Here can you find all the info about our heart project.
This is the Polo project that we have been dealing around with for a long time and the build process of this project always teaches us something new…
#Introstory – How all started :
The Polo 86c 3f has always been one of the cars that caught my attention alongside the VW Golf, Opel Corsa and Lancia Delta. They all have a great combination of weight, size and shape. But when you are 18years old there’s normally no money for a Lancia Delta … so I decided that the Polo is the one to go.
The first 1.8T engine SWAP 2WD:
The first plan was to only swap the VW 1.8t engine from a Golf 4 GTI into the Polo and modify it with a bigger turbocharger.
After finishing this first build with a theoretical Performance of over 300whp, we decided to break everything apart and build something a bit different. We did this because we would not be able to get enough traction without 4WD.
Start of the Quattro swap idea:
I always thought that All-Wheel drive would be the best in all Ways but at the moment when I saw this Audi A3 1,8t Quattro, I recognized that this is the right moment to put all this AWD technology inside the Polo.
In retrospect: I would probably use a different donor car now with a permanent 4WD system like a Mitsubishi Evo …… But you never stop learning.
The tear down
First, we had to make up a plan, how we will integrate all this AWD drivetrain inside a 2WD Polo. After a lot of measuring on both cars, we were ready to turn the plan into reality.
We planned to put all the AWD underbody with the two-axis, differential and engine mount inside the little Polo. We hat to make several modifications to the Quattro underbody like shortening the wheelbase and the width to be ready for Weld in.
And then we started cutting …
After modifying the Audi underbody, we cut out the needed space on the Polo. Then we searched for a precision method to put the 2 parts together.
We fabricated a steel frame on which we screwed the Audi Quattro underbody on, then we moved it under the Polo
After what felt like 1000 times trying and fitting the underbody to the polo shell, the time had finally come…the floor fitted into the Polo.
Everything was aligned and tack welded, the two pieces became one!
After endless hours of welding and grinding. It was time to test fit all the parts from the Audi inside the Polo. We wanted to make a short test drive before we finally started the racecar build.
So we installed the axles, engine and all the other parts needed for driving. And finally, we were able to drive some meters on the street.
After this successful test drive, we started with the disassembling again.
The racecar build:
We had (and have untill now) a lot of things to do, to turn the Quattro Polo into a serious racecar…
We tried and still try to build the Quattro Polo into a Rally inspired racecar, the engine bay is inspired by the mythical Skoda Oktavia WRC 2002 in which a 1.8t engine was used.
Chassie & Body work:
- A lot of welding and sheet metal work was required to get the body ready.
- We build a custom strut bar for the front and rear.
- A custom roll cage according to the FIA regulations was fabricated.
- We installed custom seat mounts. But they were not completely right and need a rework…
- With the help of german rally expert Haug Motorsport, we build a complete custom made bodykit for the Polo.
- Shortened the prop shaft to fit under the Polo body.
- We welded in 4 mounts for the racecar pinstands.
- Still not finished…Building a completely new tubular frontend that contains all the radiators and the intercooler and holds the bumper.
- We cut out the original strut towers and had to fabricate new custom strut towers to mount the new BMW e46 Camber plates for full adjustability.
Engine & electric
- For our Ecumaster EMU BLACK we had to make a completely new wiring harness that includes Lights, Engine and CAN BUS for the original Haldex 4WD system.
- Fabricated a sidewinder tubular exhaust manifold for the Turbocharger inspired by the Skoda Octavia WRC, with a fresh air Anti-lag system.
- Complete rebuilt engine with forget parts, sinter clutch lightweight flywheel and some Special WRC parts.
- Engine characteristics should be the same as in a Rallycar.
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