[Car_Restoration] My 1989 205 1.9 Gti Restoration Project

[mrfirepro 127 1 Cars]

Alex,

 

Well spotted, it's an E reg 1.9, was going to be the next project but it too far gone, just a donor now. Need to use the dash and rear loom for my car, plus whatever else I break along the way.

 

The last major task is to get the front and rear seats and steering wheel re-trimmed, then it's on with putting the interior back in and it'll all be done.

 

I have a (like new) parcel shelf but it's blue, any ideas how I can get it grey?

Edited November 9, 2014 by mrfirepro

[ATK 137 1 Cars]

Great stuff mate. Is the engine running well now?

 

What are your intentions once finished mate - will you be using it regularly or just for shows etc?

 

Parcel shelf - well on the 205 episode of Wheeler Dealers he sprayed the shelf with fabric spray, not sure if that would work though! Might work spraying it black though? But I assume a G plate needs a grey shelf so might not be an option.

[Andy_C 50]

Stunning - really can't wait to see this once it's finished. Real credit to your hard work mate.

[dobboy 231 2 Cars]

mrfire, my freind sent me this from the NEC car show.

 

Thought it might interest you

 

[mrfirepro 127 1 Cars]

Been having a bit of a nightmare with the last rear quarter arch trim.

 

First of all they seemed to be too thick and try as I may I couldn't get the clips on without deforming the holes

 

This is a picture with the clip held in from the outside and the picture taken from the inside.

 

old one virtually flush

 

 

new one, no where near flush

 

 

so I get another new one to find the holes like this

 

 

the problem with the above is there is nowhere for the cheeks of the clip to locate against.

 

Others look like this

 

 

The reason for posting this is to ask if I'm missing anything because I have been told today that this is manufacturing tolerance and what Peugeot produce, and the trim in the first picture that was very think has been fitted to a car today quite quickly.

 

I am very frustrated with this as if it is me I'd like to hold my hands up and say fair cop, but I have tried for hours and hours to get these to fit.

 

I have also been giving the supplier quite a hard time (they were all unopened OE bags) and they have been very supportive back, but now I think they have had enough as they have now sold out but to be fair have offered me a full refund.

 

 

 

 

 

 

[dobboy 231 2 Cars]

No probs, you're welcome

 

What's the horizontal line on your picture of the new trim running parallel with the slot (that looks like a stanley knife blade run)?

 

The line looks as though it would/should have been near the correct thickness of the trim during the moulding of it, and everything clip side of it is excess, stopping your clip getting flush with the body of the car?

[farmer 327 1 Cars]

Paul

 

Before I try and find another trim

 

Do you want me to send a NOS down to try?

[mrfirepro 127 1 Cars]

Farmer, that would be great.

 

well spotted Jack, what is strange is that this one is from an original unopened OE bag

 

Bit annoying as this is the only bit of trim that is left to replace.

[mrfirepro 127 1 Cars]

Wow, where's the time gone last update was early November.

 

My project photobucket archive is nearly at 5000 photos, all the photos from this update are here http://s1238.photobucket.com/user/mrfirepro/slideshow/205%20projects/4%20jan%2015

 

Doing the interior has been one of the most frustrating times with this project, virtually every bit of plastic was either cracked or broken and replacements where very hard to find, here's the story of the last 2 months

 

Some of you may remember we did a group buy on brand new red carpet, which I picked up in France.

 

 

loose fitted

 

 

The dash in the picture was taken from my donor car as each of the three dashes I had, had some degree of imperfection, either some considerate person had drilled holes in it or the mounting lugs were broken.

 

 

clips for the carpet

 

 

 

Both my original door seals were FUBAR so got a set of NOS grey which Farmer manged to find for me in some far flung part of Europe..(thanks farmer)

 

 

Sad I know but wanted to keep this box, as it seems as old as the car..cheesy.

 

 

new door seals fitted

 

 

 

Next came the front interior, broken parts needing replacing were

 

Glovebox door

Glovebox frame

Central chassis

Dash Binnacle (Speno came up trumps here )

Clock surround

All air vents (all had holes drilled in them)

Steering column shroud

Drivers lower (cubby hole) section (still not found a replacement for this)

Lower fixing bracket (behind and below gear stick)

 

some photos

 

 

 

 

Next came the doors...

 

Refurbished door cards, replaced all fixings and following a tip picked up at Pugfest last year used a sharpie marker to recolour the red strips

 

 

 

 

 

 

Fitted the washer pipes with the OE clips (yes they really are that colour )

 

 

Refurbished the doors upper weatherstrips

 

 

 

 

Only issue with the first ones was the 3m strip was a little thin so on the other side I used a slightly thicker strip

 

 

The only way I found to remove the old foam was using a small wire wheel on my Dremel with very light pressure

 

Got a brand new gear knob and fitted it with one of Rjuhar's reproduction tops from this thread http://forum.205gtidrivers.com/index.php?showtopic=161658

 

 

 

more new bits

 

inner door seals

 

 

 

 

 

 

Bonnet sealing strip

 

 

 

 

 

 

Random pic of engine bay (sorry I couldn't help myself... )

 

 

Also went to meet Scott Barton and pick up loads of left over stuff from his build as sadly his 205 is now gone (Thanks Scott)

 

Some time ago I changed the front pattern bumper for an OE one, luckily Farmer managed to locate a grey OE rear bumper so both the front and rears are now OE and they are very different from the pattern ones.

 

 

 

OE Bumper with ribbing around the fixing points

 

 

OE Bumper fitted

 

 

Replaced door switches as rubber had perished on old ones

 

 

 

 

Putting it all down like this it's hard to see how the above has taken 8 weeks...well it is cold in my garage...

 

Not really a lot left in this project.

 

The single biggest item left to do is to find a trimmer who can refurbish the front and rear seats (any recommendations welcome), then it'll be done, just hope I'm still not saying the same thing next new year.

 

Happy new year to you all and thanks for keeping up with my innate ramblings.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

[farmer 327 1 Cars]

looks impressive and well worth the investment

[james_pug 26 1 Cars]

This is looking great! I should have one of these if your still after one?

 

​Drivers lower (cubby hole) section (still not found a replacement for this)

[Andy_C 50]

Labour of love there mate. I assume you're working inside with your shoes off? I'd be s****ing myself over dirtying that carpet!!

[ATK 137 1 Cars]

Amazing Paul. Will you be driving this regularly do you think?

[mrfirepro 127 1 Cars]

Amazing Paul. Will you be driving this regularly do you think?

 

Drive it....god no, I'd be scared of getting it dirty...

 

Labour of love there mate. I assume you're working inside with your shoes off? I'd be s****ing myself over dirtying that carpet!!

 

Bit like a scene out of CSI........

 

 

This is looking great! I should have one of these if your still after one?

 

​Drivers lower (cubby hole) section (still not found a replacement for this)

 

That would be fantastic as I can't find one anywhere, is yours grey? PM me price and payment details, perhaps I'll pop down and collect it...

 

looks impressive and well worth the investment

 

Couldn't do it without the parts you find for me.... . Don't think it'll ever be worth whats been spent on it but I have really enjoyed doing it and I've learnt soooo much...more cheese

[farmer 327 1 Cars]

Enjoy it.

 

Won't be many following in your footsteps, the parts will probably come to the end at the end of this year, unless things change it will be over.

 

Be time to log into the 106 forum lol.

[mrfirepro 127 1 Cars]

firstly thanks to James_pug for coming up with a lower cubby hole trim piece.

 

as usual all the photos for this update are here http://s1238.photobucket.com/user/mrfirepro/slideshow/205%20projects/16%20jan%2015

 

 

Since the start of this project I have always wanted an original Clarion radio, having missed out on at least 6 or 7 on eBay due to silly prices and just not being around at the end of the auction, I finally ended up with two at very reasonable prices.

 

However the state of the radio was very much reflected in the price and only one came with a code.

 

 

Both needed buttons resprayed, following others I used this to paint the buttons

 

 

 

 

The front panel is held on with two small screws at each end and a single clip top and bottom, which allows access to the buttons.

 

 

The next issue was that one of the radios was missing the pug orange/red connector, to remedy this I had an ISO to Pug adapter like this one http://www.ebay.co.uk/itm/PEUGEOT-106-1991-TO-1996-CD-STEREO-ISO-WIRING-LOOM-HARNESS-LEAD-PLUG-PC2-06-4-/360803581571?pt=UK_In_Car_Technology&hash=item540191be83

 

I cut the end off and soldered the pug connector onto the flying leads from the clarion with a little (well a lot actually) help from folk on here.

 

this is what it looked like originally

 

 

If anyone else has to do this here's the final connections (these have worked)

 

 

 

 

 

 

I am not 100% sure that standard colours are used for the iso to pug connector (perhaps others can confirm) but if they are not the above photos will be of no help, so please check.

 

Next issue was to sort the radio code out on the one without a code. I prepared a spreadsheet with all combinations of 4 digit numbers, with the numbers 1-5....oh and a few beers to help me concentrate.....not looking forward to this task, I remembered from another thread that there is talk about the people wanting photos of the PCB to be able to assess the codes. I decided to put a known code PCB next to an unknown code PCB and see if I could spot any differences.

 

picture of known code PCB (look for solder joints at around 5 o;clock)

 

 

the code for this one above was 2213, so I though it may be very obvious what the code was I just needed to read the solder joints on the PCB, so this was the unknown one, is life ever that simple?

 

 

 

To cut a long story short, I still couldn't figure out the combination, apart from I was pretty sure there wasn't a 1 in it.

 

So I got to thinking if I re-soldered the joints to match the known code it may well work or it might just bugger the unit...oh well what the heck, so out came the soldering iron ​ (not my strongest skill as you will see)

 

so I turned the above into this

 

 

sorry it's a rubbish photo there is a piece of wire soldered in the top right link.

 

very nervously powered it up, expecting the universe to end, entered the code (2213) and blow me down it only went and worked ​ . so now have two radios with the same code.

 

The next thing was to sort out the radio connector on the loom as there were clearly loose connections, these are the parts I used to renew the connection (thanks to a WP post)

 

 

so now I have toons.....The only issue I have is the radio plays from all 4 speakers but the cassette (for the younger readers you'll have to google "cassette" ​ ) only plays through the left (N/S) channel, is this usual or is the tape player buggered, I can't test another cassette as I only have one.

 

now the saga of the radio was sorted I moved onto the boot side lining.

 

Thankfully Farmer kindly lent me an OE one to copy.

 

this is the OE one

 

 

 

I then made a template on a standard A1 sized sheet.

 

 

I have scanned this and should anyone want a copy please drop me a PM. I have checked that when printed in A1 it is accurate, hence the V&H dims.

 

I then cut out a carpet for each side with all the slits in.

 

 

I decided not to use the templates as the slots made it look a bit awkward and were massively too big, so I opted to cut a square, glue the two straight edges down and then glue the rest a bit at a time, this meant that I could make accurate holes and not rely on slots that didn't look good and I made the edge match, so the boot line can be cut accurately as it is not perfectly straight.

 

You will also have to cut a slot for the seatbelt to pass through, which was not present in the OE one.

 

I also decided to cut the tops different so that they could be trimmed when the rear trim was fitted, here are some photos.

 

 

 

 

 

I haven't cleaned the overspray off nor done the final trim in the above photos. I also never figured out why there would be a semi circular cut out on the original lining..

 

If I did this again (and I still might) I would use the template (without any cuts), then you won't need to trim it again as I may have to.

 

Finally after the saga of several brand new (still in OE bags, bought from a well known source) off side rear quarter trims, farmer provided one that fitted perfectly without any hassle, which meant that all my bumpers and trims were all new OE and more importantly now fully complete.

 

 

That's it for now, hopefully next post will be the interior trim all complete, providing I don't break anymore parts.. ​

Edited January 16, 2015 by mrfirepro

[lightflow 59 1 Cars]

Excellent work on the radio and liners Paul. I can confirm that the cassette player should playback through both L and R channels. From the PU-9469A and the wiring available, there will also be no front to back fade on that setup (only left to right). Clarion do still do a repair service (they are in Cricklade not far from Swindon) and I spoke to someone on the phone there and they still may be able to repair them and have parts. They will only take deliveries by post however.

 

Failing that and if you are really motivated I do have a mint condition PU-9469A...

[mrfirepro 127 1 Cars]

Have not tried the second clarion yet, so will give that a go today and report back, I'll drop you a PM about the radio

[ATK 137 1 Cars]

Paul,

 

I had the same issue with my Clarion playing tapes - before you try anything else, run a tape head cleaner (cassette annd fluid) on it - usually it's the tape heads which are gunked up. Worked on mine perfectly!

[mrfirepro 127 1 Cars]

Thanks Alex, I'll give it a go.

[mrfirepro 127 1 Cars]

cleaned tape heads with isopropyl alcohol and cotton bud and I now have music from all 4 speakers....

[ATK 137 1 Cars]

Great

[Andy_C 50]

Gets better & better Paul. Wouldn't mind a copy of that template for the rear 1/4 carpet pieces for mine if you have a sec!

[mrfirepro 127 1 Cars]

No problem, I think I have your email.

[acox99 71 1 Cars]

http://www.cauptonandson.co.uk

 

A very very good trimmers in Hastings. Used many times and had complete cars done through him. His work is fantastic.