Kevin Abbott Posted January 29, 2011 Share Posted January 29, 2011 I love the colour of that! Awesome Quote Link to comment Share on other sites More sharing options...
Devil Fish Posted January 31, 2011 Author Share Posted January 31, 2011 (edited) Yes, some annoying set-backs, but thanks to Retro and Paul for helping to point me in the right direction... Just been spending some money radiator ordered, headlining ordered and hose for catch tank ordered... trumpet socks (temporary measure before getting custom plenum made) have arrived today... Hopefully we can busy ourselves with the servo until the other bits start arriving Edited February 1, 2011 by Devil Fish Quote Link to comment Share on other sites More sharing options...
Devil Fish Posted February 2, 2011 Author Share Posted February 2, 2011 (edited) Bumperage How to fit a Polo servo (Disclaimer: this is a rough guide only, I take no responsibility if you follow this and your brakes dont work!) Firstly, thanks to Paul Newport (legend!) for guidance. Source a Polo servo: part number: 868 612 105 As you can see from the pic below its smaller than the manta servo and so frees up some much needed space around back of the c20xe/throttle bodies for pipes/custom plenum etc. However, it is not a straight swap due to the push rods being shorter. So to deal with the master cylinder side, we need a piece to fit inside the cylinder to engage the rod inside the servo... we happened to have a spare rod from an old knackered servo so used this. (It is massively important to measure everything first (and triple check!), so that the distances remain the same, otherwise as mentioned above your brakes either wont ever come on or will be on all the time, either of which could be considered non-desirable)!) We then drilled into the end to make a nice socket for engaging the end of the rod inside the servo. ...then insert into the master cylinder Now we need to deal with the pedal end... a threaded bar (we used a normal m10 bolt) is required to extend the pedal end rod. Taper off the ends of the rod on the servo and the bolt to form a nice groove between the two ready for welding. (Remove any zinc plating etc). Line up... Weld, we used some grips as a heat sink, blobbed some weld on then blasted it with air from a compressor to keep it cool (rinse and repeat), then file until smooth and presentable, not that anyones ever going to see it again (hopefully)!! Measure your distances again, cut end of bolt off leaving enough for adjustment, and screw the manta servo fork and lock nut back on. Modifying a polo servo to fit a manta, done! Edited February 2, 2011 by Devil Fish 2 Quote Link to comment Share on other sites More sharing options...
Kevin Abbott Posted February 2, 2011 Share Posted February 2, 2011 Very nice 'how to' Could you duplicate the post and add it also to the tech mods page? So it doesn't get lost in projects as this is fantastic replacement Quote Link to comment Share on other sites More sharing options...
Devil Fish Posted February 3, 2011 Author Share Posted February 3, 2011 Thanks for the kind words Kev. With the servo and master cylinder out we turned out attentions to the area of the engine bay underneath... sanded back and primed ready for a couple of coats of anthracite. Quote Link to comment Share on other sites More sharing options...
stradacab Posted February 5, 2011 Share Posted February 5, 2011 Just a splash of colour and laquer. We've also painted the master cyl and servo Quote Link to comment Share on other sites More sharing options...
Devil Fish Posted February 8, 2011 Author Share Posted February 8, 2011 (edited) Sorry folks I know these aren't the most exciting pictures! But anyway, servo etc all back on and brakes re-bled etc... you can see just how much space the polo servo free's up Just need the sunroof brackets, headlining and rad to turn up now so we can crack on with that lot and get it finished. Then I can get busy cleaning the engine bay, and refreshing the soundproofing, painting any rusty brackets etc.. Edited February 8, 2011 by Devil Fish Quote Link to comment Share on other sites More sharing options...
adz the stig Posted February 9, 2011 Share Posted February 9, 2011 lol loving this educational thred! Quote Link to comment Share on other sites More sharing options...
Rapierdave Posted February 9, 2011 Share Posted February 9, 2011 Just need the sunroof brackets, headlining and rad to turn up now so we can crack on with that lot and get it finished. Then I can get busy cleaning the engine bay, and refreshing the soundproofing, painting any rusty brackets etc.. Looking good guys. Where did you get the replacement headlining from for the Manta ? Quote Link to comment Share on other sites More sharing options...
Devil Fish Posted February 10, 2011 Author Share Posted February 10, 2011 (edited) Headlining (hopefully!) is coming from Lenk-tuning. Edited February 10, 2011 by Devil Fish Quote Link to comment Share on other sites More sharing options...
xecoupe Posted February 10, 2011 Share Posted February 10, 2011 Have really enjoyed reading this thread, its an amazing car/project keep the pics coming, Adie Quote Link to comment Share on other sites More sharing options...
Devil Fish Posted February 13, 2011 Author Share Posted February 13, 2011 (edited) Thanks for the kind words fella. Again, not a massive update, but some small/time consuming jobs carried out tonight... Fitted some socks as a temporary measure before getting a plenum made... catch tank installed, and decals fitted. (finished off with an amusing trip to the pub... seriously, listening to Bristol folk rapping 50 cent on karaoke was hilarious!) Anyway pics! Don't tell the missus where her hairdryer is The master at work,- And the 400r decals on the door... I went subtle with the design and execution of these, personally its exactly the effect I was going for... but any opinions welcomed Edited February 13, 2011 by Devil Fish Quote Link to comment Share on other sites More sharing options...
robah Posted February 13, 2011 Share Posted February 13, 2011 I really like the door graphics Where did you get them made as I would love a set of them in silver. I was looking at doing R400 or 400R for my car. As Adie said this has been a great forum post, and inspiration to myself. With the Club magazine looking for some extra content. I think this post (condensed), and the Polo Servo fit would be great additions to the mag. Quote Link to comment Share on other sites More sharing options...
steve price Posted February 13, 2011 Share Posted February 13, 2011 impressive work keep it up them bristolians dont arf sound funny to us,im from gwaun-cae-gurwen originaly,1/2 of our family r bristolians from the rough end of the city hartcliffe love em 2 bits though steve Quote Link to comment Share on other sites More sharing options...
Rapierdave Posted February 13, 2011 Share Posted February 13, 2011 Thanks for the kind words fella. Again, not a massive update, but some small/time consuming jobs carried out tonight... Fitted some socks as a temporary measure before getting a plenum made... catch tank installed, and decals fitted. (finished off with an amusing trip to the pub... seriously, listening to Bristol folk rapping 50 cent on karaoke was hilarious!) Darren as a Bristolian i must say your car looks GERT LUSH Quote Link to comment Share on other sites More sharing options...
Devil Fish Posted February 17, 2011 Author Share Posted February 17, 2011 (edited) Bit of engine bay bling turned up today From Rally Design (thanks to Retro Power for pointing me in there direction)... looks like a work of art, but won't get to test until the weekend/next week... will let you know how it turns out Edited February 17, 2011 by Devil Fish Quote Link to comment Share on other sites More sharing options...
Devil Fish Posted February 21, 2011 Author Share Posted February 21, 2011 (edited) Fitted a new sunroof (with the brackets not forthcoming, and well the old Britax was a bit rubbish anyway,- it leaked badly as the seals had long since given up and when open the latch would close if you went over a pothole/bump in the road!) After speaking to James @ bristol sunroof centre (really helpful chap, highly recommended)turns out a Landrover defender sunroof drops right in.. and well it does! Would highly recommend this as a swap for an old leaky pop-up sunroof Also started making some brackets for the rad fan Edited February 21, 2011 by Devil Fish Quote Link to comment Share on other sites More sharing options...
rallycinq Posted February 21, 2011 Share Posted February 21, 2011 Why not mount the fan directly to the rad? Cheers D Quote Link to comment Share on other sites More sharing options...
Devil Fish Posted February 22, 2011 Author Share Posted February 22, 2011 (edited) Why not mount the fan directly to the rad? Cheers D Why? Because this is better, don't say it isn't, it is. Seriously (well, mildly seriously!) We made these ally brackets to mount the fan because we thought 'A' they look good/shiny/better than cable-tie/plastic block things and 'B' they hold the fan off the core and 'C' ease of removing/replacing etc. It's probably no better or worse than using any other method, but we do like a bit of metalwork! We are pretty convinced this engine is going to be over-cooled with this bling rad, being in the cavernous manta engine bay, exhaust wrapped and heat shielded etc and so aren't too worried about the brackets blocking air flow too much (they only cover a small portion of the rad and aren't up against the core anyway (there's a good 10-15mil gap) .. if they do, will just drill some holes in them! Anyway some more pics As always, we love feedback, comments, suggestions from you guys (good or bad) so keep them coming! Edited February 22, 2011 by Devil Fish Quote Link to comment Share on other sites More sharing options...
robah Posted February 22, 2011 Share Posted February 22, 2011 Looks the Dogs Testies Like you said if it does block airflow, you can always swiss cheese the brackets. Looks like I might have to add one of those radiators to my bling list Quote Link to comment Share on other sites More sharing options...
steel Posted February 25, 2011 Share Posted February 25, 2011 fantastic project really enjoyed reading it given me great motivation to get stuck into my own Quote Link to comment Share on other sites More sharing options...
cact1972 Posted February 25, 2011 Share Posted February 25, 2011 (edited) Bit of engine bay bling turned up today From Rally Design (thanks to Retro Power for pointing me in there direction)... looks like a work of art, but won't get to test until the weekend/next week... will let you know how it turns out Thats what I got going on my 'Scona .Got mine from Demon Tweeks( thanks Jase!) Really nice bit of kit and liking the the fan mounting too! Really enjoying ths thread keep it up!!! Edited February 25, 2011 by cact1972 Quote Link to comment Share on other sites More sharing options...
stradacab Posted February 25, 2011 Share Posted February 25, 2011 Headlining arrived from Lenk-tuning, .... so screens out, a-posts etc all cleaned up, new vinyl on the a-posts and offering up new headlining.... Quote Link to comment Share on other sites More sharing options...
2908642343 Posted February 25, 2011 Share Posted February 25, 2011 How did you find the fit of the Lenk rooflining? As have one to fit soon...... John Quote Link to comment Share on other sites More sharing options...
stradacab Posted February 25, 2011 Share Posted February 25, 2011 How did you find the fit of the Lenk rooflining? As have one to fit soon...... John It's only about half in tonight, we stopped for a curry! Can I let you know if it fits in about 2 days?!! It seems like it will go in well, quite well made and accurate. Be mindful that it isn't perforated like the original but I think it's going to look really good in there. Quote Link to comment Share on other sites More sharing options...
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