VR6 Conversion......

[Drizz]

Hi guys, although not strictly a Seat its more like a Seat than a VW being the Saloon, so i thought id put it here for you to see. Ive asked a few questions on the conversion, and read some others on here too but hopefully you can help me out during my progress. Ive copid and pasted from another forum so may seem a bit messed up but ill update it regularly from now on. So here goes from the beginning starting on January the 2nd......


I recently gave into my Mrs and went sensible and bought a 2005 330d for daily duties. Therefore my toys needed to go, so my Mk3 VR6 has gone to my Mum and sold her Fiesta, my Audi Quattro Sport Turbo has gone to my Dad and we will sell his Merc, and ill have my Defender build to carry on with (see here: http://retrorides.proboards.com/index.cgi?board=readersrides&action=display&thread=77251) but as I well and truly have the dub bug I need something VW to play with as the caddy I also had has been sold to help fund a Transit and the 330d cant be tinkered with under order of the Mrs.
Now, before christmas I agreed to purchase another VR6 as a breaker, as I wanted to keep an engine in stock for a future project that hadnt been decided yet, and flog the rest to make the running gear as cheap as possible or even free! Then the next day a little Polo came up for sale on my road and then the plan hatched!
So firstly take this for breaking:

Purchase this 100bhp 1.6 8v Saloon with 64k and pretty mint:

Convert to the mk3 Ibiza Cupra front end at some point in the future:

Install these:

Fit some banded steels:

Strip rear interior to fit one of these (look through the rear window)

So it just needed to all come to life.
Ive done some research, and the whole subframe transfers over which means, VR everything including uprights, hubs, brakes wheels etc, and the rear hubs will bolt up to the Polo rear beam for the full 5 stud conversion. Also using the VR front ends means I can use VR6 coilies up front too.
Only issues with the VR frontage is its width. Apparantly the strut tops are about an inch in each side to where they should be on the VR which means premature inner CV wear, and also the VR track rod ends cant be adjusted too much once lined up on the Polo, so I think I can use Ibiza Cupra shafts, and the original Polo rack, but I'm still to clarify that. Ill also need to take the VR cable shift over to the polo, and get an Ibiza diesel pedal box as the the VR is Hydraulic and the Polo cable, but being the same platform, hopefully the Derv Ibiza hydralic pedal box will make it all do'able.


Using a friends setup:

they're both back in my workshop........

 

[Drizz]

Started stripping the Golf with the couple of hours I had spare.....

And it came with a boot load of spares to sell on to make it even more free lol:

So once the golfs stripped, I can cut it up and weigh it in then begin on the Polo. If there is any interest ill carry on updating this too




This was said over on another forum:

[quote author=ims board=readersrides thread=94827 post=1224391 time=1294000670]also sit the vr6 in a mk2 cupra front assembly ive just sold one but I think ive another coming in soon, mk2 cupra runs same box as vr, you can put mk2 golf wishbones on mk3 golf subframe to sort out your widetrack issues this is what the mk2 cupra uses, so VR subframe, Mk2 Golf wishbones, and Mk2 Ibiza cupra shafts[/quote]



Any of that right??




Right so today in a bid to make life easier in stripping the golf I got creative. Upon Si's recommendation we are going to get the VR running in the Golf first to be 100% sure its a goodun before transferring it over. So back to today. A little while ago I had some dolly's which made life a lot easier moving a car around without wheels, but sold them in a deal a few months ago. Once I missed they're convenience I decided to buy some castors and make my own

So now the golfs on wheels again

 

[Drizz]

The hoist works:

So today then I carried on stripping the Golf.
Cut the roof off ready to get the dash out without restriction.
Here I'm just waiting for the screen to give way:

Then once id had, lifted out the way:

I did a few more bits not related to the project so I wont bore you with that!
More to come later in the week.....




Today then!
So got the hoist into action again:

And got the beam off and tank out:

 

[Drizz]

Then got the 9" out:

Then carried on:

Then tidied it up ready to get weighed in:

Just waiting for the ECU to turn up this week, and also still hunting for a sump and we can get it running

 

[Drizz]

Well today I scrapped the rubbish, and positioned what was left ready to get on with. Sumps due tomorrow, gaskets ordered just need to sort bolts! Once it was positioned I rigged up a battery and leads and turned the key. It turned over so at least its not siezed lol

Had an hour today, and because I'm still waiting on parts I decided to just strip the front of the polo cosmetically (not mechanically until the VR is a definite runner) and got the dash out the VR shell....

So with everything we needed, Si and I went up to get her running.....
Suffice to say it wouldnt run, so either the engines shot, or our feeble hand fuel pump wasnt enough.
TBH the noises it was making whilst turning over were bad so we reckon its fooked. Anyway I'm in profit already with the bits ive sold off it so buying another donor isnt a problem. ill use this one to get it mocked in the polo so we can just swap it for a goodun (thats if I don't deck it, rim it and use it as a 1.6 till a suitable engine is found!)

Heres Si looking pretty:

So today I went back up there and started work:

Slotted the Cupra bumper on for now to save it kicking around the floor:

 

[Drizz]

Then carried on stripping:

So the left over shell is ready to scrap, and I need to decide whether to strip the Polo now, or start using it really.....

 

[Drizz]

Sooooooooooooo, today then!
Started on the Polo:

Progress is being made






So thats what we are up to. Ive just read Pesha's thread and he is using the following:

VR6 front crossmember
VR6 Front Subframe
Polo Rack
VR6 Wishbones
VR6 Shafts
VR6 Hubs
VR6 ARB
VR6 Brakes
VR6 Front struts
Ibiza Rear Axle
VR6 Rear Stub Axles with spacers between the hub and beam
VR6 Rear Brakes
Ibiza Rear Suspension


I know the inner CVs are prone to wear but is that all i need to worry about using the above setup? Just need it clarifying once and for all before i buy/refurb bits etc etc....

 

[Torred1771]

Props to ya mate for doing all that work, looks like one hell of a project. Dont mean to sound nasty about it, but wouldnt it have been cheaper and much easier to buy a Mk3 Ibiza Cupra to begin with?

 

[Drizz]

Not really. All in the two cars owe me £100 now!

 

[MillsyFR]

Bloody hell, how much time do you have on your hands? Looks like an impressive conversion. I know some one who might sell u a vr6 charger kit if your interested?

 

[suj]

love projects like this

 

[Drizz]

Bloody hell, how much time do you have on your hands? Looks like an impressive conversion. I know some one who might sell u a vr6 charger kit if your interested?

I own my own company so i go in for a couple of hours to make sure everythings ok, then get down the workshop two or three days a week....

 

[MillsyFR]

I own my own company so i go in for a couple of hours to make sure everythings ok, then get down the workshop two or three days a week....

Lucky man, wish I had the time and know how to do something like this. Have you planned a date for finnishing it? And where did you get the banded steels from?

 

[Drizz]

I did have a date in mind in early may but i doubt itll be ready by then TBH
If the donor engine does work then maybe, but if not then i need to fund a donor first....

 

[Drizz]

Oh and the steels are a google pic. Not got any yet although i have a contact who can band them....

 

[Zlash_eX]

Looking complicated
Looks interesting though, wish I could do something like this at some point.

 

[Drizz]

Its not too complicated. As im new to VW from a long Opel/Vauxhall past its harder as ive got to forget the vauxhall stuff and relearn how the dubs work, but it should be simple enough....

 

[cus]

immense! loving this, subscribed

 

[Drizz]

Thanks again

 

[Juhuts]

love projects like this

QFT
Looking and sounding sick project. Im gonna follow this project till its finished