Mk2 1.05 => Mk3 Conversion

omicron · Post by **omicron** » Sun Jun 04, 2006 5:24 pm

A few of you will have been watching this on clubpolo, and as I was asked, I thought I'd oblige and post progress here as well.

What I'll be doing is keeping the clubpolo thread as up to date as possible, and posting here as I hit the major milestones.

Photo's aren't going to be comprehensive, just a shot now and then as a step is completed.

For now, it's just been stripping the two cars...

1983 Mk2 (pre-revisions) 1043cc Polo C (my baby)
Sadly, the engine on this one has seen better days, needs a carb and dizzy rebuild, probably a new set of exhaust valves, and who knows what else....

1992 Polo GT
This one's got a cracking little engine, despite being on about 150k. It had a top end rebuild under previous ownership, and the engine just needs a bit of tweaking. The downside is, it has excessive corrosion in many, many nasty places (battery tray, chassis legs, etc).

Step one is getting the basics (engine, box, suspension, main engine bay loom and ECU) out of the GT. Most of the plumbing will remain in situ for now, along with ancilliary bits of wiring. That way I can work out what I need to fill gaps, rather than end up with a pile of bits I may or may not need.

Then the process is repeated on the Mk2:

Worthy of note is how the Mk2 engine bay lends itself to the conversion, even down to little points like the holes for the 1043cc's vac header tank are identical to the holes for the GT's ECU mount.

Please, don't say anything about the axle stands... I know... I should know better...

Next steps:

Remove front end suspension from the GT lump, to make engine installation easier.
Transfer GT radiator.
Fit engine and box.
Gear linkage (query compatibility, full linkage transfer may be needed to accomodate 5th gear?).
Replace distributor and header tank on GT lump.
Fuel system.
Plumb and wire in.
Test engine fuction.
Service GT suspension and fit.
Exhaust system.
Install rear beam.
Service brakes.

Currently under debate:
Transfer steering damper? (I'm thinking no)
Lower front end slightly (25mm, 40mm?)
Convert from hearse to van?
GT or Mk2 hubcaps?

Mk2Adam · Post by **Mk2Adam** » Sun Jun 04, 2006 5:35 pm

Thanks for that Steve

i reckon in august i'll have to start considering doing this

omicron · Post by **omicron** » Sun Jun 04, 2006 5:44 pm

Rate it's not going at the minute, I reckon you'll probably be ahead of me by mid august.

Mk2Adam · Post by **Mk2Adam** » Sun Jun 04, 2006 6:08 pm

omicron wrote:Rate it's not going at the minute, I reckon you'll probably be ahead of me by mid august.

haha, i'm not great with cars, it'll take me 6 months to work out how to open the bonnet

don't know why i think i can do it really lol, guess i'm willing to have a go at that sortof thing, i know a couple mechanics that could help if i really **** up plus the uk-p lads and lass's are always here

polokris · Post by **polokris** » Sun Jun 04, 2006 11:01 pm

kool, nice to see a bit of step-by-step action!!

Kris

Tahrey1043 · Post by **Tahrey1043** » Wed Jun 07, 2006 1:01 am

heh, loving the ghetto axle stands........ and just how many cars are scattered around your gaff? including the two olops i count six so far... all yours?

this will be a might interesting to see how it goes down, you might start a trend amongst mk2 restorers / preservers

(mk3 MPi engine and servo brakes plus mk2's legendary bodywork and lower weight..... i think you may just be onto a winner)

polokris · Post by **polokris** » Wed Jun 07, 2006 9:08 am

this will be a might interesting to see how it goes down, you might start a trend amongst mk2 restorers / preservers
(mk3 MPi engine and servo brakes plus mk2's legendary bodywork and lower weight..... i think you may just be onto a winner)

sounds good to me.....

(im not doing it.... but alot sure will!! )

omicron · Post by **omicron** » Wed Jun 07, 2006 12:38 pm

Tahrey1043 wrote:heh, loving the ghetto axle stands........ and just how many cars are scattered around your gaff? including the two olops i count six so far... all yours?

this will be a might interesting to see how it goes down, you might start a trend amongst mk2 restorers / preservers
(mk3 MPi engine and servo brakes plus mk2's legendary bodywork and lower weight..... i think you may just be onto a winner)

Who said anything about a servo? I drive in my work boots, so heavy brakes don't bother me

How many cars? Errrrrr.......

Mine:
Toyota Camry (work car)
Ford Escort (old work car, getting a new fuel tank, then being sold)
Rickman Space Ranger Kit car (my truck)
Rickman Ranger Kit Car (abandoned project, for sale)
2 piles of polo parts
Fiat Panda 4x4 (Mine/dad's) runabout
...oh, and some 2 wheeled fun, but that doesn't count

Dad's:
205 Derv
His share of the Panda

Tractor:
Suzuki Vitara rotbox

Then there's a few my brother has, but that'll take too long....

Tahrey1043 · Post by **Tahrey1043** » Thu Jun 08, 2006 10:09 pm

lol, just how much do you pay a year in tax and insurance?! that's a major pile of metal... (is the panda in two bits with half an engine apiece by any chance? wouldn't be surprised)

ah, never mind the servo, just for some reason i was thinking of it moving over automagically with all the other engine bay parts. is there still no room for it even when you've swapped the engine over? not that i guess it really matters as its still a lighter car, and my previous tests suggested the mk3 would still be about 95% as safe without it anyway

omicron · Post by **omicron** » Fri Jun 09, 2006 12:20 am

Tahrey1043 wrote:lol, just how much do you pay a year in tax and insurance?!

Too damn much, and that's without everything on the road.

Tahrey1043 wrote: that's a major pile of metal... (is the panda in two bits with half an engine apiece by any chance? wouldn't be surprised)

Nope, it was a production vehicle. Basically a standard front wheel drive Panda, with a powered back axle and a selectable coupling to hook it up. There were loads about at the time, but most of them were abused into the ground, I haven't had it long, so haven't had chance yet

Tahrey1043 wrote:ah, never mind the servo, just for some reason i was thinking of it moving over automagically with all the other engine bay parts. is there still no room for it even when you've swapped the engine over? not that i guess it really matters as its still a lighter car, and my previous tests suggested the mk3 would still be about 95% as safe without it anyway

There's very little weight difference between a Mk2 and a Mk3, and servo aside, the braking systems are identical. The problem is in the fact that the Mk2 bulkhead can't accomodate the servo without major butchery. There's nothing actually wrong with Mk2 brakes, you just have to have the conviction to stamp on them a bit. The problem arises when you get out of a servo'd vehicle and forget (yeah, done that)/don't realise (seen a mechanic do that when he was test driving my Mk2 and came back white as a sheet

).

omicron · Post by **omicron** » Fri Jun 09, 2006 5:42 pm

A few more pics....

The GT has a taller radiator than the early Mk2, and although it will actually fit in the space under the slam panel, there's no way of actually getting it in. So, assuming the engine will fit in behind it, I've fitted the GT's two speed fan and housing onto the Mk2 rad (straight swap). Thermal switch in the radiator was also swapped, and wiring will have to be adapted to suit. There is a chance I may have to go over to a slimline fan, but this will be addressed when the engine is fitted.

As I have been advised by other members (thanks guys), the GT's steering damper has been moved across.

The offside rack bracket has to be swapped (again, straight swap)

The nearside damper mount is different on the GT, being threaded, as opposed to just a hole on the mk2. I could be flashy and swap the whole bracket, but I'm just going to be lazy and use a nut

Now for a graphic picture of something Mk2 owners may find disturbing...

The offside chassis leg is showing some surface corrosion (certain death on a lot of Mk3's). Luckily, the Polo's 23 year old semi-galvanised chassis has meant this appears to only just be getting started. My next little diversion is to clean back and investigate.