: Re: Vw Polo mk1 G60 - 196 Bhp / 228 Nm
Post by: PeteG40 on March 21, 2012, 04:55:03 pm
rs2 isn't as ported around the bearing on the outlet, but has 3 of the fins removed.
Title: Re: Vw Polo mk1 G60 - 196 Bhp / 228 Nm
Post by: PR23M3K on March 23, 2012, 09:08:00 pm
custom made radiator, core size 320x320x52 mm

(http://i1119.photobucket.com/albums/k622/PR23M3K/radiator.jpg)
Title: Re: Vw Polo mk1 G60 - 196 Bhp / 228 Nm
Post by: PR23M3K on April 22, 2012, 11:39:41 am
3D model of the new IC. Core size 300x150x80.
(http://i1119.photobucket.com/albums/k622/PR23M3K/IC3dmodel.jpg)

Fitted in a car, plastic tanks are cut off and I have made new ones from aluminium, they are waiting for welding only
(http://i1119.photobucket.com/albums/k622/PR23M3K/ICprzymiarki.jpg)
Title: Re: Vw Polo mk1 G60 - 196 Bhp / 228 Nm
Post by: djtez on April 22, 2012, 09:42:22 pm
looks very interesting ..

need to take another snap shot of the new custom end tanks .

Title: Re: Vw Polo mk1 G60 - 196 Bhp / 228 Nm
Post by: PR23M3K on May 01, 2012, 09:23:02 pm
Charger side:
(http://i1119.photobucket.com/albums/k622/PR23M3K/th_2012-05-01181712.jpg) (http://s1119.photobucket.com/albums/k622/PR23M3K/?action=view&current=2012-05-01181712.jpg)

Intercooler side:
(http://i1119.photobucket.com/albums/k622/PR23M3K/th_2012-05-01181726.jpg) (http://s1119.photobucket.com/albums/k622/PR23M3K/?action=view&current=2012-05-01181726.jpg)
(http://i1119.photobucket.com/albums/k622/PR23M3K/th_2012-05-01181801.jpg) (http://s1119.photobucket.com/albums/k622/PR23M3K/?action=view&current=2012-05-01181801.jpg)

Engine bay:
(http://i1119.photobucket.com/albums/k622/PR23M3K/th_2012-05-01181630.jpg) (http://s1119.photobucket.com/albums/k622/PR23M3K/?action=view&current=2012-05-01181630.jpg)


New Recaro seats ;D
(http://i1119.photobucket.com/albums/k622/PR23M3K/th_2012-05-01181904.jpg) (http://s1119.photobucket.com/albums/k622/PR23M3K/?action=view&current=2012-05-01181904.jpg)
Title: Re: Vw Polo mk1 G60 - 196 Bhp / 228 Nm
Post by: djtez on May 01, 2012, 10:57:47 pm
Really Tight fit huh ?

Your making fabulous progress!

wish you all the best
Title: Re: Vw Polo mk1 G60 - 196 Bhp / 228 Nm
Post by: PR23M3K on May 15, 2012, 09:05:36 pm
Inlet finished

(http://i1119.photobucket.com/albums/k622/PR23M3K/2012-05-15191112.jpg)

(http://i1119.photobucket.com/albums/k622/PR23M3K/2012-05-15191158.jpg)
Title: Re: Vw Polo mk1 G60 - 196 Bhp / 228 Nm
Post by: djtez on May 15, 2012, 09:26:40 pm
Looking great
Title: Re: Vw Polo mk1 G60 - 196 Bhp / 228 Nm
Post by: bushyg40 on May 24, 2012, 08:35:43 pm
Where did you get your custom radiator made and how much did it cost ?
Title: Re: Vw Polo mk1 G60 - 196 Bhp / 228 Nm
Post by: Boris on May 25, 2012, 11:08:47 pm
Love this.  8)
Title: Re: Vw Polo mk1 G60 - 196 Bhp / 228 Nm
Post by: PR23M3K on June 02, 2012, 03:49:30 pm
bushyg40 rad cost me around £120, done in Poland, where I live  :)

Few shots taken today

(http://i1119.photobucket.com/albums/k622/PR23M3K/foto1sm.jpg)

(http://i1119.photobucket.com/albums/k622/PR23M3K/foto2sm.jpg)

(http://i1119.photobucket.com/albums/k622/PR23M3K/foto3sm.jpg)

(http://i1119.photobucket.com/albums/k622/PR23M3K/foto4sm.jpg)
Title: Re: Vw Polo mk1 G60 - 196 Bhp / 228 Nm
Post by: PR23M3K on August 15, 2012, 11:19:57 am
PLS Hockenheim 8j x 9j x 13 on the car:
(http://i1119.photobucket.com/albums/k622/PR23M3K/polo86_PLS.jpg)

(http://i1119.photobucket.com/albums/k622/PR23M3K/pls86_2.jpg)

(http://i1119.photobucket.com/albums/k622/PR23M3K/pls86_1.jpg)

(http://i1119.photobucket.com/albums/k622/PR23M3K/pls86_rear.jpg)

(http://i1119.photobucket.com/albums/k622/PR23M3K/pls86_front.jpg)

As you can see I will need berg cup arches

2 pictures of the engine bay:
(http://i1119.photobucket.com/albums/k622/PR23M3K/engine86_2.jpg)

(http://i1119.photobucket.com/albums/k622/PR23M3K/engine86_1.jpg)

and interior (almost finished):
(http://i1119.photobucket.com/albums/k622/PR23M3K/interior86.jpg)
Title: Re: Vw Polo mk1 G60 - 196 Bhp / 228 Nm
Post by: djtez on August 15, 2012, 11:27:45 am
Looks great!

Will look pretty special with the Cup arches.

Got any video's of it running ?
Title: Re: Vw Polo mk1 G60 - 196 Bhp / 228 Nm
Post by: dubstar on August 17, 2012, 01:58:45 pm
That's bad-ass  ;D

Loving your work!!!
Title: Re: Vw Polo mk1 G60 - 196 Bhp / 228 Nm
Post by: dub-disaster on August 17, 2012, 06:28:11 pm
this is one of my favorite polos at the moment what style of front end is that ?? are you going to colour code your Bergen arches i think they would look sweet in black
Title: Re: Vw Polo mk1 G60 - 196 Bhp / 228 Nm
Post by: PR23M3K on October 23, 2012, 08:42:24 pm
Front end comes from Derby mk1, berg arches will be black.

Photo shoot that sum up my 2012 season:

More on: http://picasaweb.google.com/jacku3/VWPoloMk1G (http://picasaweb.google.com/jacku3/VWPoloMk1G)

(http://farm9.staticflickr.com/8467/8103702458_5548a4f590_z.jpg)
(http://farm9.staticflickr.com/8185/8103702304_514f1ff6b9_z.jpg)
(http://farm9.staticflickr.com/8326/8103687797_64235b7665_z.jpg)
(http://farm9.staticflickr.com/8473/8103706130_85dbc5a093_z.jpg)
Title: Re: Vw Polo mk1 G60 - 196 Bhp / 228 Nm
Post by: djtez on October 25, 2012, 08:35:51 am
this has really transformed!

fantastic work !
Title: Re: Vw Polo mk1 G60 - 196 Bhp / 228 Nm
Post by: Jester on October 27, 2012, 10:07:59 am
Can't stop looking at this, it's simply perfect, wish i had an mk1  :-[
Good job!
Title: Re: Vw Polo mk1 G60 - 196 Bhp / 228 Nm
Post by: erixtar1992 on November 08, 2012, 12:29:11 am
absoloutely love this!!!! what an awesome looking car!
Title: Re: Vw Polo mk1 G60 - 196 Bhp / 228 Nm
Post by: MaxGT on November 08, 2012, 03:08:17 pm
Looks amazing mate.

Can't wait to see it with the arches on, hopefully they wont just be riveted!
Title: Re: Vw Polo mk1 G60 - 196 Bhp / 228 Nm
Post by: PR23M3K on October 21, 2013, 04:50:55 pm
Arches won't be fit as I managed to buy new outer rims and now there is no need.
Just a little update, what have been done in 2013:
- 4-pads clutch & pressure plate - Sachs Race Engineering
- new outer rims on the front wheels
- steering wheel: RAID HP 28cm
- carbon look door cards
- second cone filter -> It is not pulling up the boost, it is still 1,6-1,65 bar but it looks a way better  8)

Next priority is to do a remap with 310cc injectors and new Pierburg fuel pump
After that I can focus on details such as
- rear backbox in which I will change pipes for single straight,
- GT stickers and GT badge

Few shots to show how does the car look like now:

(http://i1119.photobucket.com/albums/k622/PR23M3K/20130929_165342_zpsb3fd594c.jpg) (http://s1119.photobucket.com/user/PR23M3K/media/20130929_165342_zpsb3fd594c.jpg.html)

(http://i1119.photobucket.com/albums/k622/PR23M3K/20130929_165425_zps112391f2.jpg) (http://s1119.photobucket.com/user/PR23M3K/media/20130929_165425_zps112391f2.jpg.html)

(http://i1119.photobucket.com/albums/k622/PR23M3K/Enginebay2013_zps0c614474.jpg) (http://s1119.photobucket.com/user/PR23M3K/media/Enginebay2013_zps0c614474.jpg.html)

(http://i1119.photobucket.com/albums/k622/PR23M3K/doorcards_zps9cf18ab2.jpg) (http://s1119.photobucket.com/user/PR23M3K/media/doorcards_zps9cf18ab2.jpg.html)
Title: Re: Vw Polo mk1 G60 - 196 Bhp / 228 Nm
Post by: Jezza-7 on January 01, 2014, 08:58:22 pm
Liking the double filter whilst retaining the boost return mod.
Title: Re: Vw Polo mk1 G60 - 196 Bhp / 228 Nm
Post by: PR23M3K on September 28, 2014, 06:40:41 pm
GT stickers on the car
(http://i1119.photobucket.com/albums/k622/PR23M3K/20140928_121857_zps31f54594.jpg) (http://s1119.photobucket.com/user/PR23M3K/media/20140928_121857_zps31f54594.jpg.html)


As the car is after final remap I took it on rollers, boost ~1.8 bar, results below:(http://i1119.photobucket.com/albums/k622/PR23M3K/PoloG403rdgear_zps5a83b97e.jpg) (http://s1119.photobucket.com/user/PR23M3K/media/PoloG403rdgear_zps5a83b97e.jpg.html)
Title: Re: Vw Polo mk1 G60 - 196 Bhp / 228 Nm
Post by: Jacque on December 03, 2014, 04:22:44 pm
nice power lol  :o
Title: Re: Vw Polo mk1 G60 - 196 Bhp / 228 Nm
Post by: Lionheart on December 03, 2014, 11:38:19 pm
What a great project! Lovely looking car with fantastic engine/mods.
Title: Re: Vw Polo mk1 G60 - 196 Bhp / 228 Nm
Post by: Alexiskayak_7 on January 04, 2015, 11:57:56 pm
Have you mapped the car mate?
Title: Re: Vw Polo mk1 G60 - 196 Bhp / 228 Nm
Post by: PR23M3K on August 17, 2015, 08:36:57 pm
Yes, the car has been mapped, results few posts above.

Some update from this season, not a lot as I don't have time for the car.

Short shifter - custom made by my colleague, it looks and works like a CAE one
(http://i1119.photobucket.com/albums/k622/PR23M3K/short%20shifter_zpsfzsykwxc.jpg) (http://s1119.photobucket.com/user/PR23M3K/media/short%20shifter_zpsfzsykwxc.jpg.html)

Grill with red trim
(http://i1119.photobucket.com/albums/k622/PR23M3K/derby%20GT_zpsywaficzg.jpg) (http://s1119.photobucket.com/user/PR23M3K/media/derby%20GT_zpsywaficzg.jpg.html)

Custom made rear badge:
(http://i1119.photobucket.com/albums/k622/PR23M3K/Polo%20G60%20badge_zpsjog4vkvr.jpg) (http://s1119.photobucket.com/user/PR23M3K/media/Polo%20G60%20badge_zpsjog4vkvr.jpg.html)
Title: Re: Vw Polo mk1 G60 - 196 Bhp / 228 Nm
Post by: randombadger69 on August 19, 2015, 06:23:27 pm
Looking good. Cool badge!