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[Car_Restoration] 1.9 Restoration


77 replies to this topic

#41
timoth123

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Quick pic of the hubs and fuel lines!!
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7ae1abcd6e5c01feb04e9e84339bcf27_zpsf83a

Also got the front and rear glass fitted

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Edited by timoth123, 07 February 2014 - 08:53 AM.


#42
timoth123

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Ok, little bit of an update.

Got the front end together so it can be moved around easier. Quite handy as I'm moving to a new workshop this week.
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Looks like a bloody 4x4 now though
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I noticed when fitting the rear wheels that the replacement wheel nuts I got hold of were the wrong type. The original ones were stripped beyond use, I need tapered ones, the replacements were flat. Anyone got a set?
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Is it just speed lines that are tapered or is it an early late thing?

#43
welshpug

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that is the correct wheel bolt for that wheel.



#44
Slo

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Looks like some kind of washer is stuck in the recess from an old bolt. Tapered bolts are usually for steel wheels to locate them dead centre.



#45
welshpug

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just looks like its slightly disformed from having tapered bolts used on it in error.



#46
timoth123

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Ah, bugger!!

Well at least I've got the right wheel bolts.
There's no washer stuck in there. Like Merion says, they must be deformed.
Hopefully they'll be ok once they're refurbed.

#47
mrfirepro

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didn't know they did a 4x4 205 :lol:  really should add some big bumpers to give it that complete 4x4 look :D



#48
pugsley

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Very nice, would love to bareshell mine one day!

 

Nice work!



#49
timoth123

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Ha! And maybe a set of bull bars and chunky tyres ey paul?!

#50
timoth123

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Minor update as this week as I've had to move into a different workshop.

Decided to tackle the engine now that I've got a replacement block. Mine had the same issue as mrfirepro's first block, liner seal seat was corroded. Bugger. Still, after abit of searching spoox come up trumps with a very good condition block and only charged me 50 quid. And to make things even better paul, aka mrfirepro was kind enough to pick it up and drop it to my door. Good man!

Ok, so I cleaned the engine completely of all dirt, grease and oil. Then got it in a make sift spray bay and spayed some hycote engine enamel on all the bits. Finish looked awesome......
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But you have to bake it at at least 220degrees for 90 mins. I was a bit concerned about what the heat would do to the finish. Still better it happens now rather than on the car.

Enter this bad boy
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The metal bashers on camp use it to heat treat various metals. Ideal for fitting everything in there in a oner.

So after 2 and half hours at 230 degrees. (I went for longer just incase) this is what I was met with on opening the oven door
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The finish is fantastic, really very impressed. How it stands upto real life usage remains to be seen.


So on with the rebuild, got all the new main shells in and checked the running clearance with plastigauge, all good there. Fitted the new liners and checked protrusion, all good there too!! Just need to check the running clearance of the big ends and we'll have some pistons fitted too!
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One question though, I'm using bother the Haines manual and a rebuild guide off the bay. I'm getting conflicting instructions when it comes to the large crank seal. Haines says drift it in to the same depth as the one you removed (how do you know the one fitted was right?), other manual says drift it in fully.
Anyone any idea what's best? Hopefully the pros will be along shortly.


Also been cleaning the carpeted bits. Center console and drivers foot well were absolutely hanging, but some interior cleaner and some soapy water it made a huge difference. The pics really don't show just how much cleaner and fresher they look now.

Dirty side
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Clean side
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Dirty carpet
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Clean carpet
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Anyway, hopefully have some more interior bits fitted this week! Just holding out to see if those repro rear quarter seals come to light. Damn I'd be happy if they did!!

Edited by timoth123, 06 March 2014 - 03:09 PM.


#51
timoth123

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Been a few weeks since I've updated this. And I don't really have loads to report on really as I've been away for a month. Back this Friday though so full steam ahead.

I finally got round to sorting out the rear beam issue that Tom Fenton pointed out that I'd put a bolt through the wrong way. Also when I set the dummy shocks I drilled them at 330mm I think it was, a standard 205. Thank you Haynes manual. But on the advice of the gurus on here lowered it back down to 322mm, much better. Also put the torsion bars on the right side. I got them mixed up when I built the beam. Bit embarrassing. Anyway, it now sits level and doesn't feel harder on one side to compress.

One thing this has highlighted even more though is the after market 'standard' springs are jacking the front up waaaaaay too high, I'm not convinced even the engine weight is going to compress them enough. Will have to see on that one but I can see me getting a 2nd hand set of standard springs powder coated in the end.


Also got a brand new set of genuine rear clusters and fitted them, damn they make a difference.
Loads of bits came back from the zinc platers. Used a different firm this time as the last firm were just messing me around.
Electroplating uk ltd, absolutely fantastic. They have a set rate of £35 for car enthusiasts, I sent them everything in the pics below plus a sump and got it all back within 3 days, hell of a turn around.
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Not the best pic but they came out pretty good!
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So got back one weekend and fitted a few brackets to the bulk head. Naff naff stuff getting there now. Including new master cylinder and new brake lines. Also got the gear mechanism fitted with updated rods.
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I completely lucked out with an original stereo too, moved into the new workshop, and what was sitting there in the back of a cupboard but a standard 205 clarion head unit. No code, but nothing a 12v battery, a beer and a movie in the living room would sort. So I started at 1111 and work my way up. Got there eventually. So stripped it down cleaned everything, painted the buttons with a tamiya model paint that matched the original colour and hey presto, looks and works as good as new.

Decoding in process, haven't got a pic of it completed.
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Once that was installed in the car I hooked up the battery to test some of the electrics and the new jvc speakers. Speakers were good, some other electrics not so much. Electric windows were working but only down and the dial lights weren't all lit. Bugger. Window problem turned out to be dirty switch contacts. And the dial lights were blown bulbs. Strip the dash again. Got there in the end though and now all works.

But can I hell work out where the cigeratte light goes. It doesn't seem to clip into anything. Anyone any ideas?

Interior wise, I dyed the carpet a bright red, came out really well! But then mrfirepro came up with a brand new one. I couldn't pass up that opportunity! Naff pics sorry.
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Also the engine is coming on nicely. Got all the pistons fitted, head fitted after getting a new head filter, old one wasn't really doing anything anymore.
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And that's all I've got upto really, sorry for not getting more pics of interesting bits of the build. But hopefully will be getting a large delivery of some genuine bits soon so will have some exciting stuff to show then.
Cheers

#52
carmike

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awesome work. :)



#53
Rock Lobster

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Great work mate

#54
timoth123

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Well over due an update! Not that there's much to report on. Some good, some very bad! :(

I'll start with the bad!!
I'm having some serious bad luck with this body work, this time all my fault! I managed to scratch the rear quarter! Very badly! F¥$!!!
I'm no going to say how I did it as to be honest I'm embarrassed about it!
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Once I'd finished crying, swearing and shouting I phoned the bodyshop, after called me an arse they assured me not to worry and they'll sort it. But told me to get the engine in incase any more scratches appear.

Ok, not got loads on the car done, mostly interior and external niff naff stuff. And some new bits arriving!
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The new carpet is awesome, transforms the interior I think!

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Slow and steady!

Also just about finished the gearbox rebuild! Just waiting for a shim for the diff/speedo housing.

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Also just about done the engine, just need a clutch and were good to go to mate the two up and get it in the car!
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And that's where I'm upto really! Should be getting a few more interesting bits from farmer soon too! :)

Edited by timoth123, 21 June 2014 - 08:44 PM.


#55
acox99

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Wow it looks better than factory. Good work

#56
Slo

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Top notch that mate, bad luck on the scratch though. Did you get that compressor from our favourite shepherd by any chance? :lol:



#57
mrfirepro

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Nice work, carpet looks grrrrrrrrreat.

 

Scratch will be no problem to Dave the magician :D , I could think of worse things you could have done....... ;)

 

Nice gearbox work as well.



#58
timoth123

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Ok, little bit of an update...

I received an exciting package from Farmer again, this time with two brand new quarter seals, new gti badges and a few other hard to comeby tid bits!
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I fitted the quarter seals, good god they're a pig to get in when they haven't shrunk, there is no way these are going to leak!!
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One of the seals is a 'mink' colour on the internal trim part. I need to dye it a suitable colour. Anyone have any ideas on that one? Plasticare just rubs off.

Not the best pic but you can see on the pic where I've applied a little bit to the corner, it comes off quite easily with my thumb rubbing it.
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Hit a solid mile stone after 16 months after starting this project. The engine is in :)
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And so was the bonnet, which I'd found out someone at work had propped a bike up against the bonnet and scrapped it slightly, bang in the middle of it! Grrrrrr!
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Then it was time to get these nicks and scratches sorted before I went any further with the exterior. So loaded her up on the trailer to head back to the bodyshop in Woodall spa.
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Then driving away with her left outside in the sun part finished, felt like I'd abandoned her. :(
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But I picked her up a week later, and good god she looks bloody fantastic now!! I never got any pics though so you'll have to wait to see the outcome!


And, finally got one seat from the upholsterers after months of me badgering them, I'm happy with how it's came out actually. Was a little concerned when I saw it part don't that the colour was off, I still think it is. But it looks great. Apparently it has to settle with use too. We'll see what happens there. The trimmer has promised I get the rest at the end of the month. (He said that last month though)
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Managed to pick up some bits I've been after at pugfest too, bbm eom rubber coolant hose kit, very good bit of kit. And a few trim bits I've been needed to finish the exterior. Also arranged some refurbed wheels from gti distinction, I collect them at the end of the month. Need some tyres now!

Anyway, that's it for now. Next couple of weeks will be getting engine ancillaries in so can fire her up.

#59
eddie bullit

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Fantastic job and nice choice of colour.



#60
ALEX

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Not had much luck with the original air horn in the past. I spent a fortune on a new pump and trumpet and it only lasted about a year before it started to sound gay!

Just at the point where were having a horn off...(I was a boy racer at the time) and thinking I'd win having spent loads on a new horn. It came out with a sound like it was attached to the noddy mobile.

I go for the twin set up (high and low pitch) found on the 1.6 Gti's now. The horns can be bought at your local motor factors for a couple of quid which are the same ones peugeot sell.

I've seen second hand ones on ebay go for stupid money :wacko: crazy.

 

edit.

If it makes you feel any better I scratched mine fitting the door back on after having to remove it to repair the door swing catch on the chassie.

there's also a few nics and scratches that I've caught by moving around in my tight garage.

 

It'll never stay perfect if you plan on driving and it looks like the trim will cover most of your scratch anyway.


Edited by ALEX, 19 July 2014 - 04:41 PM.




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