Author Topic: Yoof's Turbo  (Read 99977 times)

Offline scully

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Re: Yoof's Turbo
« Reply #390 on: February 05, 2015, 06:56:56 pm »
Thanks for posting al of this, I now know to stay with the stock drivetrain for a while.  ;) Also a lot of respect from me that goes into al the engineering.

Offline Yoof

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Re: Yoof's Turbo
« Reply #391 on: February 05, 2015, 08:32:58 pm »
Cheers- I think in some ways I should have dropped a 20v in, and not farted around with adapter plates and making everything work with the PY lump. But that's half the fun!

I will be glad when the fabrication is over though, literally everything in my garage is covered in grinding dust  :(

A- mount has been re-designed to look similar to the B-mount now, brings it much lower in the chassis and has two pickup points. Hopefully engine should be standing on it's own this weekend. I might push it outside for a wash!

Offline JoeH

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Re: Yoof's Turbo
« Reply #392 on: February 06, 2015, 12:43:48 pm »
Do you reckon your car will make it to any magazines?
Because this is seriously nuts stuff going on here. Very impressive.
You clearly possess a lot of polo love.

Offline Yoof

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Re: Yoof's Turbo
« Reply #393 on: February 06, 2015, 01:40:44 pm »
Do you reckon your car will make it to any magazines?
Because this is seriously nuts stuff going on here. Very impressive.
You clearly possess a lot of polo love.

It's not my goal- I could bolt a set of shiney wheels on it and take some pictures I suppose. I've been asked over the years by a few different ones, car has been mentioned in PVW articles, but it's not something I'm aiming for. If I did do it, I'd probably shoot it with Andy's car (much the same hardware, suited to the road) and get our very own Alex Grant to write the words.

Cheers for the kind words  ;D

Offline Yoof

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Re: Yoof's Turbo
« Reply #394 on: February 08, 2015, 09:22:55 am »
Completed the A-Mount now, dropped it down to give similar mounting heights cross chassis to the B mount, engine now sits on its own mounts  ;D Need to weld up the C-mount, and push it outside for a wash.







Chopped the front panel for turbo clearance, I really don't like it in it's current state, so will invest in an edging tool and neaten it up.

Cheers

Pete

Offline Yoof

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Re: Yoof's Turbo
« Reply #395 on: February 16, 2015, 07:56:07 am »
So, the last few weeks has seen a few steps forward, and several back!

First off, the Team Guru Derby sold- appearing in VWDRC 2015/16  8) some pics of the old girl all clean:







And I finished all the engine mounts and pushed the Polo outside for a wash, first time in a long while!









So with that bit done, my next bit to sort out was the driveshafts. I need to get measurements as soon as possible as they're fairly long lead time items. Now, Polo CV joints aren't the strongest out there it's fair to say, so with my new stronger gearbox, it makes sense to look at the driveline too.

Inner CV joints easy- bought a set of 100mm bolt in flanges and some Mk2 Golf GKN joints. Job's a good-un. Outer CV joints, little more difficult...

A Mk1 Golf and a Mk2f Polo share a very similar wheel hub design though:



After spending a few hours in a huge SKF catalogue, I had myself convinced they'd fit... I was wrong.

Split everything down (discovered my brakes need new dust seals) ready to go:



And had two clashes (after some light machining) still with the outer CV to bearing housing:



and with the bearing housing to rear of the wheel hub face:



Solution is fettling in all available areas - I'm about 3.5mm off it fitting, so removal of some more material from the outer CV face, the bearing housing, and taking the 0.8mm feature of the rear of the wheel hub (polo one doesn't have this) should see it all clear.

Main pain is every time I fit everything together to check clearances, I knacker a set of bearings, £60 down thus far... ho hum.

So with that I also started looking at shifters, I need a short cables to fit in the Polo- so I did a little reading and purchased a set of 2003 Polo cables and shifter mech, only to find it's identical to the Mk4 Golf one I have... d'oh - Gurds confirmed cable lengths on his Mk1 for me (thanks mate!) circa 960mm and 1010mm.



I was hoping to avoid bespoke cables, cost and availability (in future) are the main worries- so if anyone knows of any VW gearshift cables that are much shorter than the ones above, I'm all ears!

VW Lupo/Fox/Up lengths would be good- I can't find any information on the interwebs.

Cheers

Pete

Offline dubstar

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Re: Yoof's Turbo
« Reply #396 on: February 17, 2015, 08:48:46 am »
Pete,

Not got any specific lengths but what about the cables off the Audi A4 with the transaxle gearbox behind the engine? Might be too short. Just a thought.

Offline pauloscooby

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Re: Yoof's Turbo
« Reply #397 on: February 17, 2015, 11:21:34 pm »
hi
I really like this project was very good but is still getting better.


cheers

paulo
« Last Edit: February 17, 2015, 11:34:56 pm by pauloscooby »

Offline Yoof

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Re: Yoof's Turbo
« Reply #398 on: February 18, 2015, 08:19:11 am »
Thanks Paulo - which gearshift cables did you use?

Ross- Not a bad shout old bean! I'll look into them.

Will take some pics tonight, but C-mount and old rear gearbox mount are now boxed in on the chassis, one more plate to do on the old gearbox mount, next up is subframe modification and finishing off the C-mount (gearbox side)


Offline pauloscooby

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Re: Yoof's Turbo
« Reply #399 on: February 18, 2015, 12:12:57 pm »
hi pete

the  cables and the gear sector that I use are a TDI engine (pd) 130cv, golf or seat.
is under way and is more accurate when crossing changes.
but to install these cables you need to get the full kit

1-selector of changes
2-cables
3-that the rod inside the housing which connects the cable
you need to get everything, but is much better

cheers
paulo

Offline Yoof

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Re: Yoof's Turbo
« Reply #400 on: February 18, 2015, 05:14:07 pm »
Paulo- I forgot you have a different gearbox to me, it looks like you use a Mk3 Golf style shift tower?

Offline pauloscooby

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Re: Yoof's Turbo
« Reply #401 on: February 19, 2015, 02:10:42 am »
hi
my box is a 02A to a golf tdi 90cv,my box out is exactly the same as your
but I to mount the box with the motor in position opened the box and changed the cover fixing the block by a golf vr6 and is just in the right position

I can post pictures for you to check out

https://imagizer.imageshack.us/v2/800x600q90/577/lhqk.jpg


https://imagizer.imageshack.us/v2/800x600q90/4/2pbs.jpg

https://imagizer.imageshack.us/v2/240xq90/c/823/ap8u.jpg


https://imagizer.imageshack.us/v2/240xq90/c/268/vpgo.jpg


this cable was the ones I had at the beginning
cables that have now are similar to those that you have al this photo on this page
and I had to mount hydraulic clutch also

« Last Edit: February 19, 2015, 02:25:42 am by pauloscooby »

Offline Yoof

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Re: Yoof's Turbo
« Reply #402 on: February 22, 2015, 10:10:52 pm »
So, a little more fettling and everything fits up. Modified wheel hubs, strut housing and outer CV... all good fun!









And wheel studs re-fitted with Loctite 270 - stood up well the last few years



Brakes back on and mounted:



Subframe modified for clearance at the rear, now picks up on the redundant cat brace, d-mount also added:



C-mount finished:





Engine back in, OSF strut assembly to finish then I can measure up for driveshafts:





Cheers

Pete

Offline Yoof

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Re: Yoof's Turbo
« Reply #403 on: February 28, 2015, 06:41:51 pm »
Mounted the Mk4 Golf gear shifter:



Now can measure up for cables and get Ringspann to make them

And I've mocked up both driveshafts, will send off to Reco-prop to be made properly. Parts used are:

Mk1 Golf GTi Wheel Hub
Mk3 Polo Strut Housing
Mk3 Polo Wheel Bearing
Mk1 Golf GTi Outer CV
Mk3 Golf 100mm Output Flanges
Mk2 Golf Inner CV
Mk3 Golf GTi driveshafts

Fairly good mix of VW bits!

So, starts with two halves of shafts:



Make sure both the CV are halfway in their plunge depth:



Find a piece of CDS that will slide over:



Tack and weld together:



Refit to car:



Driveshaft has hardly any angle, which I'm happy with  ;D

Rinse and repeat on the OSF:



Cheers

Pete

Offline JoeH

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Re: Yoof's Turbo
« Reply #404 on: February 28, 2015, 09:12:13 pm »
Lookin neat!
What quality/make of choice for wheel bearing do you go with?