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welshpug

[car_overhaul] Zx 16V Project Pt2, Re-Shell And Power Upgrades....

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kyepan

bwarpage

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rallyeash

Awesome!

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welshpug

I dun stuff!

 

as I need to get it in the garage to jack it up properly and do the welding, and that is up a fair slope I thought I;d see about making it drive, so stuck the radiator in, spent an hour hunting fruitlessly for the bottom hose wire clip, bolted the inlet manifold on.

 

Emptied 15 litres of fuel from the fuel tank that's been sat in the back garden a few months! bolted the tank on, then got the exhaust hung and clamped up.

 

 

tank on (only 3 from 4 fixings, 4th is in o/s sill right by the rust and has a snapped bolt) -

 

8915684630_71206c1834_z.jpg

 

Exhaust on, not a bad job apart from faffing with the downpipe to manifold, only the rear box has hangers, though does have three, so fit the centre loosely to the rear and hang the rear up, offer the centre up to the cat and pull together and clamp up, I'm using genuine peugeot/citroen single piece clamps.

 

8915070107_d8459e4042_c.jpg

 

wire brushed the tailpipe :lol: yeah, the box looks crusty, and has a little condensation inside, but doesn't rattle...

 

8915769332_c587b99cca_z.jpg

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welshpug

Bunged a battery on, Radio still works :D

 

8926372474_23e8f744aa_z.jpg

 

Filled the engine with water, left the bleed points open so it doesn't build pressure as I haven't got hold of a clip for the top hose yet.

 

Fitted a lambda sensor, removed the coils and plugs, spun over and got 2 bar oil pressure on the dash.

 

Plugs back in and cranked it, but wouldn't fire, couldn't hear the fuel pump going, primed the pump with a power probe and swapped the fuel pump relay, it fired up and swung straight up to 4k rpm and a great load of hissing!

 

Obviously quite an air leak, resonator intact, inlet bolted down securely on a PhillipM PTFE gasket, so the only thing left was the idle valve and sure enough it was stuck, I had a spare thankfully :D

 

8926398966_8245befa84_z.jpg

 

 

There's an ABS sensor unplugged on the drivers side, and no aux belt as I haven't got any PAS fluid yet.

 

 

A good day, the engine hasn't run in 18 months, very happy with how it sounds :D

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welshpug

Today, I bought PAS fluid and an AUX belt, dug out some track rod ends form the shed, fitted the radiator hose clip and radiator securing clips, swapped a few wheels about so I could get the summer tyres on the 205.

Clipped the Clutch cable on, adjusted it vaguely, bolted the drivers seat in, bolted the drivers door mirror on.


Then I only bloody drove it up and down the back lane :D still air in the brakes somewhere :o good thing the handbrake works :lol:

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welshpug

Tea Power, it is the future :D

 

8963602988_1ae711fc3f_c.jpg

 

New AUX belt, I didn't realise there was two options, depending on which alternator was used, presumably they have different offset or pulley size, a longer belt for the higher power units, I did swap the alternator as it was noisy but didn't think anything of it, its only 9mm longer!

 

(actual spec is meant to be 1076, but the factors list a 1078, guess more vehicles use that size and this will take that up ion the adjuster fine)

 

8962402447_2db1d34ec9_z.jpg

 

£1.20 of clip, off the shelf, quite surprised they had one as they (peugeot/citroen) haven't been using a 16v XU for some time and they are stainless so don't need replacing unless lost!...

 

8963596228_c5662a1481_z.jpg

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jonny6

Love it ... Looks really mean with no bumpers , slightly dropped , really like the shape of the old zx's , much nicer than a 306 ....

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welshpug

it does have a front bumper on there :lol: drop is quite minimal too :D

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calvinhorse

What you doing in there, painting it? :D

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welshpug

No, the bastard needs welding, and it was in the way as my brothers 405 needs to be parked off the road as that needs welding for its mot!

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welshpug

Ill probably just wrap it btw, as half the panels are black already and i have a red bonnet for it too :D

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calvinhorse

Typical sills and jacking points?

What colour is it going?

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welshpug

whoah, time flies!

 

its been sat outside the garage for a few months again as I stuck the 205 inside, not dome much to it really, I sorted the weeping brake unions and bled the brakes again, and more recently just been waiting for a friend to have some spare time to weld it up for me, we did think of making a start on it today but he has a house he's painting for his dad which is dragging on a bit unfortunately, so I took it to bits again...

 

 

14759592102_1a1533cd6e_c.jpg

20140727_121701 by WELSHPUG, on Flickr

 

Unplugged the engine loom...

 

14756761681_469e296278_c.jpg

20140727_121859 by WELSHPUG, on Flickr

 

 

 

Faffed about with the auxillary loom adding a few plugs and wrapping it in tape, then added the DTA loom I had made, made up the last few connections to mate it to the car temporarily, then bolted the bodies on...

 

14573500917_88652a6db1_c.jpg

20140727_173322 by WELSHPUG, on Flickr

 

 

yes, I do have a rusty looking rad, but it doesnt leak, AND I have an alloy ordonez rad spare I can fit to it if needs be.

 

I then thought, errr, allI need is to bung a coilpack on and it "should" run....

 

so I did! https://flic.kr/p/ocNe87 (video link)

 

 

:D

Edited by welshpug
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camgti

Great read Merion.

 

Im so glad I can put a car to a name now!

 

Get it on the road already!

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welshpug

heh thats only one of my 4 :D

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welshpug

Progress!

 

borrowed Antons trailer!

 

14606213248_1c8b497110_c.jpg20140730_170124 by WELSHPUG, on Flickr

 

though when I pulled up Anton was making funny faces looking at the trailer, I hadn't realised the nearside rear wheel was steaming away, what with Dan sticking his arm in the way of the mirror all the time, and Diesel smoke going down that side of the car too :lol:

 

14606331857_c85d33fb9c_c.jpg20140730_175749 by WELSHPUG, on Flickr

 

looks like a lining had detached itself and got wedged, cooking all the grease from the wheel bearing too!

 

in the workshop jacked up already

 

14606332167_fe6ec3d57b_c.jpg20140730_175903 by WELSHPUG, on Flickr

Edited by welshpug
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stu8v

About time you got this finished.....

 

:-)

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welshpug

I don't earn enough to do it as quick as most seem to do, I'm basically on minimum wage.

 

This is partly why its all done by me as far as my skills and confidence allow, where possible I learn the new skills, but body panel fabrication and welding is still a little beyond me especially when there are 4 layers of steel involved at one point!

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stu8v

It means more matey when you do it all.

 

A great sense of satisfaction, I must admit its one of my failings.

 

I don't trust many people to work on my things, the list only seems to get smaller these days too.....

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Goliath

I don't earn enough to do it as quick as most seem to do, I'm basically on minimum wage.

 

This is partly why its all done by me as far as my skills and confidence allow, where possible I learn the new skills, but body panel fabrication and welding is still a little beyond me especially when there are 4 layers of steel involved at one point!

You spend too much time fixing my cars :P

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welshpug

:lol: maybe I should start charging more than just being fed :P

 

welding is done, screen ordered today, might get fitted by the weekend :D

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welshpug

A few weeks have passed, Anton has waves his weldy torch over the grotty bits, and finally this evening he dragged it back for me, he'd lashed up a quick throttle cable bracket from some wire to aid moving it :lol:

 

Thought I'd best make a proper bracket and see if I could get full travel without lifting the pedal too far, or having to bury it in the carpet.

 

a bit of steel angle, a rivnut, a threaded adjuster barrel and a 90deg v-brake noodle and I have myself a £90 saving on a Jenvey linkage kit.

 

14806300000_bec4d26c0b_c.jpg20140821_204632 by WELSHPUG, on Flickr

 

14806305490_3ae59c1c78_c.jpg20140821_205738 by WELSHPUG, on Flickr

 

14969976526_5240b35b61_c.jpg20140821_205802 by WELSHPUG, on Flickr

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welshpug

more progress after work this evening, as my bodies are short and I have long trumpets, and normal length Weber gti6 injectors I needed a stepped backplate, these are usually over the £50 mark, but inspired by Kristian (Black_Mi16) who had made his own stepped backplate from some sheet steel, I cracked on with some C.A.B.A.D*

14815348698_591e095103_c.jpg20140822_174904 by WELSHPUG, on Flickr

 

(*Cardboard And Beer Aided Design)

 

14815436107_86e74fb2a7_c.jpg20140822_181739 by WELSHPUG, on Flickr

 

15001964855_28f770ecb9_c.jpg20140822_183116 by WELSHPUG, on Flickr

 

14815367968_1226e1dc2a_c.jpg20140822_183507 by WELSHPUG, on Flickr

 

 

Bolted the centre piece under the trumpets to figure out where the injector securing bolt reliefs needed to be.

 

15001975985_966e9be2a0_c.jpg20140822_190223 by WELSHPUG, on Flickr

 

 

Transferred the design onto some steel sheet.

 

14815284899_0e9561b8f9_c.jpg20140822_191317 by WELSHPUG, on Flickr

 

chopped it out.

 

14815340840_f78aa1654a_c.jpg20140822_194531 by WELSHPUG, on Flickr

 

carried on chopping and a bit of holesaw action, had nothing to hand to do the radius cut unfortunately, but it wont hurt to have some flat edges instead of curve.

 

15001993055_cb03afd0ea_c.jpg20140822_202131 by WELSHPUG, on Flickr

Edited by welshpug

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