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[Car_Restoration] My 1989 205 1.9 Gti Restoration Project


359 replies to this topic

#21
mrfirepro

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Kane,

 

can I borrow your spay booth...proper job  :D

 

On a serious note Kypan's thread is excellent, but it does also put me off a bit as following the Haynes guide seems much more straight forward.


Edited by mrfirepro, 09 October 2013 - 09:32 PM.


#22
Kane

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Of course you can  :lol:



#23
mrfirepro

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latest update...

 

Engine out, front subframe out, all wiring out, rear beam out, nearly ready to start on bodywork

 

 

 

 

 

 

 

 

Attached Files



#24
mrfirepro

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Update...

 

Rear beam and front subframe removed

Fuel tank removed

 

Shell now totally stripped

 

Was going to acid dip and treat, but now going to look at Soda blasting

 

Whilst the shell is away going to...

 

Rebuild engine. gearbox, ream beam & front subframe

 

Send parts off to be powder coated or plated


Edited by mrfirepro, 02 November 2013 - 11:55 PM.


#25
mrfirepro

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Rear brakes stripped, found problem with the bolts, left side was different to the right side and the bolts were very different, same thread but different lengths and head size...wierd

 

You can see the short one here in the picture

 

 

Attached Files



#26
mrfirepro

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Rear beam stripped.

 

Wurzels guide was fantastic, just needed the seperation tool from Tom Fenton (which worked a treat) also was a bit over enthusiastic and managed to gouge a few lumps out of the beam whilst removing the outer bearings.

 

Also managed to make a tools to remove the inner bearings was quite easy in the end.

 

Have decided to replace both shafts as there were signs of wear.

Attached Files



#27
mrfirepro

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Have also stripped the steering rack

Attached Files



#28
mrfirepro

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1. New shafts pressed into arms

 

2. Deox-c'd front suspension members, brake parts, and lots of bolts and brackets

 

3. Deox-c gel'd trailing arms, rear beam, and front engine mount

 

4. Hydrate 80 to all above

 

5. Primed, rear beam & trailing arms

 

6. Shell going for dipping in two weeks time

 

 

Attached Files



#29
mrfirepro

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parts in primer

Attached Files



#30
mrfirepro

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only Hydrate 80 (not dry yet, goes black)

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#31
mrfirepro

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1. Engine gear box seperated

2. Injectors removed ready for service

3. Parts ready to be sent for plating

4. Ancillary engine parts now all removed

5. Rear brake calipers now rebuilt and resparayed



#32
james_pug

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Good work, looks like it'll nice when it's done. Good to see someone local.



#33
mrfirepro

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Thanks James,

 

Whats the scene like down here, not really found anyone local.

 

I bought this a few months ago on a bit of a nostalga trip and now it has taken over my life, I think it's going to be some time until done, but am really enjoying it.

 

And despite some really stupid questions I have asked on here (as they turned out) no one has told me to sling my hook.

 

If ever your near feel free to pop in, I'm about 20 minutes from Leeds Castle



#34
james_pug

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There aren't that many around here there use to be meets occasionally near Brighton but there wasn't any this year, I've got 3 if you get stuck for parts I've got quite a few spares.

 

projects can take along time I think my convertible has been off the road nearly 5 years now! I'm sure yours won't take that long.


Edited by james_pug, 27 November 2013 - 08:08 PM.


#35
mrfirepro

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There's so much, everywhere I look I can find things I need.

 

The plan between now and Xmas is.

 

The shell is being picked up on Tuesday to be dipped, which will give me some space to tidy up, as my garage looks like a 205 has exploded in it. The car will be back before Xmas and should then go to the body shop, providing I get a shell back and not a tea bag that is :o

 

Whilst the car is away I plan to

 

Rebuild front subframe, brakes, shocks, steering

Finish the beam refurb

Rebuild master cylinder and servo

Get all other parts of to the electroplaters

Rebuild & refurb engine and gearbox

 

this little lot should keep me off the streets for a while



#36
mrfirepro

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Had a few days off so a little progress..

 

The shell, doors, bonnet, tailgate and subframe went of the envirostrip today to be dipped, treated and primed, should be back in about 4 weeks.

 

Head and block now stripped, everything looks in remarkable condition, shells, liners and crank all look good so hopefully a few seals, rings and tidy up should see the engine back together.

 

Just gone over 1000 pics and another 300 to upload.

 

More at the weekend

 

Just a thought as everything will be fresh...

 

Should I keep it the same colour?????



#37
mrfirepro

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update,

 

a bit frustrating as all nuts/bolts brackets have gone off the Avon Electroplaters so cant really finish anything.

 

front hubs now, rust removed, primed and painted, with new bearings

 

P1020875_666x500.jpeg

 

 

Steering rack ready to go back together

 

P1020801_666x500.jpeg

 

 

Rear Brakes nearly finished

 

P1020816_666x500.jpeg

 

 

Tailing arms, de rusted, primed and painted with new bearings

 

P1020822_666x500.jpeg

 

 

Beam nearly finished with new bearings, bushes and seals

 

P1020843_666x500.jpeg

 

Front struts stripped down for re-build

 

P1020652_666x500.jpeg

 

 

Xmas jobs

 

Recondition/paint servo, new master cylinder, re-assemble all brakes, re-assemble front struts, brakes and hubs.

Rebuild Engine


Edited by mrfirepro, 05 November 2014 - 11:23 AM.


#38
timoth123

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Good work mate!

Looks like your doing the same as me, excluding getting it dipped. I had mine baremetalled by hand. Picked it up from the body shop all freshly painted a week before goin to the Falklands. Back at the start of jan and can't wait to get stuck into it.

#39
mrfirepro

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Hi Tim,

 

Got any pics, are you running a thread.

 

Did you make the spit yourself, as that's one thing I will need when I get it back.

 

Really want to get to the point of having at least one job fully completed (hopefully front subframe).

 

Are you keeping yours stock?



#40
mrfirepro

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Quick update...

 

Mostly been blasting parts for either painting or powder coating

 

Engine - All parts (liners, rings, seals, gaskets, shells) all ordered for rebuild

Gearbox - Still not decided what to do as I need a little help here

 

Shell - Is due back from the dippers on 2 Feb (hope it's not a tea bag)

 

25 Kg of parts expected back from Avon Electroplaters tomorrow, which means I can finish beam and steering rack  :) :) :)  at last

 

More photos to follow shortly.....





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