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mech205eng

[car_upgrade] 205 Gti6 Immaculate Road/track Car

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mech205eng

I really slowed down over winter but i'm back on it now and have lots of updates, photos and purchases to add, I just need to get chance to upload the most recent photos off my phone. I'll try and get it done this weekend

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Lowercase

its a true inspiration to the children, im looking for this level of finish on my rallye..

 

so thanks for setting the bar so damn high lol

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mech205eng

thanks for that, the hardest part is keeping up a level of finish on the car, the question 'where do i stop?' has come up so many times. I degreased my gearbox and never bothered painting it, it's the only thing i left, i just couldn't be bothered. But if i'm inspiring you then i can't have that, because of you callum the gearbox is getting painted!

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Lowercase

im glad to hear it :P you owe it to the car lol

 

im stock piling my bits so i can refurb them over the year so no real rush, can just do bits as and when i feel like it.

 

lol when i put the engine in mine, i stayed up all night in my garage, freezing my tits off with a sponge and a tooth brush, degreasing my gear box ready to go in the next day, never bothered painting it lol i'd had enough by then! i didnt even bother cleaning the engine up, it was caked. im just going to have them blasted next time.

 

i've got 2 ltrs of 2k gloss black and 4 ltrs of 'campovolo grey' left over from a GTI build so once i strip my rallye down for its seam welding etc and smooothed bay, engine, gear box, subframe the lot are getting a nice generous coat of it :) should look nice and 'clean' with the grey on white.

 

how did the ford frozen white come out in person by the way?

 

i re sprayed my bay in ford diamond white as it was cheap off ebay and a bit creamier than frozen white - more in keeping with the origional colour. not sure whether to go 'whiter' for the respray.

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Roon

It's people like you that remind me how brilliant humanity can be at its best!

 

Stunning attention to detail! Tuned in!

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mech205eng

sounds like a good idea, you just need to get friendly with someone who blasts...powder coating definately isn't essentail on subframes etc. quick blast and rattle tin and they come out looking mint!

frozen white looks good, it's a bit orange peely, but as soon as the engine runs it's going on the trailer to my mate who painted it for him to flat and polish it all. I'm unsure if it will look too bright when it's all finished. I'll have to wait and see.

When i was choosing the colour i was tempted to go bianca white, i thought this would be alot brighter than the original but still suit it. Or i was going to use base white, no other colours added to it, because it's the cheapest white you can buy and it might not be the brightest white you can get but it is the whitest white. A mate of mine sprayed a clio v6 in it and it looks well!

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Lowercase

how long do you think you have left on it before its ready to roll again?

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mech205eng

I know this is nothing to do with peugeot's but i still feel that most people will appreciate it. It's a project my mate Will started about the same time I started this. last summer it's what I was doing with most of my saturdays when I should have been at home working on my 205. I did a few jobs on it..such as shortening the prop shaft and other machining bits. And just generally helped out.

http://www.pistonheads.com/gassing/topic.asp?t=1167010

Edited by mech205eng

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Lowercase

a shame to cut up a perfectly good evo, but damn thats mental!

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mech205eng

isn't it just, the cost of everything for that build (including the 2 cars) is less than £5000. Thats alot of car for your money

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clen666

Good to meet you today Mike, just read through this and I can confirm it looks as good in the flesh - good job!

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Lowercase

updates mike!

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mech205eng

haha sorry callum, it's such a task to get the photos off my phone, especially when i leave it so long and have so many. I'm doing it now though, give me and hour or 2 and it should be up to date

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mech205eng

Right it's been a while since I updated, I have done a bit since the last update but I did slow down ALOT through winter which I really regret because I could have had it finished otherwise. Right i'll try and remmeber where I left off, I think I'd just got it rolling.

 

I got my dash and clock surrounds flocked

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A little picture of my seats and harnesses

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I bought some lockable aero catches

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New peugeot badge

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New window scraper from peugeot

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Got some 2.0 rear quarter stickers from skyquake, very nice aswell, i've been chasing these for over a year through various people

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I bought my Satchshift over a year ago, it was one of the first things I bought

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My mate who painted the car came around and painted the b pillars black

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mech205eng

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Re-fitted steering column

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Gave pedal box and servo a lick of paint and re-fitted

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Went to put windows back in put my electric motors had got damp and had it, since I'd removed stereo and central locking I figured why not get manual windows and f*** off the door looms, so I got some manual regulators off marksorrento205

Also fitted the door handles, locks, boot handle, lock and rear wiper, door glass, rear glass, all seals etc.

Window winders do clear the door bars but you have to have the door open to wind them...this could be annoying. I'll sort that when it's on the road

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I mock fitted my Satchshift so I could figure out where to drill my hole in the bulkhead

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Then removed this as it made climbing around inside difficult to say the least.

 

Then I FINALLY started on the engine

 

Stripped it down to clean and paint, did sump in black hammerite and block and head in zinc, galv spray

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I put a new cambelt on, new waterpump, new ngk plugs, new oil filter, shiny new ally crank pulley off rich walker.

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Set about modding the exhaust manifold, stuck a 3mm grinding disc through it, then widened it a bit, pulled it until it touched then welded up

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mech205eng

Heat wrapped my manifold

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Re-fitted it with new brass nuts

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Sent cam covers, inlet manifold, engine mount off to be powdercoated white, sent throttle body off to be bead blasted (then I would paint it white), sent thermostat housing off to be bead blasted, got engine cradle blasted then a lick of satin black.

Painted fuel rail too.

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I'm not running p/w steering so i bought a 700pk belt, took my old cambelt tensioner and turnd down and M16 allen bolt so it had a 13mm shaft and M8 thread so I could tension my alternator

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mech205eng

Thanks to Callum (dasneakygit)

I painted my gearbox

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Got my engine off the stand, fitted a new clutch, slid gearbox on, bolted starter motor on. We were good to go :D

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Before I put the engine in I needed to do the engine bay brake lines. Can't remember if i'd mentioned it earlier but i'm doing the whole car in braided hose and running it inside. Fitted a 406 non abs m/c too.

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Got some bakerbm engine mounts and a red silicone hose kit

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mech205eng

This has nothing to do with this car or 205's but I saw it on facebook and loved it

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I figured it would be easiest to put the engine in by removing the subframe, picking the front of the car up with an engine crane and sliding the engine and box under on my creeper, this would also hopefully protect my shiny paint.

 

I made this out of some 1"x1" box and attachted it to the bumper brackets which bolt to the chasis legs, although there is very little weight in the front end I wanted to spread the weight evenly.

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Got engine and box sat on my creeper

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Lifted car up

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And she was in

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Master cylinder clearance was terrible

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Took it out to sort clearance, had to grind away at my powder coated cam cover, ground too much and broke through, was sooo pissed off! But i tigged it back up and painted over it.

Also cut my cambelt cover too

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Lowercase

cracking work! gear box looks ace ;)

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mech205eng

Took the engine out and back in a few times, exhaust manifold clearance is spot on (was a bit worried I wouldnt of bent it enough), put subframe back on and bolted rear engine mount on so I couldnt see where it would really sit. Used a solid fork bush too.

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I took the helper springs out of my coilovers while they were out as they were doing nothing and it sat too high. Now with the weight of the gearbox and engine in I can see it will still not sit very low. Here the coilovers are wound down nearly as far as they'll go

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I don't wamt it to be ridiculously low though so it'll probably be alright as it is. I'm guna need some spacer on the front though because the inside tyre wall is rubbing on the locking collars of the coilovers because they are that low. No problem there though. Ideally I could do with some shorter springs but I can do that later.

 

Forgot to mention before I put the engine in I put all the blowers, heater matrix and all that. I've got my satchshift back in to see if i could select gears, I can and it feels amazing!

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Bought a gti6 crank sensor off Dan (chipstick) and sent my looms off to spiky, got that back today

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Thats me up to date again. Not a lot to do but it'll still be a coouple of months. I'm going to the nurburgring this summer and hoped i'd be taking the 205 but it just isn't going to happen. If it is ready in time I doubt i'll of been able to do enough road miles in it first to find the niggles. A few mates have a track day booked at Croft on 4th May, I definately can't see myself making that.

 

One thing I forgot is I did need to space the bottom of the pedal box to get that master cylinder clearance

Edited by mech205eng

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Spiky

Loving the build :)

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mech205eng
welshpug

That IS pretty ruddy low tbh, pop an arch trim on and youll see ;)

 

Also have a look at the wishbone angle, and how much damper rod is still visible...

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mech205eng

i held an arch trim in place and it did look a little lower. I reckon when I get all the arches and bumpers back on it won't look too bad. My wish bone angle is completely horizontal, what is its optimum angle?

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Lowercase

any updates on this mike?

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