Author Topic: 1985 Rallye Yellow Coupe S G40  (Read 17242 times)

Offline grungeisdead

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1985 Rallye Yellow Coupe S G40
« on: April 04, 2011, 01:33:07 pm »
Yo, thought id stick this up here, as its soon to be charged,

Original Post from when I purchased the car

Good Points:

One of the earliest 13OO Sport coupes in this country
The Polo coupe S was Introduced in 1985. The car you are bidding for was registered in February of that year.
Purchase bill present and the car cost £5299.
Full 'sports' trim which included sports seats, rev counter, twin-lamp grille, 3-spoke steering wheel and 'sports' styling.
Full service history.
All bills since new  (36)This includes service bills.
All Log books and manuals .
4 Previous Owners

Bad Points:

Wipers will not come on
The car has a new battery but only starts from Jump Leads
Car will not tick over (Either air intake pipe is split or Idele speed/ choke needs looking at)
Needs a good machine polish


Comments:

Picking this lil beasty at the weekend, will get it mot'd and tax'd pronto and itll be a daily driver while I take my golf gti off the road for some remedial work (Clutch, Crankshaft oil seal & welding)

Plans:

Machine Polish
Mot & Tax
Cheap Lowering kit or buy my old coupe s back and swap over the 70/60 hnr kit, exhaust and g40 running gear, sell the old coupe s as standard.

Pics:

Exterior






Engine Bay




Interior






---- End original post ---

So I went to Brecon from Derby to pick the lil beasty up - pics taken by Steve - Yeti

quite apt the colour scheme of the petty station and cars



Steve played catch up for most of the journey




174 miles later it was at the MOT station



and i was left with a 3 page 40 item list of fail =/

so a month later, the day after the mot was done the car had its first outing at VWNW, Tatton Park



then at edition 38 - with some new wheels.



i have a fetish for the OZ "routays"




and then the quest for more power was sought




current guise




winter camo



Specifications


Model:

1985 Polo Coupe S
Rallye Yellow

Engine:

1.4 16v DOHC
CBR600 Carburettors
Lupo GTI 4 Branch
Lupo Decat downpipe
Straight through stainless system
Scorpion Bike Can Backbox

Suspension:

KW -60mm
GLadersiete ARB Blocks
Powerflex Inner/Outer TCA bushes

Brakes:

VWII Calipers
Black Diamond Discs
Pagid Pads
PSD Braided Hoses

Wheels and Tyres:

OZ Routays 14x7
195/45/14s all round

Exterior Styling:

Monkey hanging off the back
Monkey Grille Badge

Interior Styling:

Standard & Dirty
300mm Momo Team
Snap-Off Boss
Lupo 5spd Gearknob


This month is going to see a derby square light conversion, claspless mk1 polo seatbelts, new front bumper and a rolling road day at Aldon with Club Polo so I should have a figure to report
« Last Edit: May 15, 2011, 09:51:13 pm by grungeisdead »

Offline grungeisdead

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Re: 1985 Rallye Yellow Coupe S
« Reply #1 on: April 04, 2011, 01:33:51 pm »
new wheels now sold tho



went to the pod this weekend for vw action, and decided to run the car up the strip. i said to everyone that i would blow the car up, and being a man of my word, i did =D on the 6th and last run of the day


some pics and a video from the weekend





a run against a plymouth pt cruiser haha

http://www.youtube.com/watch?v=Lp32UBV6YYI

best time was 16.7 out of 5 runs, worst was 17.1

got to have a lil drag race with bluey (liz's mk2 coupe GT too)

vids thanks to Gaz

Saf
http://www.youtube.com/watch?v=5hQ_pxCBSlU

Saf vs Liz, Nick vs mk2 Golf
http://www.youtube.com/watch?v=jQxq95PpLR0

anyway new engines fitted with 200 more cc's and some lairy cams to boot.





shattered remnants after the pod




the head looking a little forelorne and stripped of its cams



anyway this lil beasty failed me early last week



the machined rod for the relay roller, failed and sheered off, leaving me in the same situation as with the previous engine!

on the plus side, the machinist managed to drill out the relay roller using a beast of a milling machine, so its now a M10 threaded bar which i will be replacing with a hi-tensile bolt.

anyway damage seemed minor, drilled out the sheered end of the rod, fitted new relay roller and retensioned everything up, car wouldnt start up, starter motor just whirrs like mad (tried two and tried smacking it with a hammer) and we tested two cylinders, no compression at all, not even a smidge.



floor jacks ftw



stripped it down and she was not a pretty sight, so its game over for that engine, it will be rebuilt and my 2nd lump which has already been cleaned up and honed, is just awaiting piston rings and shells, cams installing and clearances checking and its good to go again!




Offline grungeisdead

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Re: 1985 Rallye Yellow Coupe S
« Reply #2 on: April 04, 2011, 01:35:14 pm »
on the way to G-dom, utilising the 170bhp lump, removed from my Grey G (seen in the background)





progressing a bit, battled some of the rain yesterday.

* removed oil breather pod, cleaned out, resealed and refitted
* fitted inlet manifold
* fitted throttle body
* fitted and bolted up all engine mounts
* removed facet fuel pump from drivers wing, to mount induction kit

job list

- fit alternator
- fit intercooler
- fit charger (after rebuilding with new seals)
- fit fuel rail and injectors (after sourcing cap and o-ring)
- fit oil cooler and sammich plate
- fit induction kit
- fit exhaust manifold and system
- fit subframe
- fit 256mm brakes
- find a way to mount the boost hoses
- fit fuel pump and fuel lines

things needed if anyone can help

one long bolt for inlet manifold to head (caphead)
one bolt for ignition coil (to hold against chassis leg)
gasket for TB to inlet manifold
gasket for TB top section to bottom section
rubber o-ring and injector cap(cover) for 250cc injectors. (three pin holes, not 1 like gt's)
a cut out of a mk2 front slam panel, to make a removable section for fitting of the charger
large boost hose from rad top cover to throttle body (ideally mk2, but can bodge a mk3)
CO pot sensor
fuel pump holder/bracket with fuel pump, accumulator, and all fuel lines
in-tank lift pump
wiring from fuel pump to fuse box

Offline grungeisdead

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Re: 1985 Rallye Yellow Coupe S
« Reply #3 on: April 25, 2011, 06:41:09 pm »
Few updates after a busy bank holiday!

bits done

Fitted full psd exhaust system, gt ported inlet mani, 51mm throttle body, alternator, pps subframe, 256mm brakes, jabbasport induction kit, ecu, ecu loom and made provisions to fit supercharger.

job list

Find a way to mount intercooler ( got a std g one and 3 front
mounts)
Mount oil cooler
Paint up fuel pump bracket and refit with mk3 fuel lines and in-tank lift pumps
Fit throttle cable
Fit charger earth and oil lines
Fit toothie pulley to charger

Few other jobs but mainly tidying up a few bits here n there.
Was hoping to have finished yesterday so I could have made it to elsecar but had to crack on with some garden work and the other two polos needed some tlc ( new centre section on mk3 g and thermostat on 6n2 )

Anyhoo a couple of pics (ecu and loom not fitted in pics)




Hmmm




Offline Volkov

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Re: 1985 Rallye Yellow Coupe S
« Reply #4 on: April 26, 2011, 08:28:23 am »
That's one of the reasons, that i chose 2F for my g40!  ;D
Where are you planned to put the cooler?

Offline grungeisdead

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Re: 1985 Rallye Yellow Coupe S
« Reply #5 on: April 26, 2011, 10:09:52 am »
I've already got a 2F, a polo 1 and 2 x polo 2's.

Just fancied a bit of boost for the yellow peril!

Planning on mounting an intercooler between the cross-member and front panel and making some sort of air ducting to channel the air into the cooler. I dont want any garish pipes or coolers hanging out the front, as they look a bit pap.

If I can get a ally cooler that resembles the same size as the mk2 g40 intercooler, I can get a friend to weld on appropriate end caps

Offline Volkov

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Re: 1985 Rallye Yellow Coupe S
« Reply #6 on: April 26, 2011, 01:43:38 pm »
Fully agree with you for the cooler!!  ;)
Keep posting pics , regards!

Offline grungeisdead

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Re: 1985 Rallye Yellow Coupe S
« Reply #7 on: May 02, 2011, 02:46:06 am »
cleaned das peril for the first time in 8 months!



Painted up fuel pump assembly and built up ready to fit with intank pump tomorrow.

Fitted inector rail and mounted oil cooler in the wing, see pics




Also upon stripping the interior and carpets to lay the fuel pump loom, found a load of surface rust under the rear bench as it was sodden. Props to biglou for the wire brush steez and to karlos for the holesaw flex.

Removed a shitload of sound deadening too as it was soggy and weighed a tonne

Offline grungeisdead

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Re: 1985 Rallye Yellow Coupe S
« Reply #8 on: May 02, 2011, 07:50:32 pm »
Made provisions for intercooler





Removed aquamist and guages from the mk3 to mount in the mk2.

Pics of subby



Brakes



The interior based fail boo. Gettin cleaned up, etch primered, 2k primed and painted yellow again. :-)

Think you can just see the intank pump




Fuel pump assembly fitted with self tappers, still gotta put clamp on for pump.


Offline grungeisdead

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Re: 1985 Rallye Yellow Coupe S
« Reply #9 on: May 13, 2011, 12:38:47 am »
Fuel lines now all fitted, custom loom made up for fuel pump and coil, with inertia cut-off switch and kill switch. Boost guage, and yellow vdo batt and oil pressure guages fitted. Boost Hoses Fitted. Fitted header tank, washer pump and tank, heater matrix hoses

Rileys picking up the car tomo and we are having a sesh on it at the unit to finish off the last few jobs

* Mount Intercooler

* Fit Toothed Pulley to charger / Fit Charger / Fit Oil Lines + Charger Earth

* Fit Toothed Belt & Tension Charger

* Fit Radiator

* Fit Battery

* Fit longer pipe from ISV to Boost Hose

* Tax

* Tracking

Cmonnn All Types! well looking forward to it!

Anyway a pic for today


Offline grungeisdead

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Re: 1985 Rallye Yellow Coupe S
« Reply #10 on: May 15, 2011, 04:40:56 pm »
Friday evenings endevaours started late so ended at 6am, back on it the next day about 1 and we were on the road a few hours later, after some smoke fuelled adventures! some pics before fitting the rad, showing the boost hose setup and space limitations in the bay! its toight!

pretty stoked with the IC mounting position!








bought some exips off matt for the tyres, as i had no useable wheels otherwise, 14x6j exips with 175/50/14s.

cars back home now on my drive and the install is a success, im really happy and the car handles well. the brakes could do with another couple of passes with the brake bleeder , needs the gear-linkage adjusting and the exhaust is knocking against the chassis tunnel, so probably needs twisting round.

the head is still smoking bad, far too much to have driven it to all types for its maiden voyage, but i knew it needed fixing before, but ive had a head refreshed with sodium valves and should have that next week, so ill be whipping the head off, and putting the new head on with the shrick cam. good times!

some pics of the end result







powaaaaaaaah

« Last Edit: May 15, 2011, 06:49:00 pm by grungeisdead »

Offline grungeisdead

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Re: 1985 Rallye Yellow Coupe S G40
« Reply #11 on: May 17, 2011, 02:11:09 pm »

Offline Boris

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Re: 1985 Rallye Yellow Coupe S G40
« Reply #12 on: May 17, 2011, 03:40:49 pm »
Superb, love the subtlety of the ic mounting, great work.  8)

Offline grungeisdead

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Re: 1985 Rallye Yellow Coupe S G40
« Reply #13 on: May 19, 2011, 11:59:11 am »
thanks mush! :)

rebuilt cylinder head was picked up today, got my aex gasket on order, so should be delivered to work today! got 4 litres of 10w40 part synth castol gtx for a bargain 14 quid from asda, so taking the peril up to the unit today to whip the head off tonight, ready for the refit tomorrow. woop!

Offline cheys03

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Re: 1985 Rallye Yellow Coupe S G40
« Reply #14 on: May 19, 2011, 12:58:15 pm »
got 4 litres of 10w40 part synth castol gtx for a bargain 14 quid from asda
Get to know your VW parts man better ;-) 5L Synta Silver 10w/40 semi-synthetic can be about £13 ;D