Club G40 Forum
Club G40 => Photos and videos => Topic started by: Thomas on March 17, 2009, 08:26:48 am
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Hi
Here's my car.
A polo Diesel 1W org. 33kw converted with turbo and modified pump etc.
Est 70kw at the moment, turned out to be much better then expected.
Going for Audi 50 S1 look... ;)
Some pics
(http://forumbilder.se/images/b77200992322A513a.jpg) (http://forumbilder.se)
(http://forumbilder.se/images/8e7200992402A6685.jpg) (http://forumbilder.se)
(http://forumbilder.se/images/8a7200992546Ad9f5.jpg) (http://forumbilder.se)
(http://forumbilder.se/images/0c7200995510A2326.jpg) (http://forumbilder.se)
(http://forumbilder.se/images/fd7200995611A75f5.jpg) (http://forumbilder.se)
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i like your style mate good going that!
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thanx´s
I´m not finished by far, and i will add more fotos as a go along.
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some uppdates from today.
Installation ready for now, what do you think?
(http://forumbilder.se/images/14720091139410fed.jpg) (http://forumbilder.se)
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the beginning..
I bougth this car in 2006 april, an old man had imported it to sweden.
He had only changed oil and filter on it over the years.
No wash, or cleening what´s so ever.
Some pics just for fun.
outside, JEEP.....
(http://forumbilder.se/images/570200950909Pd019.jpg) (http://forumbilder.se)
inside....
(http://forumbilder.se/images/700200951407Pe914.jpg) (http://forumbilder.se)
(http://forumbilder.se/images/8d0200951654Pda26.jpg) (http://forumbilder.se)
engine bay....
(http://forumbilder.se/images/ac0200951837P8bc0.jpg) (http://forumbilder.se)
Now there´s g40 interior.
just a quick make over.
will change steering wheel, gearknob etc...
(http://forumbilder.se/images/130200952153Peca3.jpg) (http://forumbilder.se)
At this time i was starting to have an idea about turning it in to a turbo charged G40TD.
The car had only 48bhp and was start to get on my nervs.....
so i started to collect this that i know i was needing later on.
Next i started to look for a manifold but due to heat problems etc i was not able to use the "german" types like rohte.
turned out to be a realy hard time finding a flange to weld on, so i started to make my own.
(http://forumbilder.se/images/450200953038P6951.jpg) (http://forumbilder.se)
After a while this was done.
(http://forumbilder.se/images/000200953234P59df.jpg) (http://forumbilder.se)
turbo charger is now flowprepaird don´t know the english word for it but it has been modified to maximize output power.
more pics and info to come..... ;)
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Hi added a clip for you to comment.
The light sucks, sorry.
0-100:
http://www.youtube.com/watch?v=gwt8dDKpCuU
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Any comments???
Need some inspiration.
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manifold looks nicely made 8)
Can't say I l;ike what you've done with the interior though, standard looked better!
Any plans to get more power from it?
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tanx for the manifold comment.
interior Will bi changed during sommar i hope, now its olny coverd with som shit fabricks.
but hang in there it will bi changed.
Plans to get mo power ,hell yeah , modifying pump eventuallty, but just taking it a bit slow at the moment to drive it, dont want to be standing with somthing major over sommer.
Any ideas your self?
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looks like a fun project! i recognise the passat b3 splitter! had one on my 1st gt square back in 2001! Whats the rear spoiler off of, suites the style of the car well. Whats it like to drive? bet its pretty punchy as i would guess it has a good amount of torque?
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Thanx for the comments, good spotting it´s a passat b3 front splitter, and on the rear it´s a golf 3 front splitter adjusted to fit.
It´s really fun to drive due to the high torque, we have a lot of young guy´s in volvo 850 turbos around here and most of them having tuningchip installed producing about 280-300bhp.
No problem to pull away from these cars, BUT due to my gear ratio i cant keep up from 150 and on.
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Mod´s to engine so far.
Modified pump, 10mm spinrod axel(std 8mm) -> more fuel=more pwr.
Increased revlimiter in the pump from 5800rpm to 6500rpm.
Need this to maximize the turbo use.
Turbo load 2.2bar at the moment but will turn it upp to 2.6bar.
2,5inch exhaust system half the way at the moment, last bit std -> 2,5" all the way in a couple of weeks.
Brakes has to bee updated as well, going fore g60 spec.
Any hint´s about this, can i use any other? minimized work is what i´m after?
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Today i have done the "springwash" and put on the sommer tyres , so NO MORE SNOW.....
Have to fix the returnhose from the turbo because i have a bit of oil comming from there.
Will add som pic´s and new movie clip, soon..
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First pics looks best good progress tho never seen a 1w before only heard of
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Hi.
Like the first pic best aswell, but in fact the car are almost the same on the other pics, only the rear spoiler on the tailgate that differs. Lightning suck though..
1W enginge is rare even here only 15 were imported to sweden, i´ve has 3 of these.
Starting to appreciate the enging due to its endurance, really hard to "kill" these engines.
Turbo convert them and you have a fast td instead of a very tired old diesel.
I have gone from 33kw to approx 70kw with very small modifications.
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Does anybody know what the diffrence is between std. and 2,5" exhaust in terms of power?
Today i have the std exhaust and i notice that i have a flow/pressure issue, so i´m about to change to a larger system maybe 2.5" or bigger.
What do you think about this? Any recomendations?
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Hi Thomas,
Just watched that 0-120kph clip, the car pulls very well mate. :) Well done, an impressive increase in performance for not much money. Result!
I can't see the need to go beyond a 2 1/2" exhaust system, that should be plenty big enough for a small capacity turbo diesel engine.
Keep us posted,
Cheers,
Richard.
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Hi and thax Richard.
I will most likely go for a 2.5 inch exhaust.
The car is realy fast compered to before the conversion.
I was in the garage and made some fine adjustments yesterday, i will try to get a new clip up during the day, hard to tell if the u can see the diffrence on a videoclip.
But the car runs a bit better now, timing was a bit off and the fuel could be enriched evenmore.... ;) ;).
So now the enging has reached its maximum performance with this setup i think.
More power, more modifications need to be done......clutch, smokelimmiter etc....
To much work for a small increase of power..
The only modification i might do is to mount a Intercooler but will not do that for the time beeing, dont see the use for it at the moment.
Added a new clip, not the best time but ok under the circumstances.
http://www.youtube.com/watch?v=fBSclfhs-84
Please comments.
Does any one have a clip from a std G40 doing the same run??
thomas
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hi mate nice car
can you tell me were i can get that audi front grill from plz
thanks
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hi
The front comes from a audi 80 model year 91 i belive.
thomas
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thank you thomas
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Hi all.
Some updates.
Have to redoo the flange on the manifold due to som heating problem.
Started to leak by cyl 1, and the power dropped due to this.... >:(
Can some one tell me if anyone has done this converting thing before me?
I have tried google but nothing pops up.
Only one guy in Netherlands but his car runs with a g-lader, am i the only one with turbo on a diesel???
Please help me in this matter.
cheers
Thomas
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hi all.
New clip added. 80-120km/h in 4 gear.
http://www.youtube.com/watch?v=MdJp5VUrPV8
Now tainted rear lights and new identity?? ;D
(http://forumbilder.se/images/b1120091033085803.jpg) (http://forumbilder.se)
Any comments??
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Some new pics.
spoiler on tailgate and scopes on the hood added for more attitude.
enjoy.
(http://forumbilder.se/images/7d420091021419ec0.jpg) (http://forumbilder.se)
(http://forumbilder.se/images/ba420091024455530.jpg) (http://forumbilder.se)
(http://forumbilder.se/images/51420091026092e5d.jpg) (http://forumbilder.se)
(http://forumbilder.se/images/5342009102719256e.jpg) (http://forumbilder.se)
New polished rocker cover.
(http://forumbilder.se/images/114200910284557bd.jpg) (http://forumbilder.se)
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Nice! Id get some rims on that baby, Its the only thing thats missing in my opinion.
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I will do that in the future, can´t deside dimension though.
I saw a polo with 16" looks quite nice but tires are realy rare and expensive, so most likely i´ll go for 15".
But pleas let me know if u find some you think would fit.
thomas
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Started today with the brakes.
Audi 80 GTE calippers etc.
Unfortuently the were in realy poor condition so it took a long time to get them sorted.
(http://forumbilder.se/images/152200910026A39fe.jpg) (http://forumbilder.se)
Any comments?
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now they are done.
Full rebuild, they were in rely poor condition.
(http://forumbilder.se/images/1f7200990120Ad9d7.jpg) (http://forumbilder.se)
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time for an update maybe ;)
Have done a some work with the brakes.
Got my hands on a set with rear discs from golf 16v gti.
these were in rely poor conditions aswell.
(http://forumbilder.se/images/af302009859200876.jpg) (http://forumbilder.se)
After some work
(http://forumbilder.se/images/98302009914052cb6.jpg) (http://forumbilder.se)
seeya
thomas
sweden
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dave g40
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Nice car u´ve got there.
thomas
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Some pics over the new project.
The engine was so damn greasy so it will need more cleening before i put some new paint on it.
(http://forumbilder.se/images/752201091410P5430.jpg) (http://forumbilder.se)
The head is in good shape just need cleening and adjuster nozzels.
(http://forumbilder.se/images/7f2201091251P3bb1.jpg) (http://forumbilder.se)
(http://forumbilder.se/images/302201091104P9df6.jpg) (http://forumbilder.se)
Some polishing done.
(http://forumbilder.se/images/962201091525P01d0.jpg) (http://forumbilder.se)
thomas
Sweden
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Welcome back Thomas,
So is the new engine from a 1.6 Golf? What is standard power from this unit and will you modify it?Should make loads of torque for the very light Polo. What turbo does it have?
Keep us posted Thomas.
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thanx
Std power are 80bhp, but hopefully when i´m done appr.160-180bhp.
Head will be from a skoda 1.9l because better flow.
Pump will be modified etc.
From golf, yes.
Will prob. go into a golf mk1.
cheers
thomas
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2010 edition
New wheels and böse blick.....
(http://forumbilder.se/images/e0201025749PMdd16.jpg) (http://forumbilder.se)
(http://forumbilder.se/images/de201024950PMaad0.jpg) (http://forumbilder.se)
Thomas
Sweden
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Hi all.
Shall i keep the wheel or change?
Any tips of new mods to do on this car would be appreciated.
thomas
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Long time sins the last update but now the journey starts towards heavy mods.
Started with the chassi update this week.
Due to cash flow probs, i´ll have to make the most parts my self.
So if any one have the parts of a chassi update and are willing to take some messurements for me i´d realy appreciate it.
First part messured.
(http://forumbilder.se/images/6010201082023fc18.jpg) (http://forumbilder.se)
thomas
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Update time!!
Moved the radiator to the right, had to make some space for the pipes from the IC.
The IC is from a beemer 525tds and fits like a glove.
The oilcooler was taken from a saab 900turbo and it fits realy good in the upper region of the radiator.
I´ve put some black paint on them so the dont be so visible.
The bumpershell had some surgery but it wasnt to much fuss, just in the corners.
mounted the chassi parts that i made last week direct fit.
Sorry for the crap pics.
enjoy
(http://forumbilder.se/images/8b272010105734e7a8.jpg) (http://forumbilder.se)
(http://forumbilder.se/images/72272010110109ec0a.jpg) (http://forumbilder.se)
thomas
Sweden
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More excellent work there Thomas, very nice!
ARB blocks came out well, are you going to fabricate some bar clamps to prevent the ARB moving sideways as per the Gladerseite setup?
Keep the good work and updates coming.
Cheers,
Richard.
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Thanx
Yes i think so, but i need to get some messures to be able to manufacture them.
So if anyone have a set of these please let me get the messurements.
thomas
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Where did you get the material for ARB blocks from as i may be interested in making my own too
Cheers
Gav
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Hi
Just walked in to a machine shop nereby and asked for some teflon armoured plastics.
The cost were 5 euro..... :D
thomas
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Next step is rear disc conversion.
Have all the parts but need som guide about the wires.
What can i use, how to modify?
So far i´ve got these parts.
Rear discs, hub´s and calipers from golf gti.
22mm hbc
239 front ventilated discs from g40 including calipers.
thomas
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Happy new year!!
Well yesterday i was out in the garage all day and sortet a lot of things.
The bumperskin is back on.
Oilcooler adapterplate with internal termostat from volvo r-sport.
After some modification this part was on the car.
Had to change the oil filter type though the old one was now to long.
Decided to put a volvo filter on and it was ok,
The tubing to the ic was a bit tricky i must say.
The lay out in the enginebay is a bit diffrent to the petrol versions.
The tube now goes something like this.
From the right
Up over the gearbox in under the brakebooster, needed to bend the brakelines to get it thru.
Efter that it goes in under the steering rods and column behind the engine.
Had to remove the braket for the exhaust.
And when i came to the oiltrap i decided to take this down and cleen it.
Tried to pas thru the diesel filter and the inletmanifold but i found out it was a bit tight so the bracket for the filter had to be changed and modified.
pics later!!!
thomas
Sweden
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I like this Polo, even it's a diesel powered (there'a s few diesels that I like). I can help about info for the diesel engine parts that will fit in the polo, I just need some mesurements and I can tell You what OEM parts You can use.
I hope You already done the rear disc brake convertion, I like this, no matter what the people says, I like the way it stops.
And I like the rims, can You tell some more info about them - ?", ?J, ?ET... If You're interested see what Volkov can say about rims and 5x100.
P.P. I don't like the halogen lights on the grill >:( It's black, so if it was mine I'll keep the wheels and lights white only. But if You like it - it's Your desition, it's Your car.
P.P. I think about doing a light-version of the fishbone suspention this spring, if You're interested I'll picture everything that I do and will tell you and all the members about the result of it.
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Hi there and thanx!
"P.P. I think about doing a light-version of the fishbone suspention this spring, if You're interested I'll picture everything that I do and will tell you and all the members about the result of it."
Of course i´m interested in that.
Your manifold flange, did you get it vectorized?
Or is there any ony whos got a drawing?
thomas
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Hi
I have been around for a while now and i am deeply impressed with the knowledge u guys have.
So when i now start a new phase of the polo 1WTD´s life some things needs to be sorted.
so!
This week i´ve started a new project, my turbo converted polo diesel will now be updated.
The engine will produce approx. 170bhp and 230Nm.
Now i really need this forums help.
Clutch, what can i use? 200mm?? or even bigger with mods?
Can i use the G40 clutch with my flywheel?
Gearbox is there ant thing u can do to increase the stiffness and strength?
Do i have to do any thing at all??
Gearbox is 8p, ratios, can i change any thing to get the revs down and increase topspeed?
The difference between the gearboxes like che, ceg i.a? i know the ratios are diffrent but is there any thing to gain material wise?
please help is needed fast in this so please help me out here??
thomas
Sweden
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hi all!!
After beeing surfing around in etka i found out that there is a gearbox called CNU and CWR that have a better ratio then 8p.
The 1.6 (75bhp) ABU engine has these gear boxes apperently.
Is there any info om here or the net about the streghtness of these gearboxes.???
I can se some diffrences in etka on some of the internals, but what it really mean i don´t know.
Is there any one who´s got some info around these 2 boxes in diffrent applications or just experiences please let me know.
thomas
sweden
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Ok.
The updates goes on and for the time being the removal of the brakes is on the way.
Got me a set of alu calipers with 38mm piston from passat 97.
New seals ordered and will be delivered next week.
Painted the whishbones and the IC tubes are installed properly.
Got my hands on a CHL gearbox te otherday, is there any one who knows the ratios on this box?
I need to change the box if i should be able to get the car through registration as a "modified vehicle".
Next is to drop the rear axle and start a rear dics convertion, any hints on this will be useful.
Found some sleevs for the handbrake wires to reduce travel.
Is there any one whoes gone this way and know if it realy works??
thomas
Sweden
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Hi, Thomas,
I've done searching about the vectorized flange file for autocad, but the man that got it told me, that he've lost all info after a virus in his computer :(
If You want You can get a new seal for the exhaust, scan it and send to me the JPEG file. I'll vectorize it and I'll make the outer shape, after that will send you the autocad file ;)
For the rear brake disk convertion You can ask Volkov. He got too much expirience in this work ;)
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DocJ: thanx for bothering.
Told my friend about this flange and he sorted it for me in catia.
On one of your pics (the one with snow and front wiew) the intercooler is diffrent looks like a bmw525tds ic??changed ??? why?
Due to poor performance maybe?
Did you move the oilfilter???
i mean the turbo is very close.
thomas
Sweden
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DocJ: thanx for bothering.
Told my friend about this flange and he sorted it for me in catia.
On one of your pics (the one with snow and front wiew) the intercooler is diffrent looks like a bmw525tds ic??changed ??? why?
Due to poor performance maybe?
Did you move the oilfilter???
i mean the turbo is very close.
thomas
Sweden
When I bought the car it was with 525tds IC. But I changed it later, because I thing the TDS IC isn't good, it's small...
No, I didn't move the iol filter, I've just bought the shortest possible oil filter and there wasn't any problems with this. ;)
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If the tds IC was changed due to the fact its small, did you notice any diffrence??
Started my rear disc conv. yesterday.
Pics any one??
thomas
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Sorry i saw this topic too late but..
On Polo operation is same
1st remove old drums
(http://images24.snimka.bg/005260430.jpg)
(http://images24.snimka.bg/005260412.jpg)
(http://images24.snimka.bg/005260415.jpg)
When old drums are down every thing should be fine... :D
(http://images24.snimka.bg/005260416.jpg)
(http://images24.snimka.bg/005260647.jpg)
When they are ready
(http://media.snimka.bg/2718/011691054.jpg)
(http://media.snimka.bg/2718/011691050.jpg)
(http://media.snimka.bg/2718/011691051.jpg)
(http://media.snimka.bg/2718/011691052.jpg)
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If the tds IC was changed due to the fact its small, did you notice any diffrence??
The bigger intercooler gave a liitle difference when the car was still with G40, but with K03 it was a bit laggy. Now I think about shorter IC - 450mm width insted of the old 550mm.
P.S. What turbo You gonna use? If it's compareable with the K03 - I think the TDS IC will be good enough :)
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Hi
At the moment the turbo will be from a BMW 525tds as well as the IC.
Don´t know the numbers on the turbo.
Can´t find any info like effektivness etc on this turbo, so if anyone has that info or know were tofind data on this i would appreciate this.
thomas
Sweden
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Look at the numbers of the turbo.
Model Year Motor Turbo Number Alternative Turbo Model
525 TDS 91-92 2.5 D 2243579 49177-06500 MIT TD04-11G
525 TDS 92- 2.5 D 2243398 465555-2/3 GAR TB2514
525 TDS 93-96 2.5 D 2245147 49177-06540 MIT TD04-11G5
525 TDS 96- 2.5 D 2246144 49177-06451 MIT TD04-13T
525 TDS 96- 2.5 D 2246670 49177-06581 MIT TD04-13T
I bet in the T25 Turbo from 2.5 TDS
If you use a stock 2.5TDS turbo and aim the stock 2.5TDS Torque and Horse power => the stock IC is good enough. For bigger plans a bigger IC is good idea, but think about the lag ;)
In the attached file You can see some turbos used in stock cars. ;)
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DocJ:
Do you have any heat problem with oil etc???
thomas
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Without oil-cooler the temp of the oil is going to 115-120 deg-Celsium. An oil-cooler and plate from Golf MK1 GTI is best solution.
I'm driving only with Motul 4100 Turbolight 10W40.
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Just for you info.
A qiuck translation by google and some swedish words in it but you get the idea anyway.
enjoy.
Project Polo TD's 250% performance increase!
Diesel Club Sweden has decided to make two technology projects this year (2011).
An electronic project where a BMW 335d 2010 shall be maximized to the new power level.
This is done through various modifications, but with a pristine engine.
Car two, as this project is about is a Polo 1.4d 1993 model year.
This car must be set against an original car in various exercises.
The idea on this project has been to maximize the car's performance on so many levels it
goes with every step.
We shall as far as possible make all things which this entails.
The guiding principles of this project is that knowledge comes first.
Engine:
The car is std, an N / A, that is, a "vacuum" diesel-1W designation.
Then this will turbokonverteras etc we change name to 1wTD.
Manifold:
New manifold to be built where the pipe length is made equal in length.
For this to be arrange to be made, a CAD file of the flange to the engine and turbo are created.
These will then be milled out of a NC-controlled milling machine. Output for external wastegate.
This is Alverby Racing.
Pump:
If that is the bosch type will be converted to a unique pump for this car.
Internally, this pump have many items made with trådgnistningsmaskiner etc.
Flue gas limiter must be added to the pump when the old pump is not designed for turbo
applications and therefore, this part.
Goran "Diesel Meken" Lindgren in Aneby.
Spreaders / injectors:
These calibrated. Remains at 130bars opening pressure.
The cylinder head / head:
Porting and processed for optimum flow and heat transfer.
The cylinder head / head porting by Jorgen on High Performance Heads.
Camshaft:
If the opportunity arises, the camshaft ground with new angles that are better suited for
overcharging.
Intake:
Portmatching against the cylinder head, crank welded again, turbotrycksnippel added and
polishing. Jorgen on High Performance Heads
Engine Block:
Renovated up that blasted and new coating applied.
Block redrilled or drilled on the new dimension.
If technology enables an adapter ring of piano wire nerfällning so this will be done
New main bearings, etc.
Bottom Bracket exchanged, and all seals.
Pistons and rings:
These refurbished alt replaced with oversize.
Rods:
They X-rayed and ballpeening for better strength.
Intercooler:
Bmw 525TDS. If this is not enough, we will replace it.
Other:
Water pump replaced and the oil pump checked.
Cylinder head gasket is made of 1.8mm copper with std gasket as a template for details etc. are
available. Oil cooler Volvo Group A 95graders thermostat, 15raders oil cooler from the Saab 9000.
Transmission:
By default, this car is a gearbox of the type 085 with mating 8p.
When this box is a gasoline engine custom box that is the ratio of this box is not suited for
diesel. This leads to high revs and low speed.
We will replace this with a box from a golf mk3 1.6 ABU engine.
This box is called the CHL and has a better return.
We will disassemble and refurbish up the box and reinforce all the gears and shafts.
The most famous problems will be eliminated in this process.
The methodology for this is kulpeening.
The goal of this is to achieve a 30% increase overall durability.
According to the information we have in the current situation so that the box in original condition hold for
165nm.
A 30% strengthening materials, gives approximately 210nm.
This along with other reinforcements and "trick" so the box should come up to about
250Nm.
Clutch:
Std 180mm diameter and are capable of 110Nm
New access is built as per new spec. 200hkr and 280Nm.
This means 200mm dia.
We are now building a machine with these target values.
The block is calculated under the following assumptions:
The castings used have the same quality as the Volkswagen's other engines and
production facilities using the same timeframe.
This means accomplish the following:
We know that 1.6liters engine in the Golf GTD designation SB withstand a maximum cylinder pressure on
about 90-110nm. That is, most construction sites, these numbers 220-240hkr 380/420Nm boost 2 -
3.5bar.
Do we take time to add a 40% safety margin on this to remove the uncertainties as
has concluded that approximately 60Nm per cylinder should be a good limit.
60x4 = 240Nm. We, therefore, builds a machine that shells withstand generating 240Nm of the crankshaft.
The pump is built to deliver fuel, equivalent 170hkr.
When viewing the engine technical spec like this:
1wTD std 1W
170hkr/4500rpm. 48hkr/4500rpm
240nm/3000rpm 85nm/2700rpm
Bore: 75mm 75mm
Stroke: 79.1 79.1
Compression: 20.5:1 22.5:1
Boost pressure: 1.8-2.5 n / a
Turbo: Garret TB2514 465555-2/3 Plugged wastgate. n / a
How much can withstand engine and transmission?
This is where our collective thinking about any problems we will try to
prevent as much as possible in the drivetrain.
Boost pressure:
Boost pressure will be around 2bar.
Past experience has shown that the engine can handle this.
To re-create the margin so kulpeenas candlesticks etc
Surface structure AB in Arboga is project partner in this.
Heat:
What we know is that the heat will be a problem.
We must cut down this factor to its minimum.
Friction, degrees of combustion and maintaining lubricity are all things that affect.
The back pressure creates heat that is known to all activities that can reduce this to be made;
manifold with good flow, cylinder head ported cylinder head, etc ported by Jorgen at High Performance
heads. If we can not bring down the exhaust temperature "so we add a water / ethanol injection.
We have this IOM also gained a partner that can heat treat surfaces with
ceramic coating, friction deal with such molybdenum to take down the friction and create
margin against the lack of oil pressure, etc. Metalock engineer has the skills that enable
this. Metalock has been contracted to all the details where you can achieve a positive result
map this should be treated according to their expertise.
Transmission:
Sprockets, stock and house shall kulpeenas, with the goal of raising the building elsewhere.
Surface structure AB, the experience of this process and given opportunities to do what
they can be on various details.
Overall:
Contorted poses problems.
Low turns and high torque is a ödestiger combination, so the tanks have been following.
The turbo was chosen to deliver the maximum pressure at higher revs than usual in a diesel car.
We have experience on how a turbo from the Golf 1.9TD behave and this charge very
early. BMW turbo Garret 2514 is slightly bigger on the exhaust side so that the boost
moves up in the code by about 800rpm. On såsätt we have created a small margin against the maximum
load. Estimated to load the previous turbo max at 2300rpm, new turbo at
3000rpm. We should probably study the wastegate and external use.
The drive axles on this car is the most serious available to the car as std, these are likely to
keep as they are mkt common in motor sports scene in germany eg Bergcup who is back racing.
Where these axes are used because of its strength, etc, we make the same assumption here, it is.
Chassis and brakes.
At the front, is the same principle as that of "bubbles", that is to say the least weak.
You could describe it like this.
When the brakes to move the wheels Ca 2-3cm back. The entire front suspension geometry changes.
The brakes are solid discs front and drums rear, and also leave them little time.
The car wobble like an old horse trailer type, feel like you should dump / tip.
During the steering is fantastic, the car slides forward.
So what are we doing this?
The chassis in general:
Lowering the car with the help of lowering springs 80mm front and 60mm rear.
Shock absorbers replaced the custom of lowering.
Rear axle:
Wheels rear angles adjusted to-2grader camber for better grip.
Stabilizers Rear needed, so one should be presented also mounts etc for this.
If possible adjustable.
Widening ~ 20mm of rear axle.
Front axle:
Rambenen (body structure) is reinforced with the help of a subframe that connects the right side with
the left side via bolts.
Link arms are changing angles as the geometry changes, a brace with unibolts built to take care of
forces in the longitudinal direction.
Shock towers are connected by rods.
Tunnel Reinforcement included the subframe.
All this is done to succeed in maintaining the geometry.
The brake system:
New master brake cylinder 23mm instead of 20.6
Rear: Disc brakes from the Golf GTI 226mm
Brake calipers Passat 2008 aluminum integral handbrake.
Requires re-submission of the hand brake wire and sleeves to take care of the battle.
Then we want to keep the standard wire.
Front: Disc brakes from OPEL Vectra B 256mm x 20mm ventilated
Ok: Opel Vectra B 1997th
Brake Hoses from HEL
Custom stålomspunnet, one part VW Opel second, adjusted length of both front and rear.
The brake relay valve from the Passat 3b.
The widening of the rear axle and the need for wider tires and larger wheels make the body
must change. Although ET measurement is changed to about 13, std is 38. This provides a 70mm wider track.
Wheel arches the rear of the car cover over the wheel at the top, making it impossible to change
needed.
Body:
To enable this expanded body 30mm per side and wheel arch edges from Golf MK1
welded to the vehicle front and back.
Wheel wells moved up x number, etc. for better spins on deck.
The expansion is made of the same type golf rallye alt BMW's M3 (e30) plus
we add the Golf MK1 wheel arch extensions beyond this.
These are shared and plastic welded to front and rear bumpers to get a factory appearance.
The expansion is made by Martin Rosendorf in Steungsund.
Multiple winners in Vallåkra for its breadth tions and modifications of the Volvo bus bodies.
The interior:
Chairs and rear seats from PoloG40.
Glove compartment lock my console from G40
The interior sewn on with a technical nature.
The following thoughts were and were developed.
No hot and cold.
Good support in hand, but also back.
Without slipping into the chair.
Creating a good and durable surface with a respectable appearance.
Michael Thors saddlery in Trollhättan account for this.
Other sponsors and partners, etc.
Autodelar.net All material in standard form.
J.-spec.se All material in the form of gauges, brake hoses, etc.
LG-dismantling all materials needed for the development beg.
Trailer 3500 All transportation sells trailers to many different needs.
Auto Tech Ltd Funded by the coupling.
Elmo Leather Leather / leather interior for details
Plus a lot more people with specialist knowledge who is acting as a sounding board.
ny questions.
Sincerely
Thomas Knutson
Project Manager / Owner
Chairman of the Diesel Club Sweden.
0736-561196
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Some new pics.
(http://forumbilder.se/images/2f201191509PMc734.jpg) (http://forumbilder.se)
(http://forumbilder.se/images/44201191544PM9be0.jpg) (http://forumbilder.se)
(http://forumbilder.se/images/f6201191628PMc414.jpg) (http://forumbilder.se)
(http://forumbilder.se/images/0c2011120455A2eaa.jpg) (http://forumbilder.se)
(http://forumbilder.se/images/bc2011120535Aa954.jpg) (http://forumbilder.se)
(http://forumbilder.se/images/272011120608Af241.jpg) (http://forumbilder.se)
(http://forumbilder.se/images/982011120648A4240.jpg) (http://forumbilder.se)
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Really nice work on the exhaust manifold Thomas. 8)
I would of thought the rear anti roll bar will need bushing onto the rear axle? Those brackets will wear as the roll bar twists.
How about some nylon blocks similar to the Gladersiete ones used on the front? What car was the anti roll bar off?
Good progress Thomas.
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Thanx!
The anit rollbar has got some bushings already, missing on the pics though.
The brackets dont grab the bar, just hold it gently to the rear beam, so the wear isn´t a problem.
Antirollbar from suzuki baleno front axle.
The track of the car is realy wide now so, i imagine the handling will be realy diffrent from the org. set up.
Any thoughts of what to do next?
(http://forumbilder.se/images/e75201194019Pd099.jpg) (http://forumbilder.se)
(http://forumbilder.se/images/315201194252P3d36.jpg) (http://forumbilder.se)
sorry for the quality.....
thomas
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ELMIA carshow 2011
First I would like to begin by thanking all involved for your efforts so far, many thanks.
The project is on the move again, and now i prepare to start the engine, an exciting event.
Elmia was a clean hit, huge interest from the more party of visitors.
80 000 visitors, plus the showcar exhibitures has seen, asked and wondered about the project more or less.
At least 1000pics was taken on the car.
Already on the first day reporters and photographers from the newspaper autosport was in place and asked questions and took pictures.
Since the car is not entirely clear where in our spec then we agree that the repotage will be written in June with a first contact by the end of May.
The idea on their part is a big repotage where they want to compare a polo G40 in, among others Superstage and possibly on the track.
They would then have the entire development team in place for repotage shall be accorded the Court considers that it has.
This project hit them by surprise in many ways, technology content, interior, engine the future widening and polish that they clearly said "Must" be made.
We have got a few new suggestions for companies who wish to participate with their knowledge about the car.
We have maxxtuning.se as first choice for setting the car when the IP pump "Dieselmeken" (George) is in the neighborhood.
Although Civinco want to be a part and I have discussed i.e a water injection with them and a lot of interest shown by them to participation.
The car is now ready for display in the Kinnekulle when Rally cross Championship final with a passuss whether to arrange this, 24sept is the date for this event.
Now we will prepare the car for the widening and paint and after that adjust everything to the best of my ability.
Google trans.....sorry
Here are some pictures from ELMIA!
(http://forumbilder.se/images/bf201162900AM7243.jpg) (http://forumbilder.se)
(http://forumbilder.se/images/1e201162939AMa1c0.jpg) (http://forumbilder.se)
(http://forumbilder.se/images/a1201163011AMd255.jpg) (http://forumbilder.se)
(http://forumbilder.se/images/f3201163037AMc485.jpg) (http://forumbilder.se)
(http://forumbilder.se/images/d0201163118AM4eb6.jpg) (http://forumbilder.se)
(http://forumbilder.se/images/f5201163143AM4034.jpg) (http://forumbilder.se)
(http://forumbilder.se/images/6a201163232AM15c1.jpg) (http://forumbilder.se)
(http://forumbilder.se/images/23201163303AM261b.jpg) (http://forumbilder.se)
(http://forumbilder.se/images/49201163328AM4b5f.jpg) (http://forumbilder.se)
(http://forumbilder.se/images/72201163406AMf53f.jpg) (http://forumbilder.se)
(http://forumbilder.se/images/be201163457AM3e47.jpg) (http://forumbilder.se)
(http://forumbilder.se/images/ec201163604AM23b2.jpg) (http://forumbilder.se)
(http://forumbilder.se/images/e7201163635AMb8b8.jpg) (http://forumbilder.se)
(http://forumbilder.se/images/af201163707AMa48f.jpg) (http://forumbilder.se)
(http://forumbilder.se/images/5c201163741AM9604.jpg) (http://forumbilder.se)
(http://forumbilder.se/images/32201163825AM0efa.jpg) (http://forumbilder.se)
(http://forumbilder.se/images/da201163854AMfa60.jpg) (http://forumbilder.se)
Thomas Knutsson
Projektledare polo 250%
ordförande i Dieselclubsweden.se
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Niiiiiiiice, Thomas 8) Congratulations, I'm waiting for updates in this topic :)
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Thomas, in what way did you modify the audi grille to fit? I have one and was going to do the same. Was thinking of doing it to get a better airflow through the engine in the hot weather.
James
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Hi
The upper part of the grill just have to be adjusted a bit to come closer to the front panel thats all. :)
thomas
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hi New pics
Comments please!
(http://forumbilder.se/images/184201183219Aabad.jpg) (http://forumbilder.se)
(http://forumbilder.se/images/334201183302A747d.jpg) (http://forumbilder.se)
(http://forumbilder.se/images/b54201183345Ae983.jpg) (http://forumbilder.se)
(http://forumbilder.se/images/424201183459A630c.jpg) (http://forumbilder.se)
thomas
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Hi all!
Today is a happy day.
Taken the car for a ride just now and i must say, jeeeesuuuus!!!!
It´s a f--ing beast!!
Earlier the car was more or less dead after 4000rpm but now its just going and going.
Pulling hard on every gear even the 5th.
Havent floored it yet, just hitting 1.6bar at the moment and i can say its fast as hell.
Max is around 2bar.
Egt temp max 700deg C.
Oil temp max 90deg C.
Water temp 110deg C which is a bit to high i think.
But the tourqe is amazing.
To day i put in 5th gear in appr 150km/H before just 120km/h.
G40´s , look out!!
Have a issue with the water temp rising to 110deg fast but i guess my radiator needs a good cleaning out.
Video coming up soon, if there is any intrest in a special Diesel.
thomas
Sweden
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Hi Thomas,
I'd love to see another video of the car, nothing wrong with a torquey turbo diesel!
Sounds like very good progress Thomas.
Cheers,
Richard.
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This update is something beyond the ordinary.
Now the pump is modified into a monster just for this engine.
You can read what is done and see a clip of the test run on the flow bench.
Many thanks to Göran "diesel mech" Lindgren.
************************************************** *****************************
OK, then it was time for the 2nd upgrade of the pump, Edition R
Do not miss the movie clip I have made for the sake of you readers, further down the topic.
The following was the first performance upgrade.
Replacing rotors 80-10 mm
Change the direction from right to left using wire EDM, among other things ;-)
Then the pump is delivering about 230% more fuel than stock, ended up on about 80 cc of fuel.
(http://forumbilder.se/images/f13201132956Pd8ac.jpg) (http://forumbilder.se)
Edition R is reworked like this:
Modified RPM controller weights, it was not enough speed first round, now it will be sufficient.
(http://forumbilder.se/images/5d3201134203P92d9.jpg) (http://forumbilder.se)
LDA, cover with specially sharpened stick to get more fuel at full turbo boost pressure and eliminate smoke in large quantities, it will probably smoke a bit anyway, but not as bloody as before
(http://forumbilder.se/images/853201134252P07c4.jpg) (http://forumbilder.se)
Regulator Spring, changed from a separate idle spring into an integrated spring-in controller package (VAG 2.4 d)
(http://forumbilder.se/images/8c3201134338Pe96d.jpg) (http://forumbilder.se)
Modified controller bridge for longer travel of LDA = more fuel around 100cc @ 1500 rpm
Test run of the bench and shot.
(http://forumbilder.se/images/8c3201134533Ped66.jpg) (http://forumbilder.se)
Movie Link here http://www.youtube.com/watch?v=aXl8x9dOC9k
Happy Midsummers eve wishes Göran "diesel mech" Lindgren
************************************************** ******************************
Thomas
Sweden
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Hi there!
Is there anyone whos tried to modify the front arb, struts and subframe etc from the early audi 80 1980´ish to fit on polo.
Just want to know if there is a way of making the subframe from the audi to fit on polo.
There are some simularities geometry wise.
I also want the sterringkolumn to fit eventually, due to registration as amature built vehicle here in sweden.
Any ideas?
Thomas
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The car is currently in cut open and started widening.
Without saying too much I can say that the car in one place is 17cm wider / side. ;-)
Pictures will come when the car is ready.
Right now, work is underway in full swing, and i would of course keep you a little on the rack.
The IP pump smoked "too much" without boost pressure and the rev´s a bit too low.
So what is Göran "dieselmech" has now done is to raise the rev´s to 6500-7000rpm.
Check out the link in previous message.
Now he has also "screwed" up the pump to 300%!!!!!! more fuel than stock.
started to hunt down a water methanol injectionsystem because I think we wil have an EGT that raises.
Becomes a bloody hecktic period around the start of week 29.
Everything should run smoothly until on Wednesday and test through as much as possible.
Because of the LDA, I will have to move the firewall approx 3cm back,rework the strut, etc.
A bit more work, but it we will get it sorted.
Thomas
Sweden
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This is really turning into a massive project Thomas!
Keep us posted and good luck.
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Hello!
Now I come back.
I've lived in the garage this weekend.
Worked constant from Saturday 08.00 until Sunday 19.00 without sleep, when we really needed to be done.
We have set up some odd ideas about this project.
One of these was to do a metal widening on a car in a weekend:)
And that, without having done it before.
Can say that it went well!
Plus that we grinded and adjusted all dents etc
My early ideas with urquaattro etc was thrown in the bin and scrapped because I had a couple of new thoughts and ideas.
Finally Me and Martin had a "new" way.
We take the hourglass broadening, racing, bergcup, DTM, and 90's design throw it down in the blender and what do you get?
see in this sequence:
(http://forumbilder.se/images/031201181201A7a4f.jpg) (http://forumbilder.se)
Work in progress!!!
(http://forumbilder.se/images/1a1201182325Abc58.jpg) (http://forumbilder.se)
Front wing with wheelarc extensions!
(http://forumbilder.se/images/fe1201182408A312f.jpg) (http://forumbilder.se)
Blurred image, but an idea with wheelarc extensions.
(http://forumbilder.se/images/931201182914A2758.jpg) (http://forumbilder.se)
Ready for transport, without wheelarc extensions.
I will add a pics rear wiew later ther you realy can se the total with over the "ass" :)
Thomas
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I think the rear extensions look similar to the ones of other Polo, but little moded ;D
Waiting for other pics 8)
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Hi!!!!
Yes the are quite similar these 2.
Nice work by the way on your car, hows it going?
thomas
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It's going too slow. I'm saving money for transmition and some required body details (tunnel from BMW E30). I'm hesitating between 8V and 16V head...
How's the drive with the rear sway bar? I guess now it's on the limit before oversteering ::)
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Hi
So far the car behaves so much better that before so you cant belive.
The chassi became much more consecvent in it´s behaivor.
But trackday is comming up so after that i can tell you more.
thomas
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(http://forumbilder.se/images/c87201195541Af25f.jpg) (http://forumbilder.se)
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Now the car is assembled and the performance pump change started.
A very difficult period, I can promise, but now you can drive the car in the rain, This update has been hard,working around the clock more or less.
But just wanted to show how the car looks now.
Please enjoy !!!!!!
First car last summer.
(http://forumbilder.se/images/de201024950PMaad0.jpg) (http://forumbilder.se)
(http://forumbilder.se/images/c99201160447P2e85.jpg) (http://forumbilder.se)
(http://forumbilder.se/images/e89201155118P7a64.jpg) (http://forumbilder.se)
(http://forumbilder.se/images/a59201155227Pc798.jpg) (http://forumbilder.se)
What do you think?
Will all the work be visible !? : thumbup:: D
thomas
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Good work fella.
Good to see the bonet vents have gone.
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A small clip from dyno-day.
Not the best result but anyway.
http://www.youtube.com/watch?v=LAHUlf4e9ks
thomas
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Some pics!!!!!
(http://forumbilder.se/images/5e2201112303971b2.jpg) (http://forumbilder.se)
(http://forumbilder.se/images/00220111231107608.jpg) (http://forumbilder.se)
(http://forumbilder.se/images/67220111231348ccd.jpg) (http://forumbilder.se)
(http://forumbilder.se/images/4722011123221195c.jpg) (http://forumbilder.se)
(http://forumbilder.se/images/9122011123245ee5d.jpg) (http://forumbilder.se)
(http://forumbilder.se/images/b6220111233422999.jpg) (http://forumbilder.se)
Thomas
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I think it's a good result. Yes it's possible to acchive more, but it so good 125bhp/200Nm.
How much boost it's used to acchieve this results? On what RPM spools the turbo?
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Hi.
At the moment the car is running 2.8bar max, but after 2.2 the counterpressure is rising fast and only heat is produced.
We will ad the intercooler and a 2-stage radiator to keep the heat down.
The pressure kicks in around 2200 rpm and drops slowly down at 3800 prm.
Doe to the fact that i have no intercooler added at this stage we saw that the heat was rising fast in the inlet.
But now we have something to work from.
We will most likely add a waterinjectionsystem aswell.
Nice to see that someone is reading this topic.
I know this is not a G40 but i think it will fit i this club anyway or am i wrong??
Thomas
Sweden.
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I know this is not a G40 but i think it will fit i this club anyway or am i wrong??
Thomas, with the time, effort and success you have had with this it defiantly fits in the club!
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I've been reading it too! I think as it's quite a different project people don't know what to say.
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Hey Thomas, I'm still following this with interest. 8)
Don't worry about it not being a G40, I haven't got one or indeed want one either. As long as it's a pre 6n Polo I think most people will want to see this and read your updates.
Personally I'm not keen on cosmetic body modifications on any car. However, your mechanical work and the fact you are tuning a diesel in a Polo is very interesting.
Keep us posted,
Cheers,
Richard.
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Glad that you guys feel thisway.
Over the years i´ve never seen any project like this my self.
Performance wise this car is now FAST.
As std the car has a topspeed of 142km/h now 205km/h.
0-100km/h as std goes on 14sec, now it does it on around 6-7sec.
The project it self has grown realy fast to become one of swedens most advanced projects this year.
The tecnical spec in this engine is by far one of the most advanced technical wise, ballpenned rods and ceramic couted pistons etc.
The head is now ported by people from STCC. (swedens BTCC) etc.
Thomas
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How about watercooled IC.
Any hints about this?
I think i will seperate the waterkooling inbetween the head and block/bottom.
Adding an extra pump just for the head itself.
Do you guys think its nessesary to have 2 seperate rads in this setup.?
thomas
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Hi, Thomas,
You just need a good air-to-air FMIC. The wathercooled sistem is good for high horsepower cars that havent good air-flow to the IC (for exaple - dragsters: for good start and and rally cars made for tight tracks with hard corners and some off-road machines). The other negative side of the wather IC is the complicated system - IC, wather rad with fan, wather thank, wather pump, tubes and electrics... do You have enough space for this???
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Yeah, I agree with Doc here.
Watercooled systems are excellent but complicated, expensive to buy/install and do take up a fair amount of room.
I'd go for a good FMIC. The intercoolers themselves are cheap to buy and there are plenty of different sizes and shapes to choose from.
-
Hi
A late update to this subject at night.
Today I will take down the front and begin to modify this so that I can fit an intercooler model "great" to this car.
Likewise, the radiator will be replaced with a larger and an extra waterpump must be added on.
Will take down the manifold and wrap this due to thermal radiation.
Then, the generator have a review and an additional tachometer output is taken out from the coils inside.
A lot of effort that will definitely have an effect.
The turbo is now in the hands of turboservice.se in the hunt for more effect and power, is up to them to find the solutions.
Perhaps these will come onboard as sponsors of this project aswell, which I would think is great when it obviously need a massive modification, we'll see.
What this will give, we shall see, but it is quite clear that it will get better.
What color is concerned, it is now leaning to a white pearl for those of you who are wondering.
thomas
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Hi
Now I have probably found a setup on the work regarding CV joints and driveshafts, etc.
These are always a issue on a polo with power as you know.
Used a Golf 16v as a reference here.
The car was assembled yesterday chassis wise.
The car is of to the paintshop during the next week so it must be possible to move on the wheels.
The job today is to take down genertor and fix W output for tachometer must now also begin to work with the interior and some other things.
Now the J-spec sent down an intercooler, so this will be in next week.
thomas
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Very interested in the driveshaft upgrade. Can you let us know any more details on this Thomas?
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Yes of course.
As soon as the setup is tested and so on.
Keep looking!
thomas
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Hi
Some new pics!!!!
(http://forumbilder.se/images/a62201110203414f2.jpg) (http://forumbilder.se)
(http://forumbilder.se/images/63220111022502591.jpg) (http://forumbilder.se)
(http://forumbilder.se/images/eb22011102408dcfa.jpg) (http://forumbilder.se)
Thomas
Sweden
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Some new pics.
(http://forumbilder.se/images/8d201180613AM280b.jpg) (http://forumbilder.se)
(http://forumbilder.se/images/9c201182121AM50e1.jpg) (http://forumbilder.se)
Was thinking of using these, but i changed my mind...... ;)
(http://forumbilder.se/images/4c201182634AMf2bf.jpg) (http://forumbilder.se)
Thomas
Sweden
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Hi
Now I have spoken to my new sponsor Swedish turbo service again who said that the turbo was ready for pic up.
They had apparently turned inside out of everything in this job.
They had spoken to pro´s in England and Germany to get more information about what's to be done and what would be good, whats fun to hear is that they had never heard anything like this during his years in the industry, either here in Sweden or abroad.
It´s fun that the car makes such interest from the most experienced people in the industry.
I must say I really like everyone´s engagement to get involved in the project.
The turbo is now in base an Schwitzer (Borg-Wagner) units, but we have retained the exhaust housing from the previous Garret aggrigatet becuase we wanted to see how much a special processing of this would bring.
Exhaust house has now been modified significantly.
The shaft has been replaced and the diameter of the turbine wheels changed, the turbine wheel has trimed wings on them for increased flow and power.
Happily it is now turbo good for 200 diesel horses and more ..... :)
See pictures below:
(http://forumbilder.se/images/c5201172246AMacc2.jpg) (http://forumbilder.se)
(http://forumbilder.se/images/2f201172342AM6047.jpg) (http://forumbilder.se)
(http://forumbilder.se/images/39201172417AM8c46.jpg) (http://forumbilder.se)
(http://forumbilder.se/images/d8201172456AM4821.jpg) (http://forumbilder.se)
(http://forumbilder.se/images/ff201172533AM5dc6.jpg) (http://forumbilder.se)
(http://forumbilder.se/images/45201172607AM903d.jpg) (http://forumbilder.se)
(http://forumbilder.se/images/31201172647AMae4e.jpg) (http://forumbilder.se)
(http://forumbilder.se/images/51201172724AMeaa1.jpg) (http://forumbilder.se)
(http://forumbilder.se/images/73201172801AM0767.jpg) (http://forumbilder.se)
You can see that it's right clever processed in the exhaust housing and the compressor side.
Today, i will get a new return piping from the turbo as we now have a different connection than before.
After that a tachometer goes in the car with a shift etc.
We'll see where I put this, there's not really much space in the cabin as you probably know already. :)
Thomas
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Hello again.
Now it has happened stuff i think you should know.
We have been on Kinnekulle raceway and with the help of a talented driver who now works as a driver instuctor within just racing i belive we couldent get a better tryout on the car.
Peter had fixed the ring completely to ourselves, which is an incredible feeling just that.
Think about it, we got at a race track all to ourselves ... ;D
Many thanks Peter.
Peter Lundrgen from Götene Motorclub has thus been the one driving the car.
The car behaves consistently and very well on a track according to Peter.
Peter ran around the ring as the best at 1,10:52.
Which I think is good.
For reference, I can say that it is faster than orginalcup Volvo's cars run on the ring, and when they're built to run on racingtrac with weigth reductions and tuned chassis, etc.
We have a std car more or less, this is Very impressive in my eyes.
But something was wrong with the car, the effect did not occur so it could not bring better times.
This was on Friday and on Saturday, I talked with my filter provider.
Guess my suprise when he says that the filter attached to the car "just now" leave X liters of air / minute, it takes more than twice as much air .....
The filter povided was for a petrol instalation NOT Diesel.....WTF
This worked then as a restriction and we could only get maximum 1.2 bar then filter imploded
together and as they say put the lid on it.
The effect were about 80bhp measured by G-Tech on Saturday morning.
No wonder the car smoked, the car was so black in the ass so we had to wash the car before driving home.
Take it away, i will send the correct filter to you next week.
Said and done.
I did it and Holy shit ...............
Sure the car was good before but now it is a monster.
The effect is brutal.
It's just so that tires can keep the power down on third and fourth gear.
Turbo charger keeps going on with ease throughout the registry and the increase in speed is more or less linear.
No turbo dip at all under free acceleration.
I guess that the effect now is 160-180 hp.
This is now to be confirmed on the dyno again.
Temp problems are blown away both the exhaust and water and oil temp is laying still.
Will come back with a real report later.
With this effect, and a minor update to front so I can say that the car is probably running around the ring in under a minute. And it's fast
This is an incredible car.
Peter will write a report later this week about how he feels the car.
He is, however, independent and used to run cars on trac.
See you soon then with pictures and some video if you want .......
Thomas
-
Excellent progress Thomas, more pics and definately a video are wanted!
It really sounds like this is coming together now, should be a torque monster once it's finished. 8)
-
Here is some new pics.
Some of them from kinnekulle raceway.
(http://forumbilder.se/images/9e9201172030A29a2.jpg) (http://forumbilder.se)
(http://forumbilder.se/images/a39201172102Aa18f.jpg) (http://forumbilder.se)
(http://forumbilder.se/images/4b9201172130A8962.jpg) (http://forumbilder.se)
(http://forumbilder.se/images/e19201172155A2529.jpg) (http://forumbilder.se)
(http://forumbilder.se/images/a09201172345A53f0.jpg) (http://forumbilder.se)
(http://forumbilder.se/images/b99201172444A948e.jpg) (http://forumbilder.se)
(http://forumbilder.se/images/e39201172532Aa8ac.jpg) (http://forumbilder.se)
(http://forumbilder.se/images/ee9201172644A92ab.jpg) (http://forumbilder.se)
(http://forumbilder.se/images/3f9201172709A40e0.jpg) (http://forumbilder.se)
(http://forumbilder.se/images/709201172753Afb1b.jpg) (http://forumbilder.se)
Thomas
-
Hi.
Was up on the dyno again today.
(http://forumbilder.se/images/2342011105932a88b.jpg) (http://forumbilder.se)
Only 2.7bar pressure.
and i know it holdsup to 2.9 bar boost.
That would have give us 174bhp.
So project 250% power increase project have reached its goal.
Thomas
-
Hi
Just a new pic.
(http://forumbilder.se/images/8812011104632d650.jpg) (http://forumbilder.se)
Thomas
-
hi.
New video up.
http://www.youtube.com/watch?v=XmrbH7qFVg0
Thomas
-
hi and thanxs!
A new pic from the day on the race track.
(http://forumbilder.se/images/bf3201111081239ad.jpg) (http://forumbilder.se)
another pic.
(http://forumbilder.se/images/e032011111007545d.jpg) (http://forumbilder.se)
Thomas
-
New video from dynoday
http://www.youtube.com/watch?v=U3RYPkMv9P4
Thomas
-
Hey if anyone is reading.
I now have an outside report regarding the car from Peter Lundgren.
Peter has many years experience in racing and today is the driving instructor in racing gave us the chance to get a test drive and evaluation of the car.
Here's his little story about his part of the story Polo 250% project.
************************************************** *********************************
Last winter rang a Thomas Knutsson to me and told me he was working on a project. Building on a VW Polo D Kombi to something more advanced than the original. And it was urgent because the car is visible on the car show in Elmia at Easter. He is neither the first nor last to have ideas about building a car, but I listened to what he had to say. He had some issues that we talked about. He called several times and we talked some more. And over time i began to understand that he really was doing something. So at one point he asked also if I could think of to test drive the car. If I had the time I could think of doing this. And here I sit now with a new experience.
I had arranged a date at Kinnekulle raceway for testing.
A little late Thomas came to an end. We got started just after lunch.
I ran some laps with Thomas as a passenger. The perception I had was that it felt very insecure. How much should you dare to push this car?
But, out with Thomas, and add about 10 laps. The feeling that the car was unbalanced remained, especially the rear end that was not as it should.
We discussed it and I also got the information that the car is not built as a race car. We adjusted the tire pressure as the only option. Drove another 10 laps. Checked the temp, tested braking, throttle and so on. I started to get me some more feeling of the car behavior. The feeling of understeering was there all the time. Prior to Run No. 3, I felt that it is time to push the car, see what it can do. But with understeer in the head, regular street tires on, a gearbox that does not want to rough handeling I still had to take it a bit "careful". Tested to hit the throttle earlier in curves, correcting understeer and now it started to go much better. I also began to get warm in “my clothes”, better temperature in the tires and the lap times fell,
Now that i knew where i had the car I could begin run it in a different way. Begin to reflect on what I'm driving. And little by little, I got the feeling that the car can "become something".
What I think of as the main action's to be taken is due to the handling. It is being understerred, but still feels very stable. But with other struts and so on. this should not be a problem. The next thing to work with the engine power. It is smooth o fine but with a little high exhaust temp at the end of the straight. Output Register is far too short. It came nicely at 4500-5500 revolutions but nothing more.
Later it turned out that it sat quite wrong air filter in your car, which explain a lot.
So overall, having been told the whole story of this project, I think you managed to build a surprisingly good car. Thomas is enthusiastic and energetic with his project, and it is also what it takes things like this. There is every opportunity to get this car to a potent and competitive race car in the appropriate regulations, if you like. It is interesting to follow the development of this project and it has definitely given a taste to participate and test the car while it develops.
Peter Lundgren - Test Pilot
************************************************** ******************************
Must say it feels quite strange to read this for me.
We have built a car, we have done something extraordinary that you know who have read the thread.
When I talked to Peter about how we wanted to do so where he's quite "off" at first.
When one is so up in the project are easily biased and do not always see the reality.
We must be open to others' experiences, etc. Therefore, I stood on me.
But the car was ready and tested.
Had time been available before the test drive on Kinnekulle I had found the error but unfortunately it became as it were.
Motor supplied only 80bhp most and then in a register at 1000rpm´s.
Despite this, he run the car.
Now that the engine performs 160bhp such an assessment is made to the car to get around the Ring of around 1min.
It is very good. It was so good thanks to the sponsors' contribution.
But ...
Now we have built this car ready for road use with std articles regarding handling, etc.
Soon we are taking the step towards this and start with "Step 2".
Now we will optimize it for the track and racing.
Now there is no requirement for std stuff anymore, but now we take a deeper step into the world of racing.
Then it's gold with Peter's experience.
Watch this space for thoughts on this.
How good can a polo diesel from 1993 realy be???
There is great potential as Peter writes to get to a really good car.
Thomas
-
New videoclip.
http://www.youtube.com/watch?v=PF1WgCkAOtI
One more:
http://www.youtube.com/watch?v=mtiv8o6yzS4
Thomas
-
If you dont mind me asking how much did you spend sorting out the rear anti roll bar set up.
-
No, absolutely not just ask.
I din´t spend anything due to sponsorship.
But i can tell u what you need.
Thomas
-
(http://forumbilder.se/images/a89201110352604dc.jpg) (http://forumbilder.se)
(http://forumbilder.se/images/a89201110352604dc.jpg) (http://forumbilder.se)
(http://forumbilder.se/images/f5920111042082959.jpg) (http://forumbilder.se)
Thomas
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Well done Thomas. Very nice project.
Have you done anything to the engine to handle all this boost?
Also, can you post up more details about the rear ARB setup?
Alex
-
Well done Thomas. Very nice project.
Have you done anything to the engine to handle all this boost?
Also, can you post up more details about the rear ARB setup?
Alex
Yea get up the spec list for your anti roll bar setup, I might be wanting to stiffen up my back end as its rubbish at the moment.
-
Hello and sorry for the late reply.
The engine has gon through a swedens most experienced enginebuilder.
but basicly the engine is mor or less std.
BUT all tolerances are matched together and some of them even thougher.
I.e the headgasket is still a fiber one and we have not put in oring or even made a topdeck.
The piston rods are heavly modified for keeping up with the boost.
The list can be made long so instead of me writing in bad english go to my thread and read.
You may have to use google translator for the swedeish but i think you understand the pics??;)
Engine renovation starts at page 6.
http://dcsforum.se/dieselsnack/viewtopic.php?f=4&t=6444&start=60
The rear swaybar is realy a suzuki baleno front swaybar.
The mounting ends just straightend and 2 brackets made up.
Just did a quick bracket and welded this on to the rear beam.
there you have it.
cost for this set up is around 5-10 euro....... :)
So it´s up to you guys to try this and se what you think.
some new videos to make you wana go diesel ;)
http://www.youtube.com/watch?v=mtiv8o6yzS4
http://www.youtube.com/watch?v=PF1WgCkAOtI
Starting to be satisfied with the performance.
0-100km/h around 5.5 sec. and 10-140km/h ~10sec.
think this is rather good. :)
Thomas
Sweden
-
Excellent progress Thomas. 8)
Looking at the vidoes it's pulling really well now. Fantastic result for a 1.4 litre diesel!
Keep up the good work,
Cheers,
Richard.
-
New pics from your raceday.
http://www.garaget.org/?car=152336
You find them in my gallery.
Thomas
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Hi.
Now the car has got a new inner ceiling in black pics later.
The rear wing/spoiler is on the makeing and i´ve got a link for you to look at if any intrest.
Its gonna be made in carbonfibre...
Alot of work to do this....
http://madcamcnc.blogspot.com/2012/01/foam...ed-milling.html
thomas
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new pic.
(http://forumbilder.se/images/a17201214940P1a55.jpg) (http://forumbilder.se)
Thomas
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Hello.
Some new pics of the inner headlining.
(http://forumbilder.se/images/3e4201291051A7e84.jpg) (http://forumbilder.se)
(http://forumbilder.se/images/094201291122A8b69.jpg) (http://forumbilder.se)
(http://forumbilder.se/images/214201291153Ad5e2.jpg) (http://forumbilder.se)
(http://forumbilder.se/images/fd4201291351Ad098.jpg) (http://forumbilder.se)
I will paint the sunvisor mounting clips later on.
Thomas
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Now i´m proud to say that the car is in swedens most popular and largest auto news paper.
Next for the car is the largest autoshow in sweden during easter, approx. 75000 visitor over 4 days.
Thomas
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Congratulations Thomas!
-
Thanx.
Thomas
-
Hi folks!
this time i need your help.
I´ll have to rebuild my front set up becuse i want to move the wheel hubs approx. 10mm out.
so..
is there any one on this eminent fora how has done somthing in this matter please give some ideas.
I was thinking in this way..
Change the drive shafst to a golf setup if there is any out there with appr 10mm longer drive shafts.
Make a new set of wishbones in a-shape with 2 conectionpoints.
or maby there is a "thicker" CV joint that i could use instead?
Please need help here...
Thomas
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why cant you use 10mm spacers? or if you dont want to use spacers machine or get machined a 10mm thicker wheel hub ?
-
Hi and thax for the reply.
Well i cant rely the swedish organisation SFRO hows in charge of all rebuild cars wont accept spacers due to some strange rules....
Thats why.
But what i can do is that i make a spacer that enlongate the drive shaft and then remake the controlarms etc.
Just a thoght dough.
What do you guys think of that?
Thomas
-
We have a guy in Blackpool that emigrated from sweden because he was fed up of all the laws regarding the modifications of vehicles.
-
oh, i fully anderstand of that move...... :)
-
Hello
Now, the chassi update has begun.
first we dissmounted all at the rear, beam wishbone etc.
(http://forumbilder.se/images/242720121129279be9.jpg) (http://forumbilder.se)
Empty...
(http://forumbilder.se/images/66272012113055f1dd.jpg) (http://forumbilder.se)
(http://forumbilder.se/images/fa272012113301aa2f.jpg) (http://forumbilder.se)
It´s always more work..
(http://forumbilder.se/images/ff2720121134164174.jpg) (http://forumbilder.se)
On this pic, you can see two other taction arms that we was thingking of using but no, we will make a new set with unibolts... :)
time to start up the lathe, had to produce this..
(http://forumbilder.se/images/6b27201211355865b4.jpg) (http://forumbilder.se)
Can anyone see what this is?
(http://forumbilder.se/images/fa2720121137199718.jpg) (http://forumbilder.se)
When we found the rigth pivot point for the rear beam, I could start with the front end.
(http://forumbilder.se/images/6f272012113934ae1c.jpg) (http://forumbilder.se)
Then to the fun parts. :)Rear beam modification.
We will build a trailingarm setup.
Man in action....:)
(http://forumbilder.se/images/4e272012122637e867.jpg) (http://forumbilder.se)
(http://forumbilder.se/images/fa27201211422186d1.jpg) (http://forumbilder.se)
One done .
Did make a new set of shorter steering arms.
These will give us quicker steering respons.
(http://forumbilder.se/images/7d2720121146195e1c.jpg) (http://forumbilder.se)
Thomas
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Hi if someone reads this
the picture shows the center line pivot point bracket for the rear beam.
IRS on a Polo 86c is far beyond the normal mods.
The front and rear beam are now done and mounted.
Fully adjustable in front and rear.
Today we will start with the front hub angle.We want the wheel to dive in more when we turn the steering wheel.
IRS is a far bit "overkill" but i like the idea of having a Advanced rear beam.
i also want to have control over the toe-travel, have the possibilities to adjust camber , caster and toe.
So far the setup has changed the wheelbase with ~50mm in length and the track width by 60mm.
Caster in front 3deg. so we will see what we end up with but it will definite mean that we have a better situation then before.
pics coming up.
stay tuned.... :)
-
Now comes the pictures.
After a whole lot of work during the Christmas and New Year eve, now the car is down on its own wheels again.
First a picture of the modified section of the section toward the torpedowall to handle the increased load.
(http://forumbilder.se/images/c92013113912A13cb.jpg) (http://forumbilder.se)
Then comes a picture of the rear axle mount in the middle.
(http://forumbilder.se/images/ae2013114010A5a77.jpg) (http://forumbilder.se)
Wishbones have been modified.
The spring plate is moved up 20mm, a stabilizer bracket is welded and steering arm has a new position. The angle of the hub modified to provide more angle in the hub that little sloppy expressed as more camber angle and better precipitation of the wheel when steering.
(http://forumbilder.se/images/27201310007PM8b18.jpg) (http://forumbilder.se)
(http://forumbilder.se/images/202013125536Pf70a.jpg) (http://forumbilder.se)
Finally a picture of what the front end looks now :)
(http://forumbilder.se/images/252013114105A61aa.jpg) (http://forumbilder.se)
Thomas
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Awesome work mate love reading your build thread
-
Thomas- looks good, but have you got enough travel on the rose-joint (uniball) with it in this orientation:
(http://forumbilder.se/images/252013114105A61aa.jpg)
I would mount it 90 degrees from this so there's no limitations.
CHeers
Peter
-
Brilliant stuff there mate :)
-
hi there.
yoof!!- yes i have, checked this and i have full travel without any problem at all.
But i have Another issue, my drive shafts is now to long..... :(
Is there any quickfix to solve this??
On the golf there is a spacer i can take away but does this exist on polo?
thanx for Reading.
By the way, if i´m going to use the car on track what kind of springrates are you running.
is there any page on the internet where i can find the spec of a winning g40 cup car?
Thomas
-
Too long? on both sides? Can you not adjust the wheel position with your TCA/Strut so you can use the correct length shaft?
You could also fit different output flanges.
There's a bi thread on here about spring rates http://www.polog40.co.uk/forum/index.php/topic,8835.0.html
-
Hi sorry for the late reply.
output flanges what do you mean?
on the gear box?
I could do the adjustment on the TCA, but he camber would be appr. -8deg and thats for track use only.
Braking will be affekted aswell as you know.
Isn´t there any shorter driveshafts on any/some model...??
-
Output flanges?
on the gearbox?
what about driveshafts? any shorter?
Thomas
-
output flanges are where the driveshafts attach. on later 1993/94 Polo the are larger and use a shorter driveshaft.
-
Hey.
Now it has taken off again ....
Got a problem when I realized that I have not blasting cabinet that is big enough.
Has a small table cabinet that works great most of the time but when it comes to such intake, cylinder head or cylinder block then I am totally screwed.
Thought I could not keep on struggling with this little box more, everything takes so much longer so I decided to spend some time and build a cabinet.
Will upload some pictures today on how to do, so please come with advice and comments, it is always fun.
Have collected some parts etc so it should go fast.
Thomas
-
Hello again.
Yes it was time to show what last week went to. This post is long.
Well as you have gathered, I got tired of leaving away any blasting job that was larger than type 20x20cm.
So with all the work that was suffering for it, not to mention all the cost of money for the job and travel costs, etc., plus you always have to wait for it to be done, I decided to build my own blasting cabinet at the absolute lowest cost.
Sat and thought about buying sheets of metal and fold up a cabinet but have no possibility to fold that large pieces so there is a little problem directly ...
no, I thought, one more lap.
Got an idea that it has to work with refrigerators. :)
The problem is that these plastic inner side which will not last long.
If you remove this it will not be air tight so that idea went away.
But anyway, so I checked on the net and all other buy and sell sites.
2-500SEK(30£) it was ok to find to that cost but then it was an option to buy the sheet again .... fuck.
But what the fuck I was thinking a "freezer box" has the aluminum inside usually plus they're larger.
great!!but these were even more expensive.
But then the thought struck me that it is the freon in them, recycling of household goods is in our community to be free to get rid of.
Scrapyard next :)
Calling the scrapyard and talking to their boss whom showing a large interest in diesel cars ..... huh Oh well :)
After some talk, it is clear that I can come and look if there is any cabinet.
It does, fortune was made. The cabinet was already empty of gas, so it felt good.
You do not want to ruin the environment more than necessary.
This is what it looked like.
(http://www.forumbilder.se/CDMUQ/en-frysbox.JPG) (http://www.forumbilder.se/CDMUQ/en-frysbox)
Then I put the box on the stand.
Idea was that the door would be opened upwards, but because of the height it needed so it was not good.
I had marked out for the holes to put the hands in etc so it was probably the last second I checked the ceiling height in the garage.
Missing about 20cm for it to go free. It goes fast sometimes ... :)
Was to turn the cabinet.
i put a few locks jumpers from the local hardware store that I had lying around, believe they were the kind 1£ each or something.
Then it looked like this.
(http://www.forumbilder.se/CDMUQ/halmarkerade.JPG) (http://www.forumbilder.se/CDMUQ/halmarkerade)
But while I was on the scrapyard, I took the opportunity to pick a stove door.
Awesome resistant glass in these windows, they are not scratched for quite some time.
Another good thing with these stove lids is that they are in metal, and have a ready framework to cut out ..... :) Free is good.
(http://www.forumbilder.se/CDMUQ/ugnslucka.JPG) (http://www.forumbilder.se/CDMUQ/ugnslucka)
By far the hardest thing to sort out in blast cabinets, is visibility, you have to have a good situation for air to enter and exit efficiently.
Had a an old airfilter from a Volvo 850 laying around, perfect.
Was to cut out for this and make a frame that holds it in place.
Wanted easy access to be able to change it from the outside. On with 2 valve cover I had on the inside.
Took the opportunity to drill a hole for airfeeding into the cabinet, created an air connection and with water separator, becuase water we do not want in the cabinet. I have this already on my second box and is easy to move over.
I installed a quick release on the inside because I want to be able to put my old cabinet in this one to save space. Turned out like this.
(http://www.forumbilder.se/CDMUQ/luftfilter850.JPG) (http://www.forumbilder.se/CDMUQ/luftfilter850)
But the air must be filtered and everyone who has worked with a blasting cabinet know how fast all filters etc clogging. Vacuum cleaners are fighting like an idiots and pretty soon it has died.
Has this problem in the small cabinet.
No, now I build a cyclone filter.
But where shall I put this, course it also takes space.
But there is the place where the compressor is in the freezer ..... behind it perhaps there is space.
(http://www.forumbilder.se/CDMUQ/ventilationslucka.JPG) (http://www.forumbilder.se/CDMUQ/ventilationslucka)
Began to measure and soon i saw that it was quite possible to get a filter with good airflow capacity in there.
But it is not so easy to make a cone .... but after some counting and searching on the web, etc. I found a formula that could be used.
But now I had no sheets of metal ...... Damn, it becomes the next problem.
But then the thought struck me that one of my sponsors are working with sheet metal.
Went down to Piaab and had the possibility to take some waste pieces from their container., Free AGAIN .... :)
Drawn and cut, rolled and bent as best I could,
Found a pipe that was just the right size for connections and welding sheet metal is not my favorite.
Mounted the cyclone filter and then it became like this.
(http://www.forumbilder.se/CDMUQ/cyclonfilter.JPG) (http://www.forumbilder.se/CDMUQ/cyclonfilter)
Now it was to get a steelnet/mesch? or something , this was not easy, but down to the store in the village, and asked if they had a shelve that were broken, that they had ... :) Free again Fantastic!!
Now it was to fold a sheet metal square cone, and this was not so hard up with the spare pieces of sheet I received from Piaab and draw, cut and bend it.
Tried to see if it fit, and it did.
Before this, I cut out the bottom of the cabinet.
Glue and blind rivets so it was airtight.
Measure out where to put my arms, find the position for the window on the box and cut out for them.
Had two old floor-well connections I bought for the laundry room renovation.
Mounted these parts on the boxdoor.
Attached the rubber gloves that I bought.
(http://www.forumbilder.se/CDMUQ/skapetklart.JPG) (http://www.forumbilder.se/CDMUQ/skapetklart)
Underneth the cabinet you can see the nice yellow and black roof plates that became a cone in a blasting cabinets in there "second" life ..
Bought a blast nozzle and modified it where the connection to the sand.
If you buy a blast nozzle gun, do check all the races there is always burrs that cause malfunction.
Connect all hoses and in with the grid.
Turned on the vacum cleaner and put in a bit of old rusty parts from a vw golf.
A rear brake caliper bracket, a strut, everything with rust since 1983 ....
Closing the door on with the air and try.
Sweet jesus it worked :): Thumbup:
(http://www.forumbilder.se/CDMUQ/skapet-in-action.JPG) (http://www.forumbilder.se/CDMUQ/skapet-in-action)
Inner dimensions are for the interested is 85cm deep, 95cm wide and 65cm high.
Believe the cost ended up with glue and screws etc about 80£. : D
There's some adjustments to be made, but on the whole ... : Thumbup:
Exceeded expectations ...
Thanks to me for this time.
Thomas
-
Started with the golf again.
This weekends work was the sillarea.
Did som blasting and painting first.
some pics..
(http://www.forumbilder.se/CDUIF/blastrat-och-lackat.JPG) (http://www.forumbilder.se/CDUIF/blastrat-och-lackat)
(http://www.forumbilder.se/CDUIF/troskel-hoger-klar1.JPG) (http://www.forumbilder.se/CDUIF/troskel-hoger-klar1)
(http://www.forumbilder.se/CDUIF/troskel-hoger-klar2.JPG) (http://www.forumbilder.se/CDUIF/troskel-hoger-klar2)
The other side done aswell. :)
(http://www.forumbilder.se/CDUIF/troskel-hoger-klar3.JPG) (http://www.forumbilder.se/CDUIF/troskel-hoger-klar3)
(http://www.forumbilder.se/CDUIF/troskel-vanster-klar1.JPG) (http://www.forumbilder.se/CDUIF/troskel-vanster-klar1)
Thats all for now.
Thomas
-
Haha!! that bead blasting machine is awesome!!! you should do private jobs or rent it out, could make your money back ;D
-
Hi and thanx for the comment.
As far as making the money back its more or less already done. ;D
Have a Q which Camshaft is the best when turbo´ing a petrol polo?
Need the info to update the polo for some more power in top range.
The orig. cam is optimized for low revs and non turbo.
Any tips about this topic would be appreciated.
Thomas