Jump to content
  • Welcome to 205GTIDrivers.com!

    Hello dear visitor! Feel free to browse but we invite you to register completely free of charge in order to enjoy the full functionality of the website.

Sign in to follow this  
pugpete1108

[car_overhaul] Reshell, Restore And Rebuild

Recommended Posts

pugpete1108

after ballsing up my sunroof and being fed up with driving a matte black car i decided to reshell all my bits onto this very lovely (if not a little rusty) graphite shell courtesy of James_pug.

 

shell.jpg

 

the doors are a little ripply but i have a nice set of straight doors here ready to paint, i cant decide if to keep the std arches are refit my rallye ones (bearing in mind the std are painted body colour and a bit flaky and one is missing)

 

it need a new drivers wing which i have 2 good ones of and couple of small patches cleaning up.

 

and after last weekend i am now probally looking for a new vts/gti6 engine too as mine is a little poorly

 

anyway here is where i started with the 205, door first:

 

DSC_0018.jpg

 

both doors done, and my son not helping very much :lol: :

 

DSC_0019.jpg

 

i have now stripped all the rear end electric and bumper/glass and have most of the dash and the spaggheti wiring loom. i'll add more pics tomorrow when i should be well on the way to having the engine out.

Edited by pugpete1108

Share this post


Link to post
Share on other sites
Daviewonder

Nice seats. What they out of?

Share this post


Link to post
Share on other sites
pugpete1108

Nice seats. What they out of?

 

 

405 mix4 ones. there are up for sale and in near mint condition (apart from some small weld burns i made which you can barely see)

Share this post


Link to post
Share on other sites
GLPoomobile

For god's sake get your priorities right! Stop pissing about with doors and such like, and get the dam ugly pin stripes pulled off of the graphite.

 

Can you guess I'm not a fan of them? Wrong side of the retro/tacky line for me I'm afraid.

Share this post


Link to post
Share on other sites
Leet205

new shell looks lovely and shiney. i love the pinstripe - very retro B)

Share this post


Link to post
Share on other sites
pugpete1108

Glp I agree with you mate. I hate em and yes they will be coming off.

 

They are std though I do believe

Share this post


Link to post
Share on other sites
Arahan

What don't you like about the matt black mate?

Share this post


Link to post
Share on other sites
pugpete1108

What don't you like about the matt black mate?

 

Pita to keep clean to be honest. It looks good for about a week after it was sprayed.

 

And I miss spending a Sunday afternoon polishing a car :)

Share this post


Link to post
Share on other sites
Tom Fenton

What is happening to the old shell? Is it a non sunroof?

Share this post


Link to post
Share on other sites
pugpete1108

What is happening to the old shell? Is it a non sunroof?

 

being scrapped mate, its pretty solid though so would be a shame but i got a new one coming next week so it got to go.

 

and with regards to the sunroof; it was a sunroof, i plated it over but in the process i managed to warp the roof somewhat. i filled it but it still looks warped and the filler is now cracking.

 

this was another reason for reshelling tbh.

 

you want it? its free if it goes within the next week.

Share this post


Link to post
Share on other sites
pugpete1108

right, been round this morning to empty the fluids.

 

this was what came out of the radiator:

 

DSC_0020.jpg

 

no wonder it overheated.

 

interior nearly done:

 

DSC_0022.jpg

 

engine out today hopefully:

 

DSC_0021.jpg

Share this post


Link to post
Share on other sites
pugpete1108

well i am now nearly ready to drop the engine out, takes bloody ages to remove all the little bits

 

it was also like a scene from a bad porno; there was white gunk pouring out of every hole :lol: and i now have little puddles of mayo all over the garage floor.

 

DSC_0026.jpg

 

just got to figure out how i am going to get all these wires through that tiny little hole.

 

DSC_0027.jpg

 

and i now know why i couldn't get the idle below 1500 even with the butterfly fully closed and no idle valve.

 

blown the whole side of the resonating box open:

 

DSC_0025.jpg

Share this post


Link to post
Share on other sites
Masekwm

Why do you use Megasquirt instead of the standard ECU?

Share this post


Link to post
Share on other sites
pugpete1108

Why do you use Megasquirt instead of the standard ECU?

 

i was running bike bodies but had a lot of trouble balancing them so went back to std inlet.

 

plus it gives me the oppourtunity to upgrade to turbo/supercharger or bodies again in the future.

 

on top of that when i bought the engine it didnt come with any loom or ecu

Share this post


Link to post
Share on other sites
Stolton

petes new shell looks pretty solid & clean in the flesh & i def know that it willl look mint when done, if you need any help pete just give me a call. get some more pics up :P

Share this post


Link to post
Share on other sites
damien

how bloody quick do you work !!!!!!

 

what did you use to spray your block?

Share this post


Link to post
Share on other sites
pugpete1108

cheers martin :rolleyes:

 

and damien, im in a bit of a rush as the shell is coming next weekend. once this one has gone and the new one is here work will slow down considerably.

 

im sure i just used engine paint for the block? tbh its started to shown through as you can just make out on the bottom of the engine. i'll prob do it again when its out.

 

how you getting on with the engine? dont sell your old one just yet as i may need it if mine is buggered.

Share this post


Link to post
Share on other sites
pugpete1108

right well the engine is out on my home made trolley (que wincing as im moving it incase the wheels collapse)

 

DSC_0031.jpg

 

yum mayo:

 

DSC_0034.jpg

 

so its nearly all done now, just the brakes and running gear to do but thats easy really.

Share this post


Link to post
Share on other sites
james_pug

Good work so far Pete when do you think it'll be completely stripped by? I'll try and get your new shell ready to go this weekend, what day next weekend do you want it?

Share this post


Link to post
Share on other sites
pugpete1108

Good work so far Pete when do you think it'll be completely stripped by? I'll try and get your new shell ready to go this weekend, what day next weekend do you want it?

 

there's not much left to go mate, but im back to work tomorrow so wont get alot done until next thursday.

 

just got to finish the wiring and then drop the front subframe complete and the rear beam complete and the fuel tank + lines etc. god that sounds alot

 

im thinking sunday would be best provided i can get rid of this one. i might be able to get the bloke to take mine after he has dropped the new one off. just gotta drag it out of the garage with no wheels on :ph34r: i wonder if my little engine trolley will be up to the job?

Share this post


Link to post
Share on other sites
james_pug

All the engine bay wiring pulls into the cabin easy enough and the boot wiring Is still in the grey shell

 

Does he have a winch that'll pull your shell out easy enough no were will be open on a Sunday to take it away though? Can you ask the bloke how much to pick mine up from warhorne and take it to mine?

Share this post


Link to post
Share on other sites
pugpete1108

All the engine bay wiring pulls into the cabin easy enough and the boot wiring Is still in the grey shell

 

Does he have a winch that'll pull your shell out easy enough no were will be open on a Sunday to take it away though? Can you ask the bloke how much to pick mine up from warhorne and take it to mine?

 

2 problems there mate.

 

i have all the engine managment loom on the bay side and the wiring aint going through that hole (but seeing as the shell is being scrapped i'll just cut the hole big enough)

 

and my garage is i a block that has another block opposite and there aint enough room to get the truch straight on to it if you see what i mean?

 

he'll keep it on the truck until tuesday i should imagine? have a word with him when we come to yours mate, im sure it wont be much?

Edited by pugpete1108

Share this post


Link to post
Share on other sites
damien

cheers martin :rolleyes:

 

and damien, im in a bit of a rush as the shell is coming next weekend. once this one has gone and the new one is here work will slow down considerably.

 

im sure i just used engine paint for the block? tbh its started to shown through as you can just make out on the bottom of the engine. i'll prob do it again when its out.

 

how you getting on with the engine? dont sell your old one just yet as i may need it if mine is buggered.

 

 

im picking up the engine on sunday but im still unsure if im keeping the bodies, im in no rush as im not planning on getting her back on the road this summer

Share this post


Link to post
Share on other sites
pugpete1108

im picking up the engine on sunday but im still unsure if im keeping the bodies, im in no rush as im not planning on getting her back on the road this summer

 

yeah me neither mate. i dont plan on having it done until after xmas at least. just dont go getting rid until you've spoken to me :blush: cheers

 

is your new engine complet with manifolds etc?

Share this post


Link to post
Share on other sites
Stolton

if you need someone to take your shell away pete let me know as i know someone that will pick it up for you. like i said if you need a hand doing anything just give me a buzz. cant wait till its all done tho :P

Share this post


Link to post
Share on other sites

Create an account or sign in to comment

You need to be a member in order to leave a comment

Create an account

Sign up for a new account in our community. It's easy!

Register a new account

Sign in

Already have an account? Sign in here.

Sign In Now
Sign in to follow this  

×