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[Car_Upgrade] 205 Diesel


63 replies to this topic

#21
dirtdog

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Any pictures of your repair to the under rear seat / above fuel tank rust hole? The state of the windscreen if mental! Nice car otherwise though..don't seen many on P

#22
BERTMAN

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Been a while since i've been able to get near this car as someone is always using it! Here's a picture of the repair. The crap all over the place isn't rust by the way! Just dirt and general crap; next move is sort that windscreen frame out!

Posted Image

#23
BERTMAN

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Well the other week I was trawling through a scrap yard as you do and stumbled across a 306 DT that was lingering on the outskirts. Had a word with the owner and 10 minutes later I had a donor car!

 

IMAG0391_zps92350fa3.jpg​

 

Other than needing a clutch and a vacuum pump it's ready to drop into the 205! The rest of the car will be broken for spares to get my other 306 through it's MOT, parts for my other project and the rest can be sold off to reduce the deficit! 

 

I've also got some new(ish) door seals to go on, and bought some butyl tape to hopefully get rid of the leaks which have left me with a half stripped car for the past month or so! 



#24
BERTMAN

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Before I put the DT engine in I wanted to upgrade the suspension and brakes, plus make the thing look a bit better. 

 

So on went a new front bumper and GTi valance (in graphite grey :/), some headlight protectors and some 1600 GTi wheels. I've got a new rear bumper/GTi rear valance to go on soon too. 

 

IMAG0452_zps63ddf644.jpg

 

Then onto the suspension. I've removed the knackered base model subframe/ARB/wishbone set up (I hate that set up) and have put on a GTi subframe/wishbones/ARB. I've also put on some GTi dampers with some cheap lowering springs on to the front. I've got a GTi rear ARB, torsion bars, and dampers too go on as well, and i'll lower the back to match.  Until then though it's the dragster look. 

 

IMAG0486_zps8cbda6c4.jpg

 

I've also picked up this old girl for beer money:

IMAG0445_zps6f4bd5e8.jpg

 

Bosch fuel pump, with fuel lines and injectors to suit, front mounted intercooler, inlet manifold and associated pipework etc. Thought I might aswell try and get it to fit under the 205 bonnet for a nice OEM feel. Might be tight though after seeing the size of the intercooler! If not, I can sell it on at an easy profit so all is well :D

 

Didn't all go nicely though! When removing the N/S/F wheel I was faced with some nicely cross threaded wheel bolt threads and 4 knackered wheel bolts. Not entirely sure how that's happened but the hub, and bolts have been replaced. Also the headlight protectors have both been cracked/broken and a chunk of the O/S indicator is missing. Looks like possible damage from a stone or something. 

 

IMAG0480_zpsa4545969.jpg

 

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Not too fussed about the damage to the protectors as I thought they made the car look abit goofy, but I did quite like the little Peugeot emblem and stripes on the headlights. So might try and find a way of getting some stickers or something made up for them.  

 

and the complimentary random shots:

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#25
BERTMAN

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Not done an awful lot to this but I have got round to sorting the rear end out! Not much fun messing around with a beam that has never been apart before but I got there in the end. 

 

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#26
Lan

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that's not how you roll is it? (numberplate in the windscreen) just shouts pull me! and is illegal which any anal officer will know.

 

nice work other than that, even if there seems to be a lot happening for just a run around!



#27
BERTMAN

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It initially got stuck in the window as we changed the bumper and didn't have any sticky stuff! You'd think you would get pulled but not a thing yet. 



#28
welshpug

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liking the Xantia, can't kill that :P



#29
BERTMAN

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liking the Xantia, can't kill that :P

 

Can, and have  :lol:. Found it in a field where it had stood for 2 years and it started up first turn of the key. Even the suspension worked! Still; parts of it will live on in the 205! 


Edited by BERTMAN, 09 July 2013 - 04:49 PM.


#30
welshpug

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bastard!  :(



:P



#31
cybernck

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Any updates on this? :)

#32
BERTMAN

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Yeah, there is an update!

 

Stripped the car down to rectify the rust issues on the front windscreen & also the massive leak that has emerged in the drivers side passenger foot well. I ended up getting a little carried away and ending up stripping the whole car down to sort out any rust I could find.

 

Front needs filing, and flatting, and I'm half way through the inside. The only real issue I've found is a 3" section of the boot that I've had to chop out.

 

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#33
BERTMAN

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I got bored of doing bodywork before I finished it all and moved onto the more fun stuff...

Out with the old lump

20150404_124613_zpszdmjbmos.jpg

 

Then with the new engine:

- I retained the 205 alternator belt set up and tensioner

- Decided to keep the TMIC as I want this car running asap.

- Fitted a new vacuum pump

- Removed the old Lucas pump and housing

- Fitted the 205 rear water union on the backside of the block so I can just run the exact same 205 cooling system

- Removed the oil/water exchange 

- swapped the clutch for a 405 Mi16 Pull type

 

Gearbox:

- Bought a 306HDi box for £5!

- Swapped the 205D differential into the 306 box with the 306 FD.

- Swapped the 205D gear selector arm on the HDI box

- and also swapped the speedo housing and gearing from the 205 box.

 

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and then dropped it all in..

 

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#34
BERTMAN

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Today I thought I'd spend a little time on the fuel pump. The Xantia had a keypad immobiliser so that meant the removal of a small security block over the fuel stop solenoid.

 

- Removed the bracket that houses the plugs, and also the bracket on the opposite side.

- Remove as much of the plastic housing as possible with a hammer and screwdriver

- then hacksawed into the security pins to turn them into screws and unscrew them

 

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Next on the list is give the thing a bit of a clean up. Find the switched live that goes to the black plug and wire it upto the stop solenoid. 

 

I think the blue plug is for the EGR off the Xantia. So I'll be removing that as soon as I've confirmed it is unneeded!



#35
BERTMAN

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Not been able to get down to the unit too much this weekend. Alton Towers and then drinking got in the way. However I did manage to get the fuel pump in, alternator and cambelt all timed up. 

 

95% wired up and new radiator in too. I've used a Nissens radiator that I had in my S16. So will have to find a new top hose and extend the radiator fan switch wiring also.

 

Think this may be f***ed:

20150419_140202_zpsgcgpzn6l.jpg

 

looks alot better!

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I've also found that the bonnet doesn't fully shut, and I've not fitted the intercooler yet! So I'll be swapping the auto bonnet off of the S16 too.

 

front end built back up:

20150419_183230_zpsegckfmim.jpg



#36
BERTMAN

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It's been nearly a month since I updated this but things are progressing.

 

Intercooler is on, and everything is plumbed in and wired up with the exception of the heater matrix hoses! Which i'm struggling to find replacements for.  

 

I've bought some second hand b4 billies with skip brown springs for the front and new-ish bearings for the front. I haven't looked at the rear yet so will base what I need depending on what the back ends like!

 

Replaced the inner CV gaiter on the N/S driveshaft and also made a start on the roof: Treated/cut out the rust, filled and smoothed in the damage caused by the corrosion.

 

20150502_173611_zpsugioqgji.jpg

 

Just need to flat back the rest of the roof and it'll be ready for a lick of paint!

 

Next on the cards is to find some matrix hoses, bolt up all the new front suspension & shafts stick some oil in it and see how it runs!



#37
BERTMAN

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Roof is now painted, it's a little thin in areas and the colour match ain't perfect but I'm quite happy at my first paint attempt with rattle cans!!

 

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Finally sourced some rear 1/4 window seals and also bought some 10mm sticky-back underlay foam so the new interior is on its way in also...

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#38
BERTMAN

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Today I made a start on the suspension - now... a woman has been driving this car since it's last MOT (can you tell?  :lol:

 

- N/S spring snapped 

- N/S damper leaking

- both droplinks f*****d

- both TRE's f*****d

- both lower arm b/j's f*****d

- N/S outer CV gaitor split (badly)

- both rear suspension mounts had split in half

- bearings had collapsed on the O/S/R

- 1 of the threads on each drum had disintegrated - I'm not sure how the wheel bolts have stayed in!

- buckled alloy

- and other little bits too... a good effort I'd say.

 

Anyway; went and replaced the whole lot on the front. 

- retained the GTI subframe and ARB (bushes were ok)

- new ARB droplinks

- new lower arms

- new O/S drivehsaft

- replaced the gaitor on the N/S

- new TRE's

- b4 bilstein dampers with skip brown springs and top mounts

 

The shocks mounted up fine, however the droplink tabs fouled badly on the brake lines. So I've ground them off and intend on remounting them out of the way.

 

on the back I've replaced the rear suspension mounts with some solid mounts I had knocking about and stripped the brakes down.

 

- ordered some new brake drums and bearings.

 

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#39
BERTMAN

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Most of the new interior is in the car now.. looking alot nicer in there as I think the grey and black goes alot better with the exterior! 

 

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Next for the interior is fitting electric windows/central locking and the new door cards also. 

 

Also got a phase 2 steering wheel and the centre console to fit. 

 

Stripped the back end down too, cleaned up some pretty groggy looking brake lines with some wire brushes and sandpaper. 

 

Thinking I might replace the rear shocks whilst I'm back here as they look... OLD!

 

Half the torsion bar nuts and bolts are rusted to buggery so the plan is to raise the back end using the old '1-click' method for now. I have a spare GTI axle so I might fix that up as a side project and fit that at a later date.

 

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20150717_164610_zpsn6cgbsbo.jpg​‹



#40
BERTMAN

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Changed my mind and ripped that axle off and chucked it in the scrap pile... along with the brake lines and the brakes: here's why...

 

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So instead of touching that crap. I pulled my ~10,000 mile (freshly rebuilt about 4 years ago and hardly used) axle out of storage. 

- 1900 axle (t/bs and arb)

- group A mounts

- even managed to find some decent callipers and pads to go on the back too.

 

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I've also got hold of some b4 rear dampers and fitted new brakes lines from the front bulkhead back.

 

Also found some 1900GTi front brake callipers in my garage so they have been bunged on.

 

Next: fit the exhaust and odds and sods.





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