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#Post#: 286--------------------------------------------------
Mark's Polo GT Hillclimb Car
By: Tav Date: August 17, 2012, 6:28 pm
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Goal & Background
Project Goal
The goal is to build a car to compete in the 2012 Scottish
Hillclimb Championship. I will be entering into Class A1 Road
Going Production Cars up to 1400cc. This class allows for some
limited modifications to be made in an attempt to keep costs
down and competition close.
In its current guise the Polo wouldn't stand a chance against
the other cars currently competing in A1. These include: a
Vauxhall Nova 1.4SR running Webber Twin 40's and a very well
spec'd Hillman Imp with an 1100cc screamer in the back. Both
cars have outputs the right side of 100bhp and are well piloted.
Being a "free" car I am fortunate to be able to spend a bit of
cash on the car in an attempt to make it competitive. I'll be
overhauling the brakes, suspension and attempting to squeeze a
few more horses from the little 8 valve motor. The Polo has
some strengths that we are going to play to.
I've always wanted to drive competitively but never had the
budget for karting or circuit racing. After spectating at the
majority of hillclimbs last year and watching on as Stuart
competed in his Integra Type R I thought this could be just the
ticket...
A little bit of history...
I was gifted this car from a good friend who had it stored in
his garage for the last 3 years. Ross is getting stuck in to
help with the build as is Stuart, who also previously owned a
couple of Mk3 Polo G40's. We were all once Polo mad (unusual
choice I know!), the guys have great enthusiasm and provide a
lot of support, banter and brawn.
Here are some photos of the car way back when in 2007/2008!
HTML http://farm8.staticflickr.com/7171/6722171181_8e7bfe601f_b.jpg
HTML http://farm8.staticflickr.com/7026/6722311963_ae7b471471_b.jpg
Below is a couple of photos and some spec. of my original Polo
GT Coupe that I had a few years ago:
[list]
[*]BBS RA 14x6J
[*]Toyo T1R 195/45R14
[*]H&R 60/40 Cup Kit
[*]256mm Corrado G60 Brakes - way over the top but great fun
with 75bhp on tap!
[*]OMP Velocity Suede Wheel
[*]Quaife Gearknob
[/list]
HTML http://farm8.staticflickr.com/7023/6722058583_e8da5dda94_b.jpg
HTML http://farm8.staticflickr.com/7004/6722272725_78405412c9_b.jpg
HTML http://farm8.staticflickr.com/7174/6722272493_761acc3f92_b.jpg
Here's a couple of Stuart's second G40 - this thing was properly
quick for what it was...like bye bye Subaru Impreza quick...:
HTML http://farm8.staticflickr.com/7002/6722170625_1e74ba238c_b.jpg
HTML http://farm8.staticflickr.com/7141/6722170955_62dc9afd39_b.jpg
#Post#: 287--------------------------------------------------
Re: Mark's Polo GT Hillclimb Car
By: Tav Date: August 17, 2012, 6:29 pm
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Removal Men
Having sat for 3 years the Polo needed to be persuaded to step
back outside. A couple of hours of chapping away at seized
brakes saw it exhumed...
HTML http://farm8.staticflickr.com/7146/6721896645_eb9d194171_b.jpg
Once out of the garage it was time to get the car loaded onto a
trailer and transferred to its new home. The trailer below
normally tows a full blown race spec. Honda Integra Type R. One
of the benefits of the hillclimb community is that competitors
really help each other out off the track.
HTML http://farm8.staticflickr.com/7035/6721912707_34ceaa22c7_b.jpg
The Honda Accord Type R tow car made light work of pulling the
Polo and we were soon at my rented garage 20 miles from
home...not ideal but much cheaper than renting in the city,
there's electricity, running water and a Subway near by...yum!
It also looks like we didn't hang around when it came to
removing some weight from the car...
HTML http://farm8.staticflickr.com/7173/6722482867_b48f89c75f_b.jpg
#Post#: 288--------------------------------------------------
Re: Mark's Polo GT Hillclimb Car
By: Tav Date: August 17, 2012, 6:30 pm
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A Statement of Intent
Here's one of the first deliveries I made to the garage. It's
amazing what you can fit into a Clio 182 Cup with a little bit
of imagination. Can you tell what it is yet...?
HTML http://farm8.staticflickr.com/7149/6722542475_fc3fa9a20b_b.jpg
One day I'm moaning that pukka race seats never come up for sale
second hand. The next day I get a call from Stuart telling me
there is a Recaro Profi SPG for sale on the Integra DC2 forum
and to top it off the guy only wants £220 for it delivered! I
couldn't believe my luck and literally ripped his hand off for
it. These seats normally retail at over £600. We'll be
mounting it to the floor using
HTML [url=http://"
HTML http://www.poloperformanceparts.co.uk/shop.php?cat=2"]Polo<br
/>Performance Parts Bucket Seat Mounts[/url]. It improves safet
y,
makes the car easier to drive flat out and it saves a lot of
weight!
HTML http://farm8.staticflickr.com/7147/6722547225_103828cedf_b.jpg
Here's the real statement of intent below. A Dbilas Dynamic
40mm DCOE pattern inlet manifold from Germany. Just right for
fitting some 40mm individual throttle bodies I'd say...
HTML http://farm8.staticflickr.com/7167/6722608407_89f239119e_b.jpg
...what have I got myself into...
#Post#: 289--------------------------------------------------
Re: Mark's Polo GT Hillclimb Car
By: Tav Date: August 17, 2012, 6:31 pm
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Inspiration
Time to share some inspiration I think. I've included a video
from each of the 3 venues that make up the Championship to show
folks just what the Polo will be getting used for.
Doune
Generally regarded as the scariest/fastest/craziest course of
the year watch as Graeme Wight Jnr. threads his highly modied
Imp up the hill in the video below:
HTML [url=http://"
HTML http://www.youtube.com/watch?v=36V0lotnYd4"]GW
Jnr.
Hillman Imp Flat Out[/url]
If you want to see something totally unhinged watch as he then
pilots his V10 single seater up the same skinny stretch of
tarmac. This video is not speeded up:
HTML [url=http://"
HTML http://www.youtube.com/watch?v=d9Lopg7YbUY"]V10<br
/>Predator at Doune[/url]
Forrestburn
My favorite track as a spectator. Ballsy at the start then gets
more and more technical as you go. Here we have Clark pedaling
his BMW e30 318 to a class record followed by the Integra that
normally sits on the trailer that was used to tow the Polo:
HTML [url=http://"
HTML http://www.youtube.com/watch?v=KYgSrPGI1B4"]Clark<br
/>Sutherland BMW e30 Class Record[/url]
HTML [url=http://"
HTML http://www.youtube.com/watch?v=Nnztlqzc7CY"]Nez
B
Class Integra Type R[/url]
Fintray
Our local course and it's only 10 miles away. It's the shortest
too comprising of only 3 bends. Don't let that fool you though
the first one is a tricky double apex...or single apex...or
triple...depends what you make of it! This course favours power
and traction as you accelerate out of each tight turn towards
the next. I've lined up a 16v KAD conversion Mini for this one,
great noise!
HTML [url=http://"
HTML http://www.youtube.com/watch?v=lExI6x7OmU8"]KAD
16v
Mini[/url]
#Post#: 290--------------------------------------------------
Re: Mark's Polo GT Hillclimb Car
By: Tav Date: August 17, 2012, 6:32 pm
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Jason Moyle Racing
Todays update comes courtesy of Jason Moyle Racing.
I might have mentioned earlier in the thread that my competitors
all have some tasty under bonnet mods and that the Polo would
need some extra horses to stand a chance. I decided that
throttle bodies would give the required bump in performance and
provide an interesting project to work on. Throttle bodies of
course present a significant financial/time investment; one that
can only be fully realised if they are breathing through a well
prep'd cylinder head.
Whilst I would love to DIY port the head I just don't have the
time or kit. Enter Jason Moyle; who I came across on Club GTi.
Here's the Polo cylinder head strapped down onto the flow bench
for testing
HTML http://farm8.staticflickr.com/7028/6743825271_752ebb0701.jpg
The light blue graph shows a standard 1300 8 valve Golf head.
The green graph shows this head ported to flow better. The dark
blue graph shows the standard Polo GT head.
The Polo GT head matches the modified Golf item at low valve
lift. The Polo then begins to out perform the Golf in the
mid-range due to having a bigger inlet valve. Flow restriction
caused by the standard nature of the Polo head chokes flow at
higher lifts...what does mean? It's a good starting point, but
Jason can see room for improvement!
HTML http://farm8.staticflickr.com/7016/6743908689_e8331990ec_z.jpg
After the base readings were taken it was time to inspect the
valve and inlet port. I'm told the shape of the valve is
'horrible', the short side of the port is 'poorly shaped' and
the throat is way to small for the size of the valve. It all
sounds pretty negative...but it isn't! All of these areas will
bring improvements to flow and thus performance when worked on.
She's got potential!
HTML http://farm8.staticflickr.com/7171/6743825863_2fb85e0ca3_z.jpg
Even though he has other work on Jason couldn't resist opening
up the venturi and de-lipping the back of the valve; just to see
what sort of gains can be had. This resulted in a 6cfm peak
gain and 5cfm spread across a wider range of valve lifts. I
think it's great to see what a little bit of work can gain.
HTML http://farm8.staticflickr.com/7174/6751174597_5f2d584863_z.jpg
Absolutely delighted with what will come and Jason's proving a
pleasure to work with. Regular updates via text message and a
in-depth explanation of whats going on. I'll keep the thread up
to date as it comes along!
#Post#: 291--------------------------------------------------
Re: Mark's Polo GT Hillclimb Car
By: Tav Date: August 17, 2012, 6:33 pm
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Take a Seat
Cylinder Head Update #2
Following on from the last cylinder head-centric update I can
report that Jason's been busy and had the cylinder head away for
machining. I received a text message accompanied by a couple of
photos mid-Fajita-cooking. Almost burnt the chicken!
Below is a photo of the head as it was when it arrived at JMR.
HTML http://farm8.staticflickr.com/7171/6743825863_2fb85e0ca3_z.jpg
...and here's the results of the valve seat machine work. The
seats have been cut with 3 angles in an attempt to improve flow
at large valve openings. The lead in edge as been cut back in
an attempt to de-shroud the valve during initial opening. This
should have a positive effect on flows in the low-mid range:
HTML http://farm8.staticflickr.com/7144/6802916195_5c1c54b3f9_z.jpg
Of course any improvement to the cylinder head needs to be
verified by readings from the flow bench. The pink line in the
graph below illustrates the 3 angled seat's positive effect on
flow; with an obvious increase at the larger openings. We're
not seeing much of an advantage between .300 and .400 which
Jason suggests is because it now has a bigger appetite for air.
Opening the throat and venturi should provide that and will be
be the next job! Jason predicted an increase of 6CFM from those
modifications.
[
HTML http://farm8.staticflickr.com/7141/6802915983_0424c41dbf_z.jpg
I'm really starting to trust his experience now and I'm
confident that'll be the case. Can't wait to find out!
At this point we've decided to aim for 70CFM. A standard Golf
GTi head with a 40mm valve makes 72CFM and an easy 110-112bhp.
We're already up from 55.8CFM to 62.5CFM and still lots more to
do.
I've acquired another GT head to use for parts. Apparently the
valves need a lot of work so it'll be easier to test knowing
there are spares. Never know it might become Evo II.
#Post#: 292--------------------------------------------------
Re: Mark's Polo GT Hillclimb Car
By: Tav Date: August 17, 2012, 6:35 pm
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There's more updates to copy over from my original build thread
on Club Polo but I'll leave these to settle for a couple of
days. Already a lot of work has been and gone and hopefully
some new updates soon. Hope you've all enjoyed reading so far!
#Post#: 294--------------------------------------------------
Re: Mark's Polo GT Hillclimb Car
By: mitlom Date: August 18, 2012, 7:02 am
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Great read so far mate and welcome to the forum ;D
#Post#: 297--------------------------------------------------
Re: Mark's Polo GT Hillclimb Car
By: Tonyb Date: August 18, 2012, 8:41 am
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Good write up, looks like it's going to be a fun project. Those
Polo's go well especially with a super charger!! The N/A engine
should be a screamer, I guess they are fairly short stroke?
#Post#: 301--------------------------------------------------
Re: Mark's Polo GT Hillclimb Car
By: Tav Date: August 18, 2012, 12:01 pm
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75mm bore and a 72mm stroke, so the right side of square for
revs. She'll need to rev to make the power. Just found out the
1400c 8valve 106 in my class is making 140bhp...eeek. Jason and
I set our sights a fair bit lower on the standard bottom end.
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