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mechanicalrepairs

[car_upgrade] Project Miami Blue 205 Gti6

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mechanicalrepairs

It looks as if this has been covered quite a few times on here but i thought i would add my attempt for you all to see.

 

Well some of you may know at the beginning of the year i bought a very nice example of a 1.9 205 gti finished in miami blue, i have always wanted to buy a 205 and fit the gti6 engine to it, well the car has been sat in the corner of my garage now for months collecting dust due to not having any time to start it, well that all changed yesterday as work was slack and the lad i have who works with me had nothing to do so it all started.

 

The car itself is a 1994 205 1.9 gti with the later engine and ecu setup so only produces 122bhp which back in the day was good but by todays standard is no match for anything really.

 

How it was when i bought it-

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The engine bay as it looked-

 

 

 

Then after a couple of hours this is what we managed (in the back of my head i was thinking what have i done!)-

 

205conversion002.jpg

 

With the old engine completely removed, it looks a nice and dry engine to be fair and so it should really after only covering 66k-

 

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With the engine removed the bay looked a little grubby-

 

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After a good clean with the hot washer and some elbow grease it came out like this-

 

205conversion015.jpg

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mechanicalrepairs

The only bit thats going to need a fettle is the battery tray, looks like a battery must have leaked some acid in the past and done this-

 

205conversion016.jpg

 

Well one of these lumps should fit it i guess :lol-

 

205conversion009.jpg

 

 

Not really, i had a block and head to pieces and have started to rebuild it as once the lump is fitted i want to forget about it and jsut be able to use the car when i want without any hassles.

 

Heres the block, all reassembled, just going to give the block a good rub down and apply some engine laquer to it-

 

205conversion010.jpg

 

The cylinder head is all fully rebuilt and i had the clever idea of painting it again with engine laquer but in red, well once applied it looked a bit pink to me, what do you think?-

 

 

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Well done a little more today, cleaned back the block with the wire wool adapter in the drill, acid etch primed the block and then sprayed over it with high temperature black paint.

 

Then fitted the head, have to say this may be the most colourfull engine bay i have seen once this is all back together-

 

 

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Not much more to up date as i am waiting for some parts to be delivered (sent them away to be made pretty :lol).

 

Just been messing with the exhaust manifold and this envolved cutting it and making the angle a few degress tighter so hopefully this will clear the bulk head and make it a tidier install, i set about the manifold with a grinder and cut almost through it then bent the manifold down and re welded it back up.

 

Here are a few pictures so you can understand my dribble.

 

This is the manifold once the cut and bend down had been applied and then re welded up, i never though about taking a before photo. :crazy

 

205conversion001-1.jpg

205conversion003.jpg

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mechanicalrepairs

A pic of it fitted to the lump, its angle is slightly tighter to the back of the block-

 

205conversion004-1.jpg

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Should get more of my parts back this week so can continue with the progress, will keep you all updated as the build grows.

 

Well got my shiney bits back so i can put a bit more of it back together-

 

rocker cover and cam carriers-

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Varoius brackets re painted black, heres one of them-

 

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Exhaust manifold heat sheild-

 

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Here's all the bits fitted to the engine, made up with them as they fit so well and look better than new-

 

205conversion009-1.jpg

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205conversion010-1.jpg

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mechanicalrepairs

Well thats the engine coming along nicely, just waiting for a few more bits to arrive so i changed my engine for the gearbox and stripped down a five speed Citroen Xsara box and checked it over, it looks really good and considering its done over 100k has no real marks to it at all.

 

Thinking about sending the casing off to be powder coatedB)

 

Box of bits :lol

 

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Not really done a great deal more to this project at the minute as i am waiting for various parts to arrive.

 

Although i did receive a fly wheel and a few bits back from the powder coaters, manganed to fit all the pullies, new water pump etc and fit my modified engine block bracket for the engine mount.

 

A few teasers, starting to look very pretty-

 

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Heres the bracket i modified with a rather large stil saw, cut the brackets off for the power steering pump, a bit the same way you would if you were fitting the supercharger kit, once this was done i sent the bracket away to be powder coated (its an addiction i tell you:lol)

 

Obviously you dont cut the brackets off if you car is equipt with pas, mine isnt.

 

205conversion003-2.jpg

 

 

 

Just waiting for the gear box casing to come back from the powder coaters then the engine and box are ready to be mated back to the engine bay.

 

Once the engine is sat in the bay i have another sump that has been........ yes wait for it..... powder coated :lol Not fitted that yet as i fear it would get mangled as the engine is slid along the floor whilst fitting it.

 

Still undecided as to whether i should have the bay re painted as in some places there is the odd mark/scratch and dare i say it some surface rust.

 

Little bit of an update, i got the gearbox back from the painters today, just got to put all the internals back in it and mate it to the engine then i am done with the engine.

 

I may (well you know i will) remove the subframe/lower arms and get all that powder coated whilst i am at it, i have decided to get the bay painted too, seems daft not too whislt its all out.

 

Obviousley this is going to hold the build up as there is alot more work to do but once completed it should look very smart.

 

Gear box pics-

 

Shinygearbox002.jpg

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Well the box is back together, just got to put the end cap on and fit it to the engine.

 

Have to say i am glad i removed all the internal's prior to the casing being shot blasted as when i removed the casing to put the internal's back it was more or less filled with the sand.

 

Went back togther really well, and i remembered where the bits went which was a bonus.

 

 

gearbox.jpg

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Roman

look great mate... but i think is shame too ruin so great example of miami blue for this project :unsure:

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mechanicalrepairs

I have not really done a great deal to this but i have put the gearbox back together sealed it all up and mated it to the engine-

daves306and205parts010.jpg

daves306and205parts011.jpg

 

Also got the subframe back from the powder coaters and it looks great, had the antiroll bar and brackets done too-

 

daves306and205parts009.jpg

 

 

Just got to do a few little bits now to finish the engine off and get the engine bay painted.

 

Well fter not touching the car for some time i decided to get Dave to do some work so i could carry on stripping down the engine bay.

 

The bay now is more or less bare and just needs the wiring removing, had some fun when i removed the air horn with the garage air line :lol:lol

 

Dave called me a cock and nearly smashed it up!!! I dont think he like being force fed his cob by the scare.

 

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Well as you can imagine this hase been done over a period of around 3 months, this is as far as i have got so no more updates for a little while, the car is booked into the bodyshop next week for the paintwork so once its back its the task of remembering where everything came from and putting it all back together.

 

Carl

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platty

:unsure:

 

Tis' very nice. Looking forward to the next installment.

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cybernck

great work, just try to optimise your images better - they are all over the allowed 160k limit.

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swinney88

great looking project love all the powder coating. Will be a very tidy looking engine bay when finished

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Arahan

Very nice, engine looks great and head looks red to me! Also, have sent a PM! :unsure:

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mitch205gti

This thread makes me want to do the same time mine!

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MarkK

Makes me want to paint my head whilst its out!!!Looks amazing can't wait to see some more pics!

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whizzer71

Very Very Nice indeed ! ;) ,If only I had the facilities !,You using std cams or modded ones ?.

 

Heres a pic of my old beastie (now belongs to Fangio) I do miss it ! :blush:

Edited by whizzer71

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mechanicalrepairs

Well not a great deal has happened to the car lately other than it came back home with a freshly painted engine bay, does look great and cant wait to get it all back together-

 

205andbusinesscard001.jpg

 

Carl

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alync406

This is a very nice car.Looks like everything is spotless on it.Good work.

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mechanicalrepairs

Well after a lot of time off this project due to working, i had a pretty quiet week this week and managed to get back onto the car sat looking sorry for itself in the corner, i tell you what its strange pulling all the parts out of the boot and trying to remember where all the small clips etc go.

 

I started by fitting the front suspension with a totally different set up to that's meant to be (i will tell all if it actually works) i have done this due to the extra weight of the gti6 lump and xsara box.

 

Here's all the bits and pieces i used, i had an old suspension top bearing kit minus the cups so i had my original ones powder coated and set about putting them all together, so all completely new-

205conversion002-3.jpg

 

Once that was all fitted i felt pretty smug as it was a total fluke it went together. Have to take it to bits again as i forgot to fit the bump stop and cover, doh

205conversion003-3.jpg

 

I then set about starting to build up the engine bay, this was the worst bit as the bay has been stripped for a good four months and remebering where all the little clips and brackets went was to say the least hard work, all brackets removed where either replaced with new or have been sent away and powder coated.

205conversion006-3.jpg

 

Then as i left it, just received my new Nissens aluminium radiator so that has been fitted, just waiting for my servo to come back from the powder coaters then i can get into full swing and fit the engine.

 

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As i am new to the forum i am unable to list any parts in the for sale section but whilst doing this conversion i set about and had the engine bay stickers reproduced, if you are interested in a set please get in touch, i am selling them for £13 including free postage. Hope this is ok by admin (if not let me know and i will remove it), seeing as a few of you rebuild these cars i thought it would be a nice touch.

306bitsandbobs003.jpg

 

 

Carl

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mechanicalrepairs
Very Very Nice indeed ! :lol: ,If only I had the facilities !,You using std cams or modded ones ?.

 

Heres a pic of my old beastie (now belongs to Fangio) I do miss it ! :)

 

 

Thats a nice neat conversion, you do that yourself?

 

I am using standard cams, the only thing i have done is fit a lightened flywheel and crank pulley.

 

Carl

Edited by mechanicalrepairs

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Fox

Carl, when I finallly get my finger out and buy an engine off you, I hope that I go to as much detail as this!

 

Truely stunning work mate!

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205freak

It´s looking great, love the coulor that you´ve respraied the car really appealing!!!!

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Spiky

very nice conversion,

 

i'm tempted to paint my inlet manifold, what they like for resealing?

 

should i bother with the nylon plate, instead of the std gasket?

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j_turnell

Looks very nice indeed, just to let you know you can still buy the stickers from pug for not much atall!

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mechanicalrepairs
Looks very nice indeed, just to let you know you can still buy the stickers from pug for not much atall!

 

 

I enquired but was told they were not available.

 

Got a lot more bits back from the powder coaters again this week so can finally get onto this and have it finished by the end of the month.

 

 

Carl

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mechanicalrepairs

Well on saturday i received the final bits i needed back from the powder coaters (it's a desease) so hopefully this will be finished pretty soon.

 

Had a pair of hub carriers painted black-

205conversion002-4.jpg

Fitted the wheel bearings, trying not to damage the paint-

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The servo came back looking great in anthracite, much better than the rusty crap it looked like before.

 

Ordered the last few bits i need so i am hoping by the end of the week to have a six lump sitting in the bay looking very pretty.

 

I have my fingers crossed that the master cylinder will clear and that i have no issues with the exhaust manifold. Time will tell.

 

The calipers i have had powder coated too-

 

205conversion001-3.jpg

 

Brakes all built back up and fitted, painted the centre of the disc's, once the car has been driven it will remove the over spray and will leave a nice coated centre that wont look horrible when the metal corrodes-

205conversion005-4.jpg

205conversion006-4.jpg

 

This is what it is looking like now-

 

205conversion003-4.jpg

 

Carl

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rapidcossie

love it!

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