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[car_restoration] Alien Vs. 205


114 replies to this topic

#41
B1ack_Mi16

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Ok. This car has been standing for so long now. But as the 405 T16 project was moved to my garage at home, I will try to do some work on this 205 now and then when time allows for it.

 

As the missus and my daughter has been away for a while (getting back home tomorrow) I used the last evening home alone to start working on this 205 again :)

 

Decided to fix the rust hole under the rear seat on the left side today. I also did some sandblasting of some rust that has been forming last 6 years it's stood more or less untouched!

 

Cleaned up under the main seat brackets, will need to sandblast brackets and get them welded back on.

 

IMG_20151123_181734_zpsl6wjacgv.jpg

 

Typically rusty patch underneath rear seat where the plates are double. Already cut of the thicker reinforcment part here.

 

IMG_20151123_181749_zps1k9s7fho.jpg

 

Cut out and welded in new metal. Had to grind the welds quite a lot as I was going to put a thicker plate on the outside, not looking very good.

My welding is also a bit crap yet, too long since last time :)

 

IMG_20151123_204036_zpsyrnwzy1v.jpg

 

Made a reinforcement patch to go on the outside.

 

IMG_20151123_204050_zpsjytilbxm.jpg

 

Welded it on, should be very solid, just hope it will not start to rust.

 

IMG_20151123_205957_zpsvv2qfunm.jpg

 

Not easy to spot, but I soaked the area in Owatrol penetrating oil. After it has dried I will paint with 2 pac to seal it off.

 

IMG_20151123_211132_zpssdubgrpq.jpg



#42
B1ack_Mi16

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Managed to get some time this evening so welded the cracks and the brackets for the front seats.

 

Next I guess more spot blasting of rust, and a trip to the local paint supplier for some white thick polyurethane based paint to protect it :)

 

IMG_20151206_213143_zpsex8lj21x.jpg



#43
ALEX

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I've bought and restored a Cti since the last time I commented here.

It 'ill l need restoring again by the time this one is finished! :P



#44
B1ack_Mi16

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:lol:

 

Progress is indeed slow. However at least I've restored 85% of the 405 T16 since the last post too :)

 

Today however I managed to paint the front part of the underbody. So at least some visible progress. Need to remove more rust on the rear part before painting.

 

IMG_20151228_140433_zpsislpnozq.jpg



#45
B1ack_Mi16

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Welded in a patch at the left rear crossmember.

 

IMG_20160112_212517_zpsizm9231m.jpg

 

Did more sandblasting today, more or less 80% done now I believe. Blasted a hole in the boot-floor, so seem like I need to do come more welding.

 

IMG_20160112_212523_zpslndy1l8v.jpg

 

Sprayed it one more round with Ferrobet rust inhibitor before I left today. I must say it's amusing that there seem to be rust underneath perfectly looking underseal. So surely no 205 is rust free until it's been inspected under all the orignal underseal :)

 

IMG_20160112_212501_zpst3e7uf6k.jpg



#46
B1ack_Mi16

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Got a tiny amount of time in the garage today.

 

Cut out the small rotten piece under the boot floor.

IMG_20160124_134323_zpsykfkbwaz.jpg

 

Made replacement piece

IMG_20160124_134347_zps4tdbfyt4.jpg

 

Cleaned up so it's ready for welding

IMG_20160124_135902_zpsgkmhmiyp.jpg

 

Found some rust spots on the inside of the boot floor on the left side of the car. After spot blasting the rust spots it seem like I need to cut out some metal here too, holes is seen from inside, not outside though so it's exactly where the plate overlaps with the beam underneat.

 

IMG_20160124_135909_zpsjtmw2jml.jpg



#47
B1ack_Mi16

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Managed to get some hours today.

 

Cut out the two other spots I found last time, was quite a lot of rust underneath and the boot-floor plate part were mostly a thick layer of rust,

 

IMG_20160202_170907_zps9gmu37jo.jpg

 

IMG_20160202_201507_zpsy3zvz2cw.jpg

 

Will do a bit of grinding on the inside I guess, the most important is that the welds seem to penetrate ok at the back side.

 

IMG_20160202_201549_zps2ad7ueuv.jpg



#48
Zammo

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Wow great work even if it is slow, don't blame you going to this level of restoration!

#49
B1ack_Mi16

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Thanks.

 

Managed to sandblast the rest of the underbody rust that I could identify tonight, so that's it. If theres any rust left now, it'll just have to be there for a long time :)

 

Next now will be to get some help and turn it back down the right way again.

 

IMG_20160208_202214_zpsxa7bgrab.jpg

 

IMG_20160208_202310_zpszbkswm3t.jpg



#50
B1ack_Mi16

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Pressed in new wheel bearings in the front hubs yesterday, and gave the carreirs a lick of paint at the same time.

Painted them back when I bought the car, but they've gained quite a few scratches since that so... :)

 

IMG_20160224_193633_zpsfqv6qrpn.jpg

 

Also the PAS ram and hubs were painted

 

IMG_20160224_193648_zpsrulnlhdo.jpg

 

IMG_20160224_193654_zpsh4kmqc5u.jpg

 

Found some old Bilstein dampers I'll just use in the beginning just to get suspension onto the shell, cleaned up and painted.

Also some lowering springs. 

 

IMG_20160224_193825_zpskyp12lzq.jpg

 

Now it's just to get the struts assembled and get the shell back down the right way.



#51
B1ack_Mi16

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Did some more painting today.

 

Btw. do anyone got experience using a 255mm brake booster from a 405. I believe it will fit at least. Found one and decided to spray it at the same time as the rest of the parts.

Thinking of using a 22mm master cylinder from the same 405.

 

IMG_20160302_213322_zpsgvoi8cmv.jpg

 

IMG_20160302_213258_zpswinil6f1.jpg



#52
welshpug

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a 200mm servo is about 10mm away from the scuttle panel so I doubt a 255mm one will fit.

#53
B1ack_Mi16

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Ain't the standard 205 GTi one 225mm?



#54
jackherer

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There are space issues in right hand drive 205s so even GTIs only got a base model 200mm servo.



#55
B1ack_Mi16

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Ok. it seemed to be about 10-15mm clearance on my track car (which I guess has a 225mm item) when I looked this morning.

Meaning it might be possible or just not... 

 

Will just have to try it I guess. 15mm is all that's needed.



#56
B1ack_Mi16

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Got help from a mate yesterday and cleaned out a lot of crap and large objects from the spray booth.

 

Also turned the 205 back down the right way. It's so dirty after 9 years standing more or less untouched. So I better start by cleaning it.

 

IMG_20160306_180300_zpsoxo3w5ez.jpg



#57
aldworth33

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Looks like yours has rusted in a lot of places mine has

#58
B1ack_Mi16

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Yes they seem to suffer in the same common places.

 

I'm a bit surprised though, that this low miler 91 model seem to have more rust in general than my trackday car that is a 84 model. 



#59
B1ack_Mi16

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Some small update.

 

Managed to prep and paint the subframe today, re-did the brake orginal 225mm brake amplifier as the 250mm one did not fit.

 

IMG_20160316_204957_zps7mwlimik.jpg

 

IMG_20160316_205018_zpsehhidwbj.jpg

 

Also continued the cleaning today, pressure washing with white sprite inside arches etc.

 

IMG_20160316_205131_zpsn0lqgkgq.jpg



#60
B1ack_Mi16

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Painted the 3 wheel arches that didn't have paint this evening. 

 

Tomorrow I'll put on the rear beam and see if I can move it to the paint booth. 

 

IMG_20160317_211651_zpssi4uwz4i.jpg





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