Club G40 Forum

Club G40 => Photos and videos => Topic started by: Kustom on September 16, 2013, 10:50:01 am

Title: New polo track toy
Post by: Kustom on September 16, 2013, 10:50:01 am
And so it begins.....

Many of you will rememeber me from many moons ago when I used to roll around in the shell that Robin now owns, but hello to anyone thats joined in my hiatus.

Ive now found the need for a track toy, so ive bought the silver mk3 GT Turbo that was for sale on here with a melted piston.

(http://i23.photobucket.com/albums/b393/kustompolo/Track%20Toy/86c12e20e29f32a2e195a3fab58b2d49.jpg) (http://s23.photobucket.com/user/kustompolo/media/Track%20Toy/86c12e20e29f32a2e195a3fab58b2d49.jpg.html)
Polo in its new home

(http://i23.photobucket.com/albums/b393/kustompolo/Track%20Toy/null_zpsab46e457.jpg) (http://s23.photobucket.com/user/kustompolo/media/Track%20Toy/null_zpsab46e457.jpg.html)
Before

(http://i23.photobucket.com/albums/b393/kustompolo/Track%20Toy/dadce4decb975c0e76a9168ae15caf73.jpg) (http://s23.photobucket.com/user/kustompolo/media/Track%20Toy/dadce4decb975c0e76a9168ae15caf73.jpg.html)
After :)

(http://i23.photobucket.com/albums/b393/kustompolo/Track%20Toy/d40918a1da666db0c724605ad3067062.jpg) (http://s23.photobucket.com/user/kustompolo/media/Track%20Toy/d40918a1da666db0c724605ad3067062.jpg.html)

Tucked in the corner of the garage until I can get it apart later this week and assess the damage.







Title: Re: New polo track toy
Post by: Vwdave on September 16, 2013, 09:05:46 pm
Saw that for sale close to where I work.  When it was a gt the chap lived around the corner from me I remember when he first bought it 7 yrs ago, it must have been a press car at some point solid shell.
Title: Re: New polo track toy
Post by: Kustom on September 17, 2013, 08:17:41 pm
Popped the head off and cyl 1 is melted

(http://i23.photobucket.com/albums/b393/kustompolo/Track%20Toy/b0413e9ff866a87ce6be29b0e7e4390c.jpg)

Not sure what valve shaped damage to the piston surface is though, appears to be more melting that impact.

(http://i23.photobucket.com/albums/b393/kustompolo/Track%20Toy/dc9cc257bd5c443a319213134c306caa.jpg)


Bores are scored too :(

(http://i23.photobucket.com/albums/b393/kustompolo/Track%20Toy/1d2fa888d17b3c7557185454bcd88b80.jpg)


Title: Re: New polo track toy
Post by: Jezza-7 on September 17, 2013, 08:45:27 pm
Rebore will sort that. When mine melted it was worse than yours and had it sorted out by rebore. Obviously bigger pistons though.
Title: Re: New polo track toy
Post by: PeteG40 on September 17, 2013, 08:47:45 pm
look like big valves too!  good job you dont have to try and source one!
Title: Re: New polo track toy
Post by: z3i on September 17, 2013, 08:51:00 pm
Nice! love reading build threads like this :)
Title: Re: New polo track toy
Post by: joe_lewis55 on December 05, 2013, 07:31:37 pm
Any progress on this mate? Really miss it now and have finally got some money all I keep thinking is 'if only I still had that polo' haha.
Title: Re: New polo track toy
Post by: Yoof on December 07, 2013, 03:28:03 pm
He picked up a few bits this afternoon  ;D
Title: Re: New polo track toy
Post by: Kustom on December 27, 2013, 10:21:21 am
The project has taken rather a steep twist and something new has landed on my drive.

(http://i23.photobucket.com/albums/b393/kustompolo/Mk1%20Polo/photo1.jpg) (http://s23.photobucket.com/user/kustompolo/media/Mk1%20Polo/photo1.jpg.html)

Sporting a new rollcage, top mounts and a PPP subframe.

(http://i23.photobucket.com/albums/b393/kustompolo/Mk1%20Polo/photo4.jpg) (http://s23.photobucket.com/user/kustompolo/media/Mk1%20Polo/photo4.jpg.html)

(http://i23.photobucket.com/albums/b393/kustompolo/Mk1%20Polo/photo3.jpg) (http://s23.photobucket.com/user/kustompolo/media/Mk1%20Polo/photo3.jpg.html)

(http://i23.photobucket.com/albums/b393/kustompolo/Mk1%20Polo/photo5.jpg) (http://s23.photobucket.com/user/kustompolo/media/Mk1%20Polo/photo5.jpg.html)

Its now up in the air for some inspection of the rust.

(http://i23.photobucket.com/albums/b393/kustompolo/Mk1%20Polo/60b155ed33701a16da0958bcf7de4e21.jpg) (http://s23.photobucket.com/user/kustompolo/media/Mk1%20Polo/60b155ed33701a16da0958bcf7de4e21.jpg.html)

Not sure as yet whether to get it media blasted before or after starting some remdial work.

Title: Re: New polo track toy
Post by: z3i on December 27, 2013, 10:27:29 am
Whaaaa?! Your not finishing this Yoof?
Title: Re: New polo track toy
Post by: Kustom on December 27, 2013, 10:41:26 am
He says hes got other things to focus on 8)

I say hes made a mistake and I look foward to going past him on the track in his old car.

(probably when hes broken another CV or something lol)
Title: Re: New polo track toy
Post by: Yoof on December 27, 2013, 07:15:45 pm
Whaaaa?! Your not finishing this Yoof?

Nope- too much on my plate with the Mk3, House and various other projects. Matt will do the shell more than proud, and no doubt I'll be twiddling some spanners for him on it anyway  ;)

As for coming past me, we shall see  ;D

Title: Re: New polo track toy
Post by: Kustom on January 01, 2014, 06:32:31 pm
Bit of an update from today´╝Ü

I've started stripping the under seal off the floor as media blasting cant remove it very easily.

(http://i23.photobucket.com/albums/b393/kustompolo/Mk1%20Polo/null_zps204cc686.jpg) (http://s23.photobucket.com/user/kustompolo/media/Mk1%20Polo/null_zps204cc686.jpg.html)

(http://i23.photobucket.com/albums/b393/kustompolo/Mk1%20Polo/e779326ed915db54fd50b207819d604c.jpg)

(http://i23.photobucket.com/albums/b393/kustompolo/Mk1%20Polo/045aee03122b171911dc307c09571aee.jpg)

Rear valance has some rust issues
(http://i23.photobucket.com/albums/b393/kustompolo/Mk1%20Polo/697ac8feeafcb9efbe194c64a0e0688e.jpg)

And a few small holes on the sill
(http://i23.photobucket.com/albums/b393/kustompolo/Mk1%20Polo/2893b45b52d527378855fc0a50b4fa33.jpg)

Anyone know where best to get replacement panels for these from?


Also does anyone know what the square bracket with a hole in it behind the towing eye is for?
(http://i23.photobucket.com/albums/b393/kustompolo/Mk1%20Polo/06008bbb4c93b595eabea216a361131f.jpg)
Title: Re: New polo track toy
Post by: breadman on January 01, 2014, 06:47:24 pm
I think these were used to transport the shell on the production line.
Title: Re: New polo track toy
Post by: Kustom on January 02, 2014, 10:12:41 am
I'll loose those brackets then, like some of the the other brackets the eagle eyed among you may have noticed missing from floor pics.  8)
Title: Re: New polo track toy
Post by: physicsfool on January 02, 2014, 10:38:32 am
I use them to jack the back of the car up
Title: Re: New polo track toy
Post by: Yoof on January 02, 2014, 11:19:16 am
Surprised you're contemplating leaving any of the boot floor/rear end in the car at all...  ;D
Title: Re: New polo track toy
Post by: Kustom on January 02, 2014, 11:42:39 am
Shhhh, dont give away all my secrets.  ;)
Title: Re: New polo track toy
Post by: Kustom on January 05, 2014, 11:32:48 pm
Update from today I've pretty much finished cleaning the floor

(http://i23.photobucket.com/albums/b393/kustompolo/Mk1%20Polo/54d1b706915fd29f74e390c0c94e2e6c.jpg)

But I did unearth this which is less than ideal

(http://i23.photobucket.com/albums/b393/kustompolo/Mk1%20Polo/a9ba33ba62631e760ac1ac82d6b119d9.jpg)

As it is supposed to look like this

(http://i23.photobucket.com/albums/b393/kustompolo/Mk1%20Polo/59e827733b3a7d9e2337d9488ebf29e8.jpg)

Current plan is to carefully remove the area circled in red to get access to the yellow highlighted area so I can repair that correctly.

(http://i23.photobucket.com/albums/b393/kustompolo/Mk1%20Polo/55079710859eabc0d0c5a9489387b33a.jpg)

Anyone else done this? Or got any tips on how to remove the red part without damaging it too much.

Thanks
Title: Re: New polo track toy
Post by: Yoof on January 06, 2014, 08:07:25 am
I have a thatcham Mk1 repair manual, I'll scan that page in for you  :)
Title: Re: New polo track toy
Post by: dubstar on January 06, 2014, 10:05:20 pm
Looks good man, obviously feeling your pain with rust on a Mk1! What did you use to take off the underseal? Grinder with a cup brush?
Title: Re: New polo track toy
Post by: Kustom on January 06, 2014, 10:16:41 pm
Yes I used a grinder with a knotted wheel like this

(http://ecx.images-amazon.com/images/I/51gTcGBRw2L._SX300_.jpg)

Looks more aggressive than it is i think.
Title: Re: New polo track toy
Post by: dubstar on January 06, 2014, 11:01:08 pm
Yeah me too. They do the trick.
Title: Re: New polo track toy
Post by: Kustom on May 21, 2014, 02:30:51 pm
Bit of an update, all the sealer is now removed and the car is now roofless

(http://i23.photobucket.com/albums/b393/kustompolo/Mk1%20Polo/F185C26D-5D7C-4BA6-AE75-D888DBA9AD39.jpg) (http://s23.photobucket.com/user/kustompolo/media/Mk1%20Polo/F185C26D-5D7C-4BA6-AE75-D888DBA9AD39.jpg.html)

(http://i23.photobucket.com/albums/b393/kustompolo/Mk1%20Polo/585936E3-F1A3-4237-99F0-8FBC7759AF3A.jpg) (http://s23.photobucket.com/user/kustompolo/media/Mk1%20Polo/585936E3-F1A3-4237-99F0-8FBC7759AF3A.jpg.html)

The car is going to be media blasted at the end of the week, so it will be interesting to see what state it will be in when I get it back. The doors and boot are going for acid dipping.
Title: Re: New polo track toy
Post by: Yoof on May 21, 2014, 09:53:56 pm
Not tempted by GRP ones?
Title: Re: New polo track toy
Post by: Kustom on May 22, 2014, 01:48:58 pm
Not just yet, at 500 Euros for the pair, ive got other things id rather spend the money on.

Donor roof source,



(http://i23.photobucket.com/albums/b393/kustompolo/Mk1%20Polo/A68DA723-6DDA-4726-900A-F41563C3E1BF.jpg) (http://s23.photobucket.com/user/kustompolo/media/Mk1%20Polo/A68DA723-6DDA-4726-900A-F41563C3E1BF.jpg.html)



Which is also now roofless


(http://i23.photobucket.com/albums/b393/kustompolo/Mk1%20Polo/9A9EA20D-5F70-4565-8C21-34345FD3DC68.jpg) (http://s23.photobucket.com/user/kustompolo/media/Mk1%20Polo/9A9EA20D-5F70-4565-8C21-34345FD3DC68.jpg.html)


Clearly the roof is a stressed memeber as the pillars move a bit when its removed.


(http://i23.photobucket.com/albums/b393/kustompolo/Mk1%20Polo/C6371F6E-05F9-4D71-86EB-E05CAC852C1A.jpg) (http://s23.photobucket.com/user/kustompolo/media/Mk1%20Polo/C6371F6E-05F9-4D71-86EB-E05CAC852C1A.jpg.html)
Title: Re: New polo track toy
Post by: Kustom on June 23, 2014, 12:18:35 am
Bit of an update, the car has now been blasted. The doors, boot lid and doner roof panel have been acid dipped.

(http://i23.photobucket.com/albums/b393/kustompolo/Mk1%20Polo/8ec7f8a5aeb80b2a91c2778feef818a4.jpg)

(http://i23.photobucket.com/albums/b393/kustompolo/Mk1%20Polo/d5f0c81d6e0fedebc0f6f72aaaf2eacf.jpg)

(http://i23.photobucket.com/albums/b393/kustompolo/Mk1%20Polo/b88232488cf3ac6f5a2d42f3a40515b6.jpg)

Onward now with the repairs. :)
Title: Re: New polo track toy
Post by: z3i on June 27, 2014, 07:11:00 am
Looks awesome! how much was dipping and priming?
Title: Re: New polo track toy
Post by: Kustom on July 20, 2014, 11:46:53 pm
Small update

I've fixed the rear axle mount. I cut out all the rust and built it back up in layers like the original


(http://i23.photobucket.com/albums/b393/kustompolo/Mk1%20Polo/04E0AD2C-5A41-4F4C-9FF0-1A354F3E79B8.jpg)

Here is a before and after

(http://i23.photobucket.com/albums/b393/kustompolo/Mk1%20Polo/2D7B76BB-8920-4B53-B72D-CE9367AAA864.jpg)

I've also fixed one of the arches. It had previously been partially cut to allow larger wheels/tyres under the arches. So I just finished the job a bit neater and also repaired the rear section

(http://i23.photobucket.com/albums/b393/kustompolo/Mk1%20Polo/A19C01D5-3193-4411-9D8C-F9B692D03688.jpg)

More updates soon, hopefully.
Title: Re: New polo track toy
Post by: Yoof on July 21, 2014, 06:58:52 am
Good work  ;D

I was hoping for titanium goodies by now...  :'(
Title: Re: New polo track toy
Post by: hayesey on July 23, 2014, 04:43:33 pm
I really should look in this section more often.  I didn't even realise you had this car Matt till t'other week.  Some good progress going on here.
Title: Re: New polo track toy
Post by: DaBigGinger on August 09, 2014, 02:45:34 pm
This looks fantastic! Keep up the good work :)
Title: Re: New polo track toy
Post by: Fred on September 15, 2014, 09:33:47 am
I was just thinking same thing when I saw your reply Paul.
Especially being as I'll be starting My G40 in a couple of month.
I was also thinking the red golf was repairable but oh well.
Must be more than I can see.

Fred.