1977 VW Polo mk1 resto, pic heavy... updated 20/8

UPDATE TIME

Got loads done over Easter and have really got my motivation back, so heres some pics of whats been going on...

Picked up this (in the boot of the saloon ofcourse) from Newcastle on my way home from uni. Got ridiculously lost in the city centre at rush hour, which wasn't enjoyable, but made up for it when I was told what power it made with its previous cam and bike carb setup



Its the engine I wanted to put together myself, Mk3 Polo 1300 GT head and Mk3 Golf 1400 bottom end. I already had a full 1300 GT and was going to scour the scrappies for the bottom end at Easter, but I saw this up for sale, and its all fairly low-mileage, with a little bit of headwork too. So couldnt say no really!

Ofcourse I couldn't wait to trial fit the package which was waiting for me at home...



I'm after all the associated fueling bits to set them up, I've put a wanted post up and would really appreciate it if anyone could help me.
retrorides.proboards86.com/v45index.cgi?action=display&board=FSW&thread=38721

Shell-wise quite alot has been happening too. Nearly all the interior is in primer and all the welding on the floor has been completed.

Battery tray












Just need to attack the old adhesive on the roof not and primer that. Then its ready for a decent coat of primer and paint

Outside quite alot has been going on too. Removed the rear valance as it had a nice dent from the towbar (the car had a 895cc engine std, whats it going to tow!?)





Copy arch repail panel bit fits nice aswell



This all awaits welding next time I'm home.

And to the front of the car. The inner wings had been bugging me for ages, they were really rotten and needed to be replaced. But no repair panels here, just some sheet metal and a hammer

Before





After









Really happy with how they turned out ;D

Before I moved to Uni last year I'd painted the whole front clip in clear POR15. I don't doubt its effectiveness (I better not as the whole underside is painted in it!) but I didn't like the look of it at all and wasn't happy with the finish in places, nor laying primer and paint over the top. So it all came off!

Before



During



Plated up the holes for the fusebox as all the wiring will be hidden (more on this later)



And I also did this, makes working in the engine bay SOOOO much easier! Just got to wait for my replacement from Germany to turn up now.....



After all the bay was bare-metalled I gave it a few coats of high build etch primer.





Couldnt resist sticking the engine (on our new engine stand for a pic

great thread Tom

keep up the good work, it will be awsome once its finished

Huge amount of work there , fair play to you. Looks great so far

looking good. For those people looking in awe at tom's workshop i've been there, and it really is the coldest workshop i've ever visitied. We had to huddle round the lights to keep warm lol.

Matt

That is some seriously narrowed beam action going on there - how does it manage to steer - glad its getting the proper 'Rat-look' treatment, I.e solid immaculate underbody with the essentially solid but tatty shell on top Please tell me its got/getting a hot motor in the back?

Work on the Polo is continuing at a pace - and is looking really good. Will be good to catch up with you again in June @ club charlies

P.S; thats the kinda a roofrack i'm after (in your 1st picture)

Dan- Its a 6 inch narrowed beam, you should see the tuck when its on the original wheels! (which he'll be reverting too) 125 tyres! Unfortunately it's going to be running the stock motor for now, I feel the same way about a blown motor but he wants to keep it original. That and the cost/power of tuning them isn't too economical either.

And it doesnt steer too well if I'm honest. Should be better with the 'crows feet' steelies as they're alot thinner than the current Randar reps.

Roof rack was a scrappy special, Paddy Hopkirk one aswell! It's for my mk2 though. Just need to customise the brackets so it sits a bit lower and then it will be loaded up with the obligatory 'scene' items haha

I'm not certain I'll like it to be honest. Was thinking of polishing it up and selling it on if not, I'll let you know first though.

See you at Charlies!

Matt- Ai feel free, especially in Ben's new mk1!

Hi Gav, sorry only just seen your post, mk1 looks very cool. I unfortunately have no idea about painting, as you, I've never done it myself, rather scared about messing it up but lots of reading and practice beforehand I think! If you're not on already check out the forum on www.mk1polo.com

Anyways... update time! I trial fitted my replacement front valance a few weeks ago (Stupid money off german eBay - mate then proceeds to find one in local panel place for £60 : with the wings (one NOS, one copy) and all panel gaps and fit looks pretty good.



Been home for the last week after most of my uni coursework is done so got down to some work on the mk1.

Well, I say I did, but it was nice to come back to the rear valance welded on courtesy of my mates I let use my barn (57 bug, 79 derby) Cheers lads! :rolleyes: I ground the welds down and zinc primered them, then trimmed and folded the corners slightly. Also re-made the brace between it and the spare wheel well.



I made a repair plate for the scuttle panel (see note :lol:), the amount of angle was a ball-ache but it turned out pretty good. Had to weld a nut underneat for the bonnet hinges as I'd sheared the bolt off the old one so had to dremel it out.

Before


Now


Ground back and zinc-primered most of the inner wings where I couldn't attack the surface rust properly with wire brushes last year. Once the front valance is on and any other plates I'll gravitex these before primer.



The base of the A-pillar needs a bit of attention <_<



I've made plates for near enough all the holes left to weld, there's a couple on the rear valance from the towbar :angry: a tiny one in the floor and a few in the engine bay. Also chopped and angled up some box section for chassis leg strengthening. We'll weld the front valance on just about last after everything in the bay is done and in another decent coat of etch primer. I've also got to grind and treat the rear arch lips, and bare-metal and zinc primer the scuttle panel.

Actually feels like I'm getting somewhere with it, really can't wait to see it all in primer and no red bits left. Going to concentrate fully on bodywork now and not get distracted by any painting and polishing of engine bits.



Heading back up to uni for a long weekend tomorrow then after a little euro-trip in the loon the weekend after I'm back for good so I can really get moving

Thats a classic look there, here's one i owned previously

Engine bay smoothing... bye bye heater!



Mmmmmmmmm new compressor!!! Should be wired up by the weekend and suffice for paint and most air tools



Gazebos? They'd be for the roof....



Matey pondering what I've got myself into with all this smoothing malarkey!



(note rather cool supercharged early mk2 saloon )

Getting to work on the 'what appeared perfect before I rubbed them back' rear arches



Primer time



No way! There's an engine in there for the 1st time in 18 months!



Checking clearances for the modified brake servo linkage



The standard master cylinder position is directly off the pedal box. This was going to be rather tight with the carbs anyway, so after chatting to a mate in the know had a go at this.



Lever mechanism is modified to fit the smaller mk3 polo servo and peugeot MC (for the outlets on the correct side) and ensure the pedal fully engages/dissengages the servo.



Mocking up a 38mm trumpet to check clearance on pedal box end of the mech.



Front panel ground back to bare metal where necessary (lots!) and zinc primed. Ready for welding on tomorrow