Rob's '98 VW Polo Build Thread

[robchalmers]

Hi everyone and welcome to my build thread for my ’98 VW Polo.
Seeing how the Polo hasn’t been released in the States it may look a bit odd (Think you might get the next generation polo under a different name) basically it runs the suspension from a mkII rabbit and came with 1.0 sohc, 1.3 sohc, 1.4 sohc spi, 1.4sohc mpi, 1.4mpi dohc, 1.6 sohc and 1.9diesel in the ‘6N’ version I have here – mine’s the 1.4 Mpi sohc it’s a great lil gusty mofo and really takes off when you squeeze the volume pedal at 70mph – that partly because it was designed for the German Autobahns before they started putting speed limits up over there, even though its shorter than the rabbit its incredibly stable at speed and will sit effortlessly and silent at 100mph all day every day (if it were legal). Although the car is now 11 years old there are no clunks bumps or bangs from the suspension of creaks etc from the interior.

My Plans
Basically I want to make the car reach 50-55MPGuk on the highway – but without the need to do P+G etc. Basically I’d like it if my fiancée could get in it and drive it in her usual carefull manner and return that figure.
The areas I’ll be looking at therefore are:
Crr (tyres/alignment/transmission/engine)
Cda ( front splitter/underpan/kamm/wheel spoilers/’DTM’ mirrors)


Side


¾ view


Inbuilt spoiler (barely see it) in the metal work


rear - need a Kamm

So far I’ve started by adding the grill block, mainly for temp testing – its running a little too hot at the mo – fans come on when slowing below 30-40mph. Saying that we’re in a ‘heat wave’ here at 90-100 degF (its all relative)

Version 1 – brought to you in association with Duck tape!!!







Next Steps:
Version 2 grille Block
Skinny standard wheels (155/70/13)
Wheel alignment (currently seems to scrubbing with a far bit of toe-out)

[robchalmers]

now running a modded 'version 2' grille block as the fans where cutting in. Version 2 survived 3hrs of stop/start/crawl traffic on the way home.

version too has a large lower opening and a more covered top grille.

mileage on this tank is going to be a little messed up - P&G Hi consumption issue / 3hr crawling in traffic etc it'll be a miracle if i see any improvement!

[SVOboy]

Radical spoiler

[robchalmers]

Factory stock - cool huh!

[Daox]

Nice car. Looks like you got a long way to go though if you're getting 40 mpg now. Good luck with it!

[robchalmers]

Have faith, fellow ecomodder, have faith.

Just converted the Grille blocker too slime tape (translucent green duct tape), added Buffet Stips to the vertical trailing edges of the rear quarter flanks. removed anothe 5 lbs of plastic trim from in and around the car. Oh and created a mirror edge cover that folds up when the mirror is depolyed yet is taught and redirects the flow when the mirror is tucked in.

I'd put pictures up but my camera battery has just died!!!

[NeilBlanchard]

Hi Rob,

If my xA mods are related to your car, I think you might find that completely blocking the upper grill will increase the effectiveness of the lower opening. If the lower opening ends up in the 4"x14" to 5"x16", then you'll be in the same situation. If the lower opening is closer to the bumper -- as near as possible to the stagnant point as possible, it may be better performing as well.

I have been able to keep the temps stable and in the same range as normal, with just the small lower opening -- and I've sealed off the chin area so that all the air goes through the radiator. The fan does come on more often in stop and go traffic, though.

I'd add a foam gasket along the front edge of the hood, to keep air from entering underneath.

[robchalmers]

Hmmm like the foam gasket Idea! and yeah I found that too with the total blocking of the top grille is much better. if only I could find some batteries to do some pics of the new grille blank - I also kinda 'borrowed' your zig zag tape /buffet strip idea ahead of the trailing rear quarter edges.

Been thinking about making wheel discs out of clear self adhesive vinyl sheet.??? and keep it taught.......

[robchalmers]

Just had to rejig my fuel log as i put in the wrong Conversion figure between imp gallons and US gallons - worse mpg

However even with the three hour traffic nightmare durin last week I still manages to squeeze and extra 15mile out of the tank tahnks to the grille block, pressures etc.

now running 48psi front 45psi rear (to help stability)

sorry i haven't done photos I was away racing yesterday.

[Southcross]

I want a Polo