[car_restoration] My 1.6 Gti Restoration Project

[Gentry_Ba 1]

hello!

 

as I'm unable to post this in car projects, I thought, I shortly present my project here.

 

in may last year I bought a 205 GTI 1.6 from 1988 in red for 250 euros. (very very very cheap here)

it came from an old man, who drove it from 1989 to 2001. since 2001 it was standing in a garage till he sold it to me. (it was found in the internet)

 

the engine runs, so I took it home with red number plates from a mate of me.

 

at home I began to disassemble the whole car. while doing this I could see, that the shell/interieur was in better condition I thought in the beginning.

so I said to me: lets restaurate it!

 

due to my bad english, pictures say more than words:

 

the car as I brought it home to my garage:

Edited November 10, 2009 by Gentry_Ba

[Gentry_Ba 1]

after a while, I began the disassembling:

 

no rust at all- very nice!

after a quick wash:

ready for the paintjob:

 

by the time the shell was away, I began to refurb the still usable old parts:

rear light refurbishment (left after, right before- I used car polish to do this- nice result)

Edited November 10, 2009 by Gentry_Ba

[Gentry_Ba 1]

gave the seats a new shiny look: (using carpet cleaner and the tornador-gun)

(my girlfriend was not amazed doing this in the bedroom, I think... )

 

bying new parts (a few things are impossible to refurbish):

 

refurbishing the trim:

 

a mms sent to me from my car paint garage man:

 

after:

 

then I began to refit all the parts:

[Gentry_Ba 1]

interieur:

 

the driver seat had a broken side-wing:

after:

 

[Gentry_Ba 1]

engine was crap, so a very friendly forum user from our french-classics.de forum sponsored me another 1.6 engine, which was equipped with many new parts:

 

slightly modified head (from a 120PS 1.9 engine, so it has got bigger valves:

schrick camshaft adjusting:

[Gentry_Ba 1]

ready to go in:

it should have about 130bhp now. (calculated)

- camshaft from schrick, 268°

- bigger valve head from 120PS 1.9 engine

- head skimmed by 3/10mm

- ports modified

- valves polished, 3 angle modified

- adjustable camshaft-wheel

 

 

thats it for the moment.

actually I have no money and its very cold in my garage... so the project has to wait a few month...

I will report every news, if you are interested in... my english is the only problem in this case...

 

cheers,

matthias

[Pob 1]

Excellent work, wish I had the space to do something similar. In the project you repaired the seats... How did you re-attach the cover after removing it? I've got a couple of seats that I want to make one good one out of. I've seen 'Hog ring's' that seem to be the same as the original, do you need the special pliers to use Hog rings?

 

Many Thanks,

Dan

[GLPoomobile 958]

Looks lovely

 

Should restore them and keep it on the 14" Pepper pots IMO.

[Gentry_Ba 1]

hi dan! thank you...

 

refurbishing the seats is no big problem. you just open whole the rings with 2 pliers, then remove the seatcover carefully.

only a velcro is holding the 2 parts together then- carefully pulling is doing the job here.

the foam cusion can easily be changed then.

reassembling in reverse order- you can use the old rings, thats no problem!

 

cheers,

matthias

[Gentry_Ba 1]

@glpoomobile:

the pepperpots are getting a new paint, and I will see, which rims look better on the car, after finishing.

I have to choose between SL201 (pepperpots), SL299 (from gti 1.9) or- and thats the point: MY SL434

the only optical mod I will do, is a good suspension. the rest will stay stock. (so I can hold it as original as possible, with a little more fun to drive )

 

oooh if I only had money at the moment...

a new windscreen is coming today, and the brake piping is new. but there is soooo much to do yet.

in the moment I disassemble the rear axle- because diassembling costs no money

 

 

cheers,

matthias

Edited November 10, 2009 by Gentry_Ba

[shalmaneser 26]

great thread, good luck!

[cybernck 400 1 Cars]

The cloth interior goes well with the original look 1.6 theme and I'd also recommend keeping the "pepperpots" on.

 

Shame it's not a phase1 car, then it would be a remake of an original 205 GTI .

 

Keep up the good work.

 

p.s. Moved to the Works section.

[Gentry_Ba 1]

thank you all!

 

things I've done:

 

- interieur refurbished, seat repaired

- dash illumination completely new lamps

- bumpers laquered with peugeot plastic color (it's listed in the service box, and the color matches PERFECT to the rest of the trim- I was amazed )

- new red trim all around

- new gti 1.6 badges

- new rear badges (peugeot, 205, gti)

- refurbed front/rear lights

- new high beam headlamps (not the crap siem, I prefered the cibies with yellow glass and white caps with logo on it- cult! )

- new brake lines

- master brake cylinder new laquered in black

- new windscreen fitted

- new sealings for the windows all around

- new front wheel bearings

- refurbished front axle complete with steering rack, etc.

- engine completely refurbed, done by a mate of me

 

things to do:

 

- new engine mountings

- new cooler

- new heater matrix

- new bbm cooling pipes

- new starter

- new generator

- refurbishing rear axle

- installing gaz suspension for the correct ride height

- refurbishing wheels (once the pepperpots, twice the sl299)

- new clutch

- new cables for clutch, speedometer, throttle, etc.

 

 

...and then: DRIVE.

 

but there's still a lot to do, and money is the problem here...

 

cheers and thanks for your interest- shame for my english, but here I can practice very nice!

matthias

Edited November 11, 2009 by Gentry_Ba

[Swazy 0 1 Cars]

Hi Ba,

 

nice project, love the car

 

Zumal ich mich immer freu wenn ich hier nen Deutschen antreffe

 

Mfg

Swazy

[Roman 0]

Great yob mate... i go thru all this job 4year ago(same project but 1.9) Now i dont regret all cost's and mess because nothing like a good blast on twisty road with little rattle rocket

[Guest WOZ205GTI]

Hi Gentry, im Warren from the UK.

 

I just had a browse through your pics of your reStoration project and was very suprised to see that your 205 is exactly the same as the project that ive just started! Im still learning how to use this FORUM and should be about to post pictures soon. Ive just bought myself a red 1988 1.6 gti and when i find out how to post some pictures on you will be very suprised that they are both in the same condition as your when you started yours-all the rust areas in the same place and engine bay is the same, it runs but needs a respray and MOT.

 

Im still learning michanics but if you have any question please ask incase i have the answer!

[cybernck 400 1 Cars]

Damn, I've always hated cloth interiors but now I just want to step into the photo and sit in that one!

 

p.s. How much did the 6994.44 kit cost?

[Tom Fenton 1,524]

Matthias, a really nice job you are doing, and your English is really very good.

[Gentry_Ba 1]

thank you all very much!

 

it's nice how friendly it is here!

 

@cybernck: the box was about 35 euros, I think... not the cheapest one, but necessary- for ONE SIDE.

(till I saw the clips and pieces in ebay.co.uk- where you can buy only what you really need.)

the box contains much things you normally don't need. the picture shows all pieces included.

and with the seats: 100% ack!

Before the restauration, before the 1.6 gti, I hated them, too. I looked for a pair of full leathers, but after refurbishing I thought that the cloth interieur is the only one to go in there! stock looks nice, and in summer when its hot, the cloth ones are more comfy unless you have no climate...

 

@WOZ205GTI: hey, nice to read that! if I have questions, I will ask you!

 

cheers,

matthias

Edited November 12, 2009 by Gentry_Ba

[Gentry_Ba 1]

hello forum!

 

the rear axle refurbishing is in its end-phase. the new bearings are in place, the torsion bars, the axle, etc... is laquered.

in the moment I'm waiting for parts from pug- to hold the break lines and handbrake lines in place, etc.

 

a few pictures:

 

 

the hub(?) is a little bit weared- but the old bearings had no wear at all?

so the question is, should I turn the hubs around at 180 degrees and insert them back or is it ok at all?

you can feel the dents a little bit- but really not heavy. only minimal.

 

tomorrow I'm going to setup the break lines and the rear axle main tube back in the car.

 

cheers,

matthias

[Gentry_Ba 1]

hello!

 

progress:

 

 

the dents in the axle hubs are gone- I pressed the hub out and turned it round to 180°. --> perfect.

the rust is gone, too. I used anti-rust tools (2 component) and finally I laquered it grey.

then I putted the rear axle back on its place (after fitting the new brake lines).

 

tomorrow I will de-rust the axle hubs and put them back on the car- then I can adjust the ride height (or should I say ride depth? )

 

cheers,

matthias

[Swazy 0 1 Cars]

Nice, i think i have to rebuild my rear beam too when i have to lower it.

 

Lovely

 

Keep up the good work Matthias

[Gentry_Ba 1]

hi guys!

 

some progress- today I gave it a wash, because of the tons of dirt from rebuilding rusty parts...

the 434's are too wide for the tall front axle hubs. so I will use the SL299's...

 

 

cheers,

matthias

[RalliArt 0]

Greetings Matthias, can you tell me pls what's the difference between your SL299's and the SL434's

[Michael 0]

sl434 6,75 x 15:

 

 

sl299 6 x 15:

 

Edited December 29, 2009 by Michael