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Old 02-08-2015, 04:20 PM   #1 (permalink)
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Grochu modding thread - eco gasser (image heavy)

Hi Guys,

This is my new thread about modding my Polo 1.4

I've worked on it recently and the plan was to install MPGuino and kill/start switch. Here are the results.

First thing was to tear apart the dash to get access to the electric harness.


Then I've installed some cables for MPGuino feed and the kill switch.

Injector signal cable

Kill switch relay - it's cutting hall sensor signal


Since my gear shift knob was made of aluminum it was almost impossible to cut the hole for the kill switch. I wanted to put it the same way as I've made it in Berta

I needed to fabricate a new knob. I used a piece of oak wood (that is over 80 years old!)
Fabrication process:




Kill/Start switch and the knob finished


Finally I was able to install MPGuino:



If you wonder where is my radio


On the outside of the car first thing I just needed to do was to limit the air going through the engine bay:
Just a duct tape, some pipe insulation and stainless steel wire mesh



That's all for now. More to come soon (hopefully)

Now I need to calibrate MPGuino

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Quote:
Gerhard Plattner: "The best attitude is to consider fuel saving a kind of sport. Everybody who has enough money for a strong car, can drive fast and hit the pedal. But saving fuel requires concentration, self-control and cleverness. It's a challenge with the nice effect of saving you money that you can use for other more important things."
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Old 02-08-2015, 08:12 PM   #2 (permalink)
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Nice work on the shifter knob and kill switch.




>
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Old 02-09-2015, 05:54 AM   #3 (permalink)
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Quote:
Originally Posted by AndrzejM View Post

First thing was to tear apart the dash to get access to the electric harness.
VW sure have a habit of making things easy to work on, don't they?
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Old 02-09-2015, 06:53 AM   #4 (permalink)
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Quote:
Originally Posted by oldtamiyaphile View Post
VW sure have a habit of making things easy to work on, don't they?
Sure they do But I've seen worst too
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Quote:
Gerhard Plattner: "The best attitude is to consider fuel saving a kind of sport. Everybody who has enough money for a strong car, can drive fast and hit the pedal. But saving fuel requires concentration, self-control and cleverness. It's a challenge with the nice effect of saving you money that you can use for other more important things."
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Old 02-09-2015, 07:12 AM   #5 (permalink)
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Kill switch details:


I just cut in the signal wire between the hall sensor and ECU. Relay is controlled by the switch on the gear shift knob.

Start switch details:


Start switch on the knob controls the relay that is connecting wires that are going from the ignition switch.
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Quote:
Gerhard Plattner: "The best attitude is to consider fuel saving a kind of sport. Everybody who has enough money for a strong car, can drive fast and hit the pedal. But saving fuel requires concentration, self-control and cleverness. It's a challenge with the nice effect of saving you money that you can use for other more important things."

Last edited by AndrzejM; 02-09-2015 at 07:38 AM.. Reason: Error in one of the diagrams
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Old 02-09-2015, 07:30 AM   #6 (permalink)
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Awesome build so far! I, too, love the shift knob.

Keep us posted!
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Old 02-09-2015, 12:42 PM   #7 (permalink)
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Nice job on the wiring and shift knob! I really like the VW Lupo and Polo models. Since your previous builds were really well done, I'm sure this one will be great too!
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2000 Honda Insight MT Silverstone Metallic #95 (CAN) 131K mi. 81.7 Lmpg
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Best commute : 130.8 MPG (US) | 157.1 MPG (Imp) | 1.8 L/100Km | 54.84 Km/L
Best Trip : 111.8 MPG (US) | 134.3 MPG (Imp) | 2.1 L/100Km | 47.53 Km/L
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Old 02-09-2015, 02:51 PM   #8 (permalink)
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First ride behind me. MPGuino needs calibration - definitely, because readings are way off. All other things works flawlessly. Kill switch and start switch works just great, but knob needs some work though... It's a bit to big and I want it to fit my hand as it should.

Thanks for the kind words.
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Quote:
Gerhard Plattner: "The best attitude is to consider fuel saving a kind of sport. Everybody who has enough money for a strong car, can drive fast and hit the pedal. But saving fuel requires concentration, self-control and cleverness. It's a challenge with the nice effect of saving you money that you can use for other more important things."
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Old 03-09-2015, 07:34 AM   #9 (permalink)
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On last Monday I got info, that i need to go to Prague. My car was still in pieces, so on Monday evening I needed to put it back together and make some changes I've planned.

Anyway I've managed to fix everything inside the car and to work a bit on the front.

Duct tape comes in handy, as always. Upper grill block:


And then I've managed to make an air dam. I had a rear bumper cover from Opel Corsa, that I got from a local junkyard.


I cut it in half, frlipped over and voila, an air dam


I've used lots of rivets, some stainless steel mesh

I know it looks like a bodywork by Freddy Krueger, but it works pretty well.

On my way to Prague and back I've managed to squeeze out 1129km from relatively small tank with an average FE of 3.83 l/100km (61.41 mpg US)

Not bad IMHO

More changes to come...

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Quote:
Gerhard Plattner: "The best attitude is to consider fuel saving a kind of sport. Everybody who has enough money for a strong car, can drive fast and hit the pedal. But saving fuel requires concentration, self-control and cleverness. It's a challenge with the nice effect of saving you money that you can use for other more important things."
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