1986 Volkswagen Polo Coupe S

[poloaddiction]

Allow me to introduce myself...

My name's Karl, and I have a problem... with collecting Polos manufactured up to 1994.

I have 2 amongst my fleet, but help out friends with theirs where I can.

I also have some slightly more grown up cars amongst the fleet including a Mark2 Golf (being converted to GTi) and a 1983 Audi Coupe GT (I couldn't quite stretch to a Quattro).

Here's one of them anyway. Apologies for the size of the pictures, I hadn't quite got to grips with my image host:

Model: 1986 Polo Coupe S

Engine: 1.3 MH with 4 speed 'box

Suspension: Standard

Brakes: Standard VW I's. VWIIs to be fitted after a rebuild.

Wheels and Tyres: Black Coupe S steels with beauty rings.

Exterior Styling: Getting there...

Interior Styling: Standard 'Denis the Menice'

ICE and Security: Cassette headunit of unknown vintage.

Comments: I've owned this now for over 2 years. It was bought off a member of the forum as a non-runner for £125 with 57K on the clock. After promptly sorting the headgasket, carrying out a service, changing the cambelt and giving it a service it was returned to full (running) health.

As I was getting ready to send it for an MOT, however, serious corrosion to the driver's rear jacking point meant I had to get the welder out. In my quest for perfection, and righting previous bodges on the car, this quickly turned into a restoration project :oops:.

Its laid dormant in the unit for the past couple of years wating for me to give it attention. This month I decided to give it my full attention, and her is where things stand at the moment. More updates will follow.






Old and new:



The nasty bits:


Hole in tailgate below screen seal caused by incorrectly fitted rear screen.


Offside rear arch/valance heavily rusted. This was after the grott was chopped out.

...

[poloaddiction]

Work begins:




Nearside sill was welded where there was some nasty rust coming through from a previous bodge repair of some accident damage.


The tailgate has been welded, de-rusted and de-dented after the hole was found in it.


Another picture of the nearside. The rear arch wasn't too bad, but there was patches of rust coming through. These were chopped out, new metal welded in, and then the repair given a skim of filler.


Rear panel finally starting to take shape after one of the cars previous bumps left it pushed in, and previous filler work was less than decent.


A crease in the rear quarter was sanded back to bare metal to allow the use of the 'pin-puller'.


The rear end starting to look more original now. This was prior to the final bit of sanding, and before the application of tone-chip paint.


24 years of careless and clumsy people's dents removed from the passenger door...


and the driver's door, which was the worst of the pair.

...

[poloaddiction]

Offside rear quarter finished, ready for the first stages of paint.


Rear end completed, ready for first stages of paint.


The MRS has eyes without a face :lol:. The start of more trim coming off in order to ensure a decent paint job. I hope I can find somewhere who can skillfully re-fit the Coupe S stripes!

And what it could look like after all this work :lol: :



...

[poloaddiction]

So, having done phase 1: strip-down, phase 2: repair, this weekend saw phase 3 commence; pre-preparation for paint.

On Friday I managed to grab a bit of time on my breaks to do the last few bits of strip down that were required. This meant the tailgate had to come off, and the doors needed to be removed and stripped down. I also removed the front arch trims and black-out stickers on the B-posts.

By the end of work on Friday things looked like this:




I'm sure you'll agree it looks very sorry for itself! But as was once said you've got to break eggs to make an omellette, so with it looking its worst, it could only start looking better...

Primer on the repaired parts of the car:





It chilled in the booth until this morning when it finally came out to make way for this weeks array of cars in need of repair.

...

[poloaddiction]

So, it finally happened.

The car was fully prep'd last week, ready for the booth this weekend.

Take one of these:



Add some of this:


Apply lovingly to get one of these:



And a pair of these:




Next stage: Rebuild, followed by polish.

[poloaddiction]

Just a quick update to show it going back together. Need to make up some new door membranes.




Some good news today as well. Fitted the fuel tank on Saturday, having had to remove it for having the sills welded. Sorted out some new fuel hose, some fuel and a new battery, and after a bit of cranking to draw the fuel through, she fired up and ran sweetly after 2 years of being pronounced dead.

[poloaddiction]

I finally got around to putting the tailgate back on. This in itself was easy enough, routing the wiring harness and the washer jet hose down the quarters, without inadvertantly putting either of the aforementioned items down the sunroof drains, however, wasn't. With some metal wire and patience things started to fall into place.

Whilst I was faffing around in the boot, I refitted the wiring harness to the rear panel and plugged in the rear lights. I need a new ring terminal for the earth on the number plate lights though, as they currently cease to function. The rear washer bottle was also re-installed and the finished item looked like this:



The front end was all re-fitted and wired up:



Archliners fitted, rubber seals on the A-pillars fitted (they needed fresh adhesive), and then on to the door membranes which were shocking after 24 years, so time to make some new ones:



They look a bit ropey, I know, but with the bracket sticking out for the mirror adjuster, it was hard tro get them sitting right.

With the doors all back together I focused my attention back on the rear of the car, and filled a big hole:



Fitted the wiper motor and interior trim. Filled the inside with cavity wax too to ensure a bit of longevity!

Next week it might finally get polished once and for all, and then the remaining part of the rebuild can continue at the unit. If it doesnt get polished next week, I can turn my attention to fitting the arches and sill covers.

[poloaddiction]

It's back at the farm now, where the final bit of re-assembly can happen. Just waiting on Xmas to come and go so I have a few more pennies to buy more bits for it.

Before it left work, I did a few more bits and pieces to it:






Very close now...

[bstardchild]

Hello Karl

Nothing wrong with an addiction - I have the same problem with old Opels

(plus the odd polo every now and then)

[poloaddiction]

Ahhh Mr 'Child, we meet again after a long absence by myself from UK-Polos.net!

[bstardchild]

Dec 23, 2010 14:51:55 GMT poloaddiction said:

Ahhh Mr 'Child, we meet again after a long absence by myself from UK-Polos.net!

Yeah they moved house again it seems ;D

On a serious note - looks like a very good job you are doing

[pablopancake]

awesome! i too have a soft spot for the mk2 coop! cracking job you've done there

I think i have a set of manuals (blue folder and the guff that goes inside) lying around still, too good to throw out, if you want them, and if i can find them, maybe i can post them to you

[poloaddiction]

Thanks guys!

It's one I had on the back-burner for a while, whilst I bitted and bobbed on my other cars and other people's. In a moment of clarity, I realised I was taking too much on, and just put full attention into this one.

Seems to be a working forumula for now anyway!

Pablo, that would be awesome, as The MRS (Mars Red Shed as it was formaly known) doesn't and hasn't in my ownership atleast had that paperwork to accompany it.

[pablopancake]

Dec 23, 2010 15:07:31 GMT poloaddiction said:

Pablo, that would be awesome, as The MRS (Mars Red Shed as it was formaly known) doesn't and hasn't in my ownership atleast had that paperwork to accompany it.

I'm sure i still have them, i remember chucking a couple of tatty old haynes for the polo, but i'm sure i looked at thhe blue folder and thought "i'll ebay that one day"

pm me your address and if i find it, i'll bang it in the post to you.

[EmDee]

This is lovely, cracking job!

[mrj]

My name's Karl, and I have a problem... with collecting Polos manufactured up to 1994.

hey, i have a similar problem, but with Passats. But one Polo is in my fleet and that looks very similar to yours :



retrorides.proboards.com/index.cgi?board=readersrides&action=display&thread=82042

not much happened to this yet, as a lot of things came inbetween my plans, but i think i'll keep it original (except of detailling,lowering and some nice steel wheels) ....


and the bug bit , as in the next couple of weeks (depending on the snow disappearing) an Audi 50 will find its way to me ....

[pablopancake]

still got the books. pm your address and i'll post in the new year

[poloaddiction]

So, its been a while since I've been about, what with Christmas and New Year festivities, and helping out on a few other projects me and my friends have. My White Polo GT demanding some attention by blowing up its gearbox, etc.

Finally with the weather picking up, and some time on my hands, I got back in to this. It's so close to being ready, but I'm having to put it on hold til payday atleast, due to those annoying things called bills zapping all this months cash, but thats boring, and we don't like to talk about that, so here goes:

Well, with the bodywork completed (virtually), I set about trying to sort some of the niggles with the oily bits. First thing was to sort the handbrake out,as it was seized on, and this was most notable when trying to move it about at work. 2 new short cables later, and removal and re-grease of the main cable to the lever, plus 2 rear brake rebuild kits and it works as it should now :-).

So problem number 2 was the engine firing on 3 cylinders. I mean it ran well for saying it only had 3 cylinders, but back in '86 VW never intended for it to be a 3 cylinder, and neither did I. After much checking of ignition components, removing spark plug number 2 revealed a plug dripping in oil that quite clearly wasn't sparking due to being drowned in oil.

A leak-down test (seen as I'm devoid of a compression tester, revealed the rings had gone on cylinder number 2.

With many fruitless weeks searching out a set of piston rings for a price I was prepared to pay at least, I concluded a replacement engine had to be sought, as whilst getting scarce, these engines are certainly easier to pick up than the mechanical head engines of the late 70s and early 80s.

Eventually a replacement engine turned up virtually on my door step, so this is where the next chapter begins...

[poloaddiction]

The replacement engine was missing:

Inlet manifold
Carb
Exhaust manifold
Waterpipe
Engine mount
Alternator
Thermostat housing
Flywheel

And I'm sure theres a few other odds and sods. This didn't bother me though, as I have the cars original engine, which was mint bar the bottom end.

So, the old engine came out, and the process of swapping bits from the 57k original lump to the replacement engine began.

Here are some pictures, as I vowed I'd take some to update this thread!


Bonnet off, carb off, and coolant being dropped.


Back into the workshop to undo gearbox/engine mounts and driveshaft bolts.


Out she comes!


Farewell old engine! You didn't serve me well!


I need to get busy with the degreaser I think!


Old engine raided of missing parts. Just the clutch and fly to come off, then its about ready for scrap.


Replacement engine about 75% built up. Just waiting on the clutch from the above engine, then the gearbox can go on and the whole lot me re-installed.

So I had a few bits to source through work:

Waterpump
Flywheel bolts
Carb bolts (holding carb to inlet)
Exhaust manifold nuts and washers
Alternator belt

...

[poloaddiction]

The flywheel and clutch were nabbed from the old engine, along with the head.

I managed to build everything up so its virtually ready to go in.

I'll give it a quick degrease, but as I don't think this engine will be a permanent fixture, I wont be going to town on it.


Replacement engine built up, bar waterpump.


Car and engine come face to face once again.