Polo on roids

[Guy_H]

Thought we would honor our poor little Polo with a fresh thread: A list of the mods our little baby has had so far:

APR K04, software flash, EMCS switching system (including race gas program)
High flow transverse manifold
Modified intake pipe (39% better flow)
Billet steel flywheel & EVO ceramic clutch setup
BMC CDA with battery modification
APR front mount intercooler
APR 2.5" stainless turbo back exhaust with metal catalyst
TT 228mm front brakes & greenstuff pads all round
Martini GS 610 brake fluid (much better brake feel)
Oettinger 17" rims & Toyo proxes 888 street rims
S3 Rims & Toyo semi slicks for weekends
V3 coilovers (work in progress)

But apart from that, its all stock ;)

Its one of our most fun cars, accelerates like a motorcyle

http://www.ozaudi.com/projectPOLO/12-10-2006%20033.jpg
http://www.ozaudi.com/projectPOLO/03-07-2005%20479.jpg
http://www.ozaudi.com/projectPOLO/03-07-2005%20477.jpg

[Guy_H]

http://www.ozaudi.com/projectPOLO/03-07-2005%20474.jpg
http://www.ozaudi.com/ebay/Polo/S31.JPG
http://www.ozaudi.com/projectPOLO/03-07-2005%20455.jpg

[Guy_H]

http://www.ozaudi.com/projectPOLO/03-07-2005%20457.jpg
http://www.ozaudi.com/projectPOLO/03-07-2005%20452.jpg

[ryan_GTI]

omfg.... *droolz*

hows the torque steer guy?

[shaneth]

Mate this truely a work of art. Cant wait to get started on my polo.

[SidGTi]

Nice! How much power is it making with those mods?

[GoLfMan]

whens the massive turbo coming?! :D
awesome mate!

[FL00DY]

Hey Guy. You know I've been following the Polo thread on the tex, but it's good to see these pics and the mod list in one post :D


How much is the intercooler and piping work going to be? Is it easy to install? Also I've been looking for a Workshop manual for the Polo, from Bentley or someone else. Do you know of one?

[PoloGTi]

Hey gee that Polo is my insperation love it to bits. cant wait to get my little beast like that must be so much fun to drive. Might have to come up one day to get a ride. :) cheers Guy sweet car.

[Guy_H]

Thanks everyone, as soon as we drove the new Polo early this year, we knew the potential of the 1.8T in this lightweight frame.

Torque steer is not too bad, I suppose you grow accustomed to it & adapt - certainly the MKV GTI is much easier to drive fast.

The clutch is different to all other 1.8T's and it was the first victim to the 104race gas program & some silly take off action.

FMIC kit will be around the 2k mark, all bolt up with a tiny bit of dremel work to the plastic radiator panel, notching of the metal bar support but no cutting to the front bar cover so its easy to return to stock. So you should be able to do a home install with jack stands & a good tool set.

Have a 260kw kit sitting here (and a 300kw kit) but not sure whether to do it or not :? it would be complete overkill, but we could say - yeah - we did it!

http://www.ozaudi.com/projectTT/12-10-2006%20008.jpg

[DubSteve]

Gday mate,

Great little car you got there.

Aren't you Guy Harding from vwvortex? That car is your project car thats on it. It's pretty good been following the progress.

Hows the progress of the Golf project going?

[Guy_H]

Hey Steve, thats me - will do a post on the Golf soon.

My Dad's borrowed it whilst his car is at the panel shop - he doesn't want to give it back to me :rolleyes:

[DubSteve]

Hey Steve, thats me - will do a post on the Golf soon.

My Dad's borrowed it whilst his car is at the panel shop - he doesn't want to give it back to me :rolleyes:

It puzzles me as to why we wouldn't want to give that back to you.j:

Keep up the good work mate. Two very fine looking dubs you have:)

[Guy_H]

Couple of pics with the "war wheels" on it today:

http://www.ozaudi.com/projectPOLO/12-10-2006%20045.jpg
http://www.ozaudi.com/projectPOLO/12-10-2006%20047.jpg

[GoLfMan]

looks horn with those rims on mate :D
you havta do the 300kw kit!!!!

[KI11Z]

! 300KW !

haha, do it! It'd be nutzo! Although you probably wouldnt go anywhere and you'd need a big tyre sponsor! . . . Great work! :D

[Flaps]

Love the wheels Guy :)

How much for the CAI/Filter setup?

[Guy_H]

Hey Flaps,

The CDA airboxes are about $650 - the adapter hose is about $120.

The battery job is the tricky part - we used an Odyessy compact battery which is a third of the size of the stocker, fabricated a clamp set. This gave us a heap of room for the CAI. You could relocate the battery to the boot, but by the time you purchased cables, it just as practical buying the smaller battery.

[DVR68U]

hey mate nice car , keep up the good work
cheers brenton

[DubSteve]

Those rims look really nice on that car Guy.

[Guy_H]

OK - the next stage has been completed,

The little POLO now has an awesome set of stoppers :)

13" Alcon monoblocks on 28mm Alcon discs - saves about 1kg per disc.

All I can say now is STOPPIES :)

new suspension next week & then the Dutton rally starting next Friday:

http://www.ozaudi.com/projectPOLO/DCP_3182.jpg

http://www.ozaudi.com/projectPOLO/DCP_3183.jpg

[Guy_H]

http://www.ozaudi.com/projectPOLO/12-10-2006%20051.jpg

[Kai]

Looks awesome guy.

You have done real well :D

[Guy_H]

Thanks kai,

Last Saturday we had a track training session & this little puppy impressed the instuctors soooo much. In a Motorkhana, the thing is just so quick it easily outpaced everything else there (including our 300kw TT - just not nimble enough!).

In typical MK1 golf fashion, the inside rear wheel would sit inches above the ground going around the witches hats. looking forward to some action pics of the little fellow :)

[DubSteve]

Awesome work there Guy great stuff there mate... Hows the Golf process going your father still have it?

[Bug_racer]

So the TT now makes 410+ hp ? Looks like Im gonna need a milkcrate to save enough weight to make our power to weight the same !

So whens the Polo going to the drags ?????


edit spelling

[Guy_H]

Awesome work there Guy great stuff there mate... Hows the Golf process going your father still have it?

LSD is sitting here for it & new fuelling in the next couple of weeks - and another slightly larger KKK turbo in May (for around 350+hp up from the 310hp it already has). My father loves all our cars, especially the get up & go of the Polo & Golf!

The Golfs in the Dutton Rally next weekend as well as our other two cars - a celebrity & an experienced pilot who neither have piloted a golf before - should be interesting.

[DubSteve]

LSD is sitting here for it & new fuelling in the next couple of weeks - and another slightly larger KKK turbo in May (for around 350+hp up from the 310hp it already has).

Love to hear some details about the Golf any pics of its development, would be great if anyone on here wanted to do anything to there Mk5.

[TassieGTi]

Looks awesome :D Love the brakes :cool:

[GoLfMan]

thats fantastic, i love this car :D

[gtimk5]

Looking forward to next week Guy. Hope everything is done up tight, dont plan on getting my hands dirty!!!! :D
I will be getting some good shots to I hope!:)

[gpk_gti]

wheres the parachute??hej: he
nice car mate!!well done!!love the war rims:D

[Guy_H]

Hey Andrew, Alex is out there with the 9" breaker bar as we speak :)

Should be a great weekend :cool: might be a little warm

[gtimk5]

Alex is so small he couldnt pick up a 9" breaker bar!!! LOL!:D
Will be a great weekend as long as your drought doesnt break!!! Geez! I am really looking forward to it. Polo is looking great too! Be a lot nicer than it was in vic? Had std suspension and brakes then,,,,,
Cheers, Andrew :)

[quozl]

Guy car looks brilliant, can't wait to see it on the stages.

Andrew just keep that esky nice and full & cold and you will have done your job perfectly.

Cya on Thursday.

Cheers Al

[gtimk5]

Good onya Al, looking forward to hearing that awesome R32 too. !!

[quozl]

Good onya Al, looking forward to hearing that awesome R32 too. !!

Andrew,

It sounds much better from the drivers seat :-) Your welcome to have a blat during the weekend if you want to give it a run. There are some good roads around the back of Warwick. Just ask Helga the German barmaid at the Horse and Jockey, she scared the beejeezuz out of me on the Indy Rally after a late drinking sess in the pub.

She had done some rallying back in the fatherland so I let her take the car for a drive with me in the passenger seat at about 2am. Needless to say she could steer a car and tested the limits of the adhesion a couple of times :o

Oh don't forget the VW Watercooled stickers mate.

Cheers Al

[gpk_gti]

guy_h or andrew ,can you guys please tell me who is the APR distributor in Sydney and if they are on forum??
thanks!!:)

[quozl]

guy_h or andrew ,can you guys please tell me who is the APR distributor in Sydney and if they are on forum??
thanks!!:)

I can help if thats okay?
Info from the dealers list on www.goapr.com.au

Derek at European Autotech Pty Limited

4 Polo Avenue, Unit 5
Mona Vale
NSW 2103
tel: +61 2 9979.4484
fax: +61 2 9979.4384
http://www.europeanautotech.com.au
email: derek@europeanautotech.com.au

Cheers Al

[gpk_gti]

thanks alot!

[jasn78]

Hey guy how much for the LSD?

[Guy_H]

We havent got it installed yet, but ballpark installed will be $2300 - 2700

[shaneth]

Is that all then im adding that to my list of mods. ( i say this in a relative sense comparing them to the intercooler or exhaust setup. i would prefer LSd to both of them. In my opinion anyway.) So now i want chip, Brakes, suspension and LSD. Dam you guy making me want to spend all this money. Once i went for the drive in yours it was all over. :D:D:D

[Eddy]

Is that all then im adding that to my list of mods. ( i say this in a relative sense comparing them to the intercooler or exhaust setup. i would prefer LSd to both of them. In my opinion anyway.) So now i want chip, Brakes, suspension and LSD. Dam you guy making me want to spend all this money. Once i went for the drive in yours it was all over. :D:D:D
Hoyhoy.
Hey Shaneth, What was it like.

[Eddy]

Hoyhoy.
Guy, are there any power gain figures with APR's lastest extras [ exhaust & intercooler ]. I can't find any on the site.

[Guy_H]

Hi Eddy,

Have Datalogs on the intercooler, but they are APR ECU Explorer so unless you have that you can't read them. Hopefully the next "closer" to standard car (ie not a K04) we do, we will get a dyno done before & after intercooler. Only get a few peak KW's with the exhaust on the K03, but a good jump in mid range torque.

We have a car to do next Monday - (Chip / exhaust) - if it works out timing wise, we will try to run 3 x dyno's but it will be tight!

[Guy_H]

Is that all then im adding that to my list of mods. ( i say this in a relative sense comparing them to the intercooler or exhaust setup. i would prefer LSd to both of them. In my opinion anyway.) So now i want chip, Brakes, suspension and LSD. Dam you guy making me want to spend all this money. Once i went for the drive in yours it was all over. :D:D:D

Shaneth, it just keeps getting better & better - I'm thinking of using the Polo in the NSW Dutton rally myself - now if we could only gaurantee it will be dry weather, it will be awesome. :idea:

[Guy_H]

OK, the new legs have arrived today :) one click adjustment, in car - front & rear

http://www.ozaudi.com/projectPOLO/12-10-2006%20053.jpg
http://www.ozaudi.com/projectPOLO/12-10-2006%20054.jpg
http://www.ozaudi.com/projectPOLO/12-10-2006%20055.jpg

hopefully have them in tomorrow

[shaneth]

Cost????? Next time im down that way Guy ill have to have another run in it. :D

[Eddy]

Cost????? Next time im down that way Guy ill have to have another run in it. :D
Hoyhoy.
Guy, better watch out, this Shaneth will wear the rocket out.
P.S. Good luck on the week-end.

[gpk_gti]

OK, the new legs have arrived today one click adjustment, in car - front & rear

http://www.vwwatercooled.com.au/forums/
http://www.vwwatercooled.com.au/forums/
http://www.vwwatercooled.com.au/forums/

hopefully have them in tomorrow
ok,,,ive seen internet porn,but this is just too much!!HOT SETUP!!!:D best of luck on the weekend!!

[Guy_H]

Thanks fella's - The Polo will do well, even with its rookie crew - if the weather stays fine, both the Polo & Golf may outpace (will outpace) the TT on all the tight stuff!

[gtimk5]

So Guy, whose driving the Golf now???? We wont tell......... :D

[quozl]

It's not a big secret anymore :) Splashdown!!!!

http://www.duttonrally.com/forms/QLDentrylist07.pdf

Cheers Al

[shaneth]

Al dont you have a CO driver.

[Guy_H]

http://au.i1.yimg.com/movies.aunz.yimg.com/xp/hww/20060614/02/438409197.jpg

[quozl]

Al dont you have a CO driver.

No Dave dropped out, he had something come up he had to do so I'm driving solo this year.

Cheers Al

[shaneth]

Dam hey. Is it hard to be the codriver? :D

[quozl]

Dam hey. Is it hard to be the codriver? :D

No easy as and heaps of fun in the Duttons too.

All you need your CAMS L2S, $1400 to pay the co drivers entry, a legal helmet, neck to wrist to ankle clothing made out of cotton as a minimum and then a room at the host hotels. All meals are included but the grog bill tends to add up at the end of the day :D

Co drivers in the Dutton series actually drive the car on each stage, Driver does the stage gets out then the co driver does the stage.

Where as on the Buller Sprint or Targa the co-driver is a navigator and needs at least a National Navigators license and expierience reading pace notes and working a terratrip of some sort.

Cheers Al

[Eddy]

http://www.vwwatercooled.com.au/forums/
Hoyhoy.
Now thats a ****TY substitute, GUY.

[Guy_H]

Hoyhoy.
Now thats a ****TY substitute, GUY.

Lol - wait till you see the photo's!

Actually he was a very good steerer, has some well earned respect for FWD golfs now :)

[Eddy]

Lol - wait till you see the photo's!

Actually he was a very good steerer, has some well earned respect for FWD golfs now :)
Hoyhoy.
Big mouth again, I must keep more up to date on things.
I just saw the picture & assumed you were playing with us, that, that was your picture. OOOOOOPS again.
P.S. I'm going to shut up for a while before I dig any deeper.

[Guy_H]

Lol -

here's his Autograph!

more pics soon :)

http://www.ozaudi.com/projectGOLF/DCP_3198.jpg

[KI11Z]

. . . . one click adjustment, in car - front & rear . . .

In car? are they electronically adjusted? I know of tein having lil controllers but not bilstein? :confused:

[Guy_H]

Sorry, in car as in you dont have to remove the shocks out of the car for adjustment (ie - Koni's in the rear of these things) you just reach under and turn the knob!- I'm familiar with the Tien units you speak of - neat idea (DRIFTER) :)

[DaveMack]

Just a thought re Polo-roids. The TSI technology for the Golf GT coming out later this year ... any thoughts regarding doing a similar thing to an existing Polo GTI? If a small supercharger, set to cut-out at say 2,500 rpm were used ... it would certainly do away with any turbo lag.

It would be a blast.

[Glide_GTI]

theres not much lag, its not a big turbo, you just need to be in the right gear :)

[DaveMack]

theres not much lag, its not a big turbo, you just need to be in the right gear :)

Thanks for the tip, Glide. I'll try to keep it in mind. :) Problem is ... sometimes my wife drives the car (I can hear the sharp intake of breath from here) ... and (it gets worse) ... she wants a slushbox. Might have to buy her a Toyota or something. :)

[ryan_GTI]

Hey guy - the car seems to be going great! your polo's a true inspiration to us all...

one question... how's the gearbox holding up in the pogo with all the mods and after the dutton rally?

[Guy_H]

Hey Ryan,

Gearbox is going fine - we found that with the stiffer engine mount it firmed the gearshift up & made it more positive.

This week we pull the box out to prepare it for the limited slip differential, and we will put one of our single mass flywheels on (its still running a stock flywheel with our hybrid clutch) - will be interesting to see what the clutch looks like after 8 months of abuse!

Looks like we will be taking the Polo to the NSW Dutton shortly!

[Glide_GTI]

details! would love to see it in action

[Guy_H]

The Polo is almost back on the road - gearbox went in today. Looking forward to some limited slip action tomorrow!

Pictures of the production clutch setups - single mass steel flywheel, EVO pressure plate, organic or puck friction plates (organic for street use) The ceramic one we use in our car - its a little grabby but takes the abuse!
http://www.ozaudi.com/projectPOLO/P5160326.jpg

Also shown are pics of version #3 & Version #4 of our dog bone mounts. Looks like we will have 3 versions with different stiffness. They will probably be sold exchange as they are hard to press in by the home user (not impossible, but difficult)

http://www.ozaudi.com/projectPOLO/P5160327.jpg


Got to drive it 14 hours next week to Goulbourn (wakefield?) for the start of three days abuse at the NSW Dutton rally :cool:

[Flaps]

Nice one Guy. I'd drive the 14 hours for you in it :)

[Wand Weaver]

Just a question about legality here - how far are you allowed to go before you need an Engineer's certificate?

Obviously, swapping a CAI or exhaust isn't going to run you foul of any regulations, but I've always wondered exactly how far you can go before you need a certificate, just out of curiosity.

[Guy_H]

Nice one Guy. I'd drive the 14 hours for you in it :)

Mate, Its almost worth the air fare! - I'll be winding the shocks off to near soft ;)

[Guy_H]

Just a question about legality here - how far are you allowed to go before you need an Engineer's certificate?

Obviously, swapping a CAI or exhaust isn't going to run you foul of any regulations, but I've always wondered exactly how far you can go before you need a certificate, just out of curiosity.

Mod regulations differ from state to state. To the best of my understanding there is no enforceable law on power upgrades utilising to original motor (Ie take a 110kw polo to 260kw).

Funny - adding forced induction requires engineering in QLD, so does swapping motor types to!

Same with Brakes & suspension - you need to check it carefully by your local regulations - I know Julian in the ACT recently had to get documentation from Oettinger in Germany that indeed his coilovers were intended for street use!

[Timbo]

Mod regulations differ from state to state.

Except with the obvious proviso that anything that effects ADR compliance of the car -- and this includes emissions -- can very quickly bring you unstuck in every state, because the ADR regulations are national. Of course, enforcement varies ....:rolleyes:

[Guy_H]

Except with the obvious proviso that anything that effects ADR compliance of the car -- and this includes emissions -- can very quickly bring you unstuck in every state, because the ADR regulations are national. Of course, enforcement varies ....:rolleyes:

Timbo - spot on - emissions is the #1 driving force.

Thankfully the K04 & APR stage 3+ kits are all fully compliant - they even comply with the California emissions law & have been tested in germany for compliance.

I think the fine in the east coast states is still well over 10k for removing your catalyst n:

[Guy_H]

Limited slip differential is in :) nice difference, only did a short drive last night, but the ability to power through a corner is awesome. I dont know what effect it will have in a straight line, but its like a whole different car now :cool:

[SoVeReIgN]

Interesting - Which one are you using, what is its expected life and will you be offering it to all customers?
Also - Whats it worth? :)

[Bboy_Sparx]

Same with Brakes & suspension - you need to check it carefully by your local regulations - I know Julian in the ACT recently had to get documentation from Oettinger in Germany that indeed his coilovers were intended for street use!

Yep that's right.

All I can stress is call RTA and your engineer. My engineer papers cost me $900 so just call and see what you are allowed to do before you HAVE to fork out the big bucks for a signature.

A lot of the time you can get away with a lot of stuff like coilovers as long as the brake line is secured (mine wasn't, now it is with cable ties), but it's luck of the draw.

[Guy_H]

Interesting - Which one are you using, what is its expected life and will you be offering it to all customers?
Also - Whats it worth? :)

Peloquin - we had to work with them on this one as they hadn't done a Polo GTI before. Price is less that AUD 2K - its the install price we have to work out. There is machining required to install (machining the old rivets off) and we had to make the shims because VW & Audi do not stock the correct shims in Australia.

[SoVeReIgN]

Ah okay, I'm assuming its very similar if not the same as the one off the mk4 GTI/A3? - Very interesting in getting one I just don't want it to lose all effect after abit of hard driving..

Mechanical lsd obviously.. Do the shims wear out?

[fuzion]

sov, check ecstuning.com they sell them (penq lsds) about $860us

[SoVeReIgN]

Yep they're the ones I've been looking at, i'm assuming Guys is the same.

[Guy_H]

Its similar to the older MKIv / A3 boxes.

the shims dont wear out, but when the diff goes back together, you have to reset the clearances with shims (the hard to get shims!)

[Guy_H]

Well the Polo & I did our first real trackday together on Saturday at Morgan Park - With the BMW Club & Porsche & Audi Clubs invited.

Well, there were several new RS4's, New 335i's, 996 TT, 997 C2S's, M3's monaro's, HSV's, R32's.

Needless to Say, the Polo had no problem outpacing all of the above. There were a lot of people checking it out in the pits between laps :D

The new diff allowed it to carry huge corner speed - after a few laps i was much more into the FWD mode on drifting out of the corner wide. I dont think I got a single lap perfect, so there is definately more in it yet.

It was really good on the tyres, the fronts were working hard & the pressures running 5 - 6 PSI higher than the rear. Firmed up the rear dampers & had the rear working a bit harder and got the difference to 3 PSI. if we had a bit more time, I would have liked to soften the fronts a few clicks.

I must run race fuel next time as the 996 TT would pull away from me on the straights :cool:

[gpk_gti]

hehe,the little polo destroying the supercars!! they must have been feeling a little pissed:mad:! good on ya:D!! was there any photos guy??

[Guy_H]

hehe,the little polo destroying the supercars!! they must have been feeling a little pissed:mad:! good on ya:D!! was there any photos guy??


Actually they were all very friendly & happy - it was a great day - there were different levels of drivers out there so it wasn't all the cars, but there were a few who were "club" level learner racers like me so it was good to see those times dropping down. I wish I had a dollar for everyone there that did not know what a polo GTI was & does now - priceless :)

[Guy_H]

No Pics of the Polo here - but some nice pics of the other cars:

http://forums.eurocca.net/showthread.php?p=308420#post308420

[PoloGTi]

lol thats so cool so guy the polo is still running the Ko4???

[pologtiguy]

Can we see any videos of the beast? Please please please,

[Guy_H]

lol thats so cool so guy the polo is still running the Ko4???

Sure is - that was just with 98 ron in the tank!

[Guy_H]

Can we see any videos of the beast? Please please please,


need a new video camera! - Hopefully someone else got some pics out on the track!

[shaneth]

awesome work Guy.

[GoLfMan]

bump...

did you end up selling this or putting in the 300kw kit?!?!

[velly_16v_cab]

WOW...only just seen this thread (dont come into the polo section too often lol)

nice build Guy, great to see someone pushing the limits ;)

[Guy_H]

We traded the wee girl, on, another VW!

Would love to have another project car, but the K04 & development work we did satisfied 99% of our customers needs.

Mind you, that new Polo GTI looks awesome, so I can't wait to get my hands on that one!

[Chipped]

Where did you trade it???

[Guy_H]

Local Brissy VW dealer. It was a year ago now I think.

It was put back 100% to stock firstly. It would have been a good buy - tyres, brakes, suspension, clutch, etc - all brand new!

[mikepologti]

hahah this thread brings back memories , one of the original reason i brought the pog was becuase of this thread.