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[car_restoration] Saved From The Chavs! Cherry Red Restoration

205 GTI 1.9l Cherry Red Restoration

184 replies to this topic

#21
welshpug

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these only need one fan, hence only one being fitted.

you will find two on a Diesel and turbo diesel, possibly auto's too IIRC, a 1.9 would typically have an air-oil cooler bolted in the middle of the right hand hole.

#22
sensualt101

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thats not a bad base car and i have certainly seen a lot worse!

i also spotted the mk 1 clio rear wiper arm and like that mod! :)

#23
Tom Fenton

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a 1.9 would typically have an air-oil cooler bolted in the middle of the right hand hole.


Could be a later 1.9 with the oil/water exchanger.

With regards the PAS, if you really feel the need to disconnect and drain, then remove the aux belt so the pump is not being driven. Obviously then no alternator but if it is just for moving about a bit it should be OK depending on how good the battery is.

#24
SkyQuake

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With regards the PAS, if you really feel the need to disconnect and drain, then remove the aux belt so the pump is not being driven. Obviously then no alternator but if it is just for moving about a bit it should be OK depending on how good the battery is.



Now, this kind of genius is exactly why I joined this forum! Having disconnected the PAS, I looked long and hard at the pump, trying to figure out a way of stopping it pissing out all over everywhere once the engine was started. I looked good and hard at the aux belt as well, and still it didn't twig. Finally, I opted to reconnect just the pipe, before turning the engine over several times.to clear the remaining fluid. This made a mess. Your way, on the whole, would have been better.

Moving on. I eventually managed to remove the mahoosive spoiler, only to find that the plank who fitted it has made a right royal mess of the tailgate! Not only has several gallons of sikaflex been used, but also the roof is bent, dented and drilled to take the sheet metal self tappers used to fit the spoiler. I fear that I will now have to re-fit the spoiler at the end just to cover up the scars! The spoiler is quite heavily weathered, but I think if I paint it in plastidip then it ought to look good as new.

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Alternatively, If somehow I manage to strip off the sika and make a reasonable job of repairing the tailgate, what spoiler should a 1.9 phase 2 have as standard. I've seen the smaller rubber ones with five mounting holes (which my tailgate seems to have, but they're blocked off), but they all seem to state Phase 1.5. Any comments on this?

Many thanks,

Mike

#25
SkyQuake

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Well, after stripping the under-seal of the rear n/s wheel arch, it wasn't looking too bad at first.

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Unfortunatly however, Welshpug appears to have been bang on the money. Damn!

I fear you will have much worse than you imagine on that lower 1/4 panel though, if it has bubbled its well gone under that seam sealant and paint.


Let the games begin!


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If you found this image amusing, then you watch too much porn!

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Having dug down to investigate this, this is clearly not the first time this job has been done. I have differing trim rivets in only this panel, and there's clearly more seam sealant around this arch than the other side. They did a bloody good job of making it look good, because it's taken me this long to work it out. It's a pity they didn't put that much effort into re-attaching the panel!

Now, obviously cutting the rust back, treating it and repairing is one thing, but how can I be sure that it hasn't travelled down from here into the sill? Short of filling it up with genolite, I haven't got much choice other than to separate the quarter panel all the way along the base and try and peel it back to inspect, without damaging it! Does anyone have any suggestions?

Finally, how would you attempt the repair? Is a glass-fibre inner liner acceptable (if a bit pikey) or will I be cutting sections out of my donor GTX and welding them into place on the inside? Any advice is greatly appreciated.

Cheers,

#26
snakeskin boots

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This is exactly where I am at with my 205 restoration, I peeled back the same area on my car (except it's the Drivers side the Passanger side seems ok) and have the same areas rusting away. I took the gamble and started to strip back the paint on the Sill and lo and behold it's rusted away along the final 10 inches and behind the Sill I found more rusty pieces on the inner Sill. I will try and get some photo's tonight as I am going to cut out the offending pieces and butcher a new sill to replace the old rusted ones.

I need to get some new parts fabricated for the inner sill and wheel arch, this thread http://forum.205gtid...howtopic=127191 shows you the extent of how bad things can get but also how easily it can all be repaired so don't despair if you keep uncovering more rusty bits!!!

Michael

#27
SkyQuake

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Dear All,

An update on how things are going. First, the good news. I had a friend of mine over at the weekend, who owns a classic mini city, and hence is a master welder. Several hours of grinding, beating and welding later, I have a sound wheel arch/quarter panel.

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Unfortunately, the boot floor was a bit of a sorry state, and is going to need a number of patchwork parts sewing into place.

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Several of these patches are completely through, so I decided to strip the underside completely to gauge the full extent. This necessitated removing the rear beam and wire brushing the underside. A disgusting job if ever I've done one! Still, I'm happier now that I know for sure that it's not much worse than it looks in the above picture.

My buddy has left me with the welder, but I doubt my efforts will be as neat as his!

Moving on, I've been looking at repairing and reinforcing the bumper mounting bracket which had come off completely. Went back to the old school with a bit of paper prototyping.

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After several iterations of this, I then CADded up the finished design and had these babies made up on the laser and brake press at work (being an engineer has some benefits!)

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Thought I was being really bl**dy clever too, before I read the article Snakeskin (thanks for the encouragement, much appreciated!) recommended to me:

I need to get some new parts fabricated for the inner sill and wheel arch, this thread http://forum.205gtid...howtopic=127191 shows you the extent of how bad things can get but also how easily it can all be repaired so don't despair if you keep uncovering more rusty bits!!!


Credit to M@tt for achieving exactly the same as I did, but without any of the high-tech weaponry I employed! Still, mine do look the part, and at 1.5mm thick, they're a good bit tougher than their Peugeot counterparts.

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One advantage of using CAD however, is that I can now make the laser file available to anyone who wants it, should you need to get your own made up.

After the little setback with the boot floor I decided to remove the centre console, carpet and insulation to check for any other rust spots. This was most amusing, as I discovered an inch deep layer of stagnant water in the passenger's footwell, coloured green by the saturated solution of insulation. Eugh! With this in mind, it was pleased to find that there wasn't actually much rust in the floor. Nothing that the jenolite can't cure anyway!

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I'd never originally intended to remove the rear beam, but as it was off, I gave it a good going over. It's actually in remarkably good condition, and everything moves nicely. I had one of these freeze solid on the GTX, so this has cheered me up a lot!

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However, I was a little discouraged to find that the rubber suspention mounts were completely shot to sh!t, and actually falling apart! Eeek!

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Not expensive, but very worrying, as I know I wouldn't have seen this if it was fitted to the vehicle. Still, with a clean up and a lick of paint, that beam will be good for years yet!

Weather permitting, I'll be having a welding weekend. I'll let you know how it goes!

#28
welshpug

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Oooo, now then if you have the drawing and brake press access you should definitely get a batch made up!

#29
TOYBOY

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I'd certainly have a pair of bumper mounts off you if a batch were made up. I think you'll find they would be very popular.

#30
Miles

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I really would still give the beam a strip down, like preventive maintenance is better than oh s***t the beams dead again

#31
SkyQuake

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Welshpug, Toyboy & Jackherer,

I will certainly look at getting a batch made up. I'm sure they won't be that expensive from my workplace. Although I'm still a passenger, so it'll be a while before I can advertise them on 'for sale/group buys.' As a result I'll briefly deviate from topic to ask, is there anyone who would have access to a better original pattern? As I said before, my mounts were rusted to hell, so not brilliant to copy!

@ Miles, many thanks for the advice, I know you're right, but I'm gonna have to take my chances with the rear beam. Otherwise I'll never have the damn thing finished! After all, it's not that difficult to take off when it does eventually freeze!

Cheers,

Edited by SkyQuake, 20 August 2012 - 10:10 PM.


#32
SkyQuake

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Dear All,

Work seem to be more than happy to run off a batch for me. I'm just waiting on some estimated prices. Therefore, a couple of questions:
  • Stick with 1.5mm, or would a more original thinner gauge be preferable?
  • Include grommet hole for galvanise drain plug?
  • Include through hole for sunroof drain pipe?
With regard to my 'welding weekend,' turns out I've forgotten everything I ever learned about welding, and I'm crap at it! More practice required. Spent the weekend painting up the rear beam and grinding more rust off the underside of my boot!

Mike

#33
snakeskin boots

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If you are getting a batch made up I would love to buy a set off you Skyquake, I wouldn't want all that effort you have put in to go to waste :-)

I have no idea answering the questions above but I am sure someone on here will know, I will keep an eye out for when you have a batch ready and be in touch.

Michael

#34
welshpug

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yes to all three :)

welding car bodywork, especially old french (or british) is quite a different art to welding clean steel on a bench!

#35
TOYBOY

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Yes to all three questions from me to.

#36
miamichris

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Its about time someone got round to making these rear bumper brackets up! Nice one :) I'd also be interested in a pair if they get made! Good luck with the project too pal.

#37
SkyQuake

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Dear All,

Just to let you know that work seem pretty happy to make up a batch of these bumper mounting brackets. Just waiting on prices..

In other news, did a lovely job of painting up my rear beam. All glistening yellow & black with plasti-dip red roll bars. I then promptly dropped it, and now I shall be starting from scratch...

Due to the British summer, I have made little progress on the car itself recently, and have busied myself plasticare-ing and trim painting, so nothing much to report.

My fuel lines look pretty cracked up, so I was wondering about replacing them. Can't seem to find any on eBay, so if you've got any in your garden shed, give me a shout! Can you get braided ones anywhere?

Cheers,

Mike

#38
johnnyboy666

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i'd be after a pair of the brackets too :)

quick question, what did you use to cut out the rust, as it looks like a very neat square of panel that you removed, cant've been with a grinder surely?

#39
SkyQuake

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Johnnyboy,

As it happens, it was the grinder. I just used a fairly well used disc (smaller) and finished the corner (and near the sill) with a hacksaw blade.

When I come to removing the through spots in the boot floor, I was planning to use a sheet metal hole saw, and then fill each hole with a punched disc. This should look the neatest, but it does give me a tricky butt weld to deal with!

Mike

#40
joed66

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One of them tail gate strips sold on ebay for £85. And did i mention it was snapped in half haha



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Also tagged with one or more of these keywords: 205 GTI, 1.9l, Cherry Red, Restoration