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timoth123

[Car_Restoration] 1.9 Restoration

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Darrens205GTI

Great thread Tim,

 

Between you and Paul you are giving me loads of inspiration to get mine out of the Body shop and work on it again. Fingers crossed our house move finally happens in the next 3 weeks then the car can come home

 

Darren

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Miles

Soda blasting for the block works wonders, Not cheap thou

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andy-mac

doing a great job here colour looks great

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calvinhorse

Great project :)

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timoth123

Thanks guys, appreciate it!!

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mrfirepro

Tim,

 

If you get much more out that block you'll be able to build a sand castle :lol:

 

I bought another block (that was knackered as well) and stripped it down the liners are in good nick if you want them, just pay postage. Can send pics if interested. I also have a spare set of seal if you want.

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timoth123

Tim,

 

If you get much more out that block you'll be able to build a sand castle :lol:

 

I bought another block (that was knackered as well) and stripped it down the liners are in good nick if you want them, just pay postage. Can send pics if interested. I also have a spare set of seal if you want.

Ha! Tell me about it mate. I was abit surprised to find that much in there.

 

I appreciate the offer mate, but I've got some brand new ones coming along with new seals. Thanks though!

 

Hows your engine coming on?

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timoth123

Ok, progressed a little bit more over the last week.

 

Finally got all of the looms in and the main upper dash (no pics of this). Waiting for the screen fitters to turn up to put the front windscreen and tailgate glass in.

 

736f61c19f2e17e3ecc75a93d04793c6_zps1551

 

 

Got lots of nice powder coating back too, including the bits I got from Tom Fenton! Still waiting for the zinc players to get that stuff to me, been ages now!

 

9e48ef2ed87ce05eebd12aec63c00e0e_zps6da5

4324f189360e30647a3b84906133f72f_zps93d4

 

Anyone have any idea what this bracket is? I've no clue!

e32fbf7d52bced5ff737a58505505bf2_zps452b

 

Got the doors all finished with locks handles (plasticare makes a big difference)

 

14e58d0cfbc55182260d34b1b7ebada7_zps6c8b

 

This was the clutch cable fitted..

ec0f2e108878259e49ab30d12a14ad62_zps4817

 

Obviously the wrong one has been fitted at some point,

I need one that will fit this pedal box

cc5f1ab67855bf27bae291a84321ecda_zpsc4f8

 

Also got the freshly powder coated front hubs sorted, new bearings and outer hubs fitted.

 

And the fuel pipes and new clips fitted ready for the tank to go on.

 

Also heard back today that the engine parts are on the way back to me, should get them tomorrow.

 

Any one got one of these crank seal brackets? Someone has butchered the one on mine!!

2fa25e4dfb53d584f93426d9c13c6606_zps5449

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welshpug

That's the earlier BE1 pedal box with a bayonet type fitting, you can make the hole round to take the later ones if you need to.

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hoody_g

Anyone have any idea what this bracket is? I've no clue!

e32fbf7d52bced5ff737a58505505bf2_zps452b

 

 

It fits between the inlet manifold and the block. Don't have a pic to hand showing it in position.

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mrfirepro

Tim,

 

I've got a crank seal bracket you can have.

 

Will be bringing my bumpers up so will drop it in.

 

Are you in any rush?

 

Paul

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timoth123

Paul, you have a PM!

 

And thank you hoody_g, I never would remember that!

 

Merion, are the old type still available? (I've not forgot about those wings too)

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welshpug

yup, usually off the shelf from any firstline dealers I know for certain, and Motaquip IIRC.

 

Depends which gearbox and clutch pedal you plan on using too, BE1 or 3 clutch arm, and pre or post 90 pedal.

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Tom Fenton

I was looking at the pictures wondering if they were bits Ihad made, they look good in black especially the bumper corner bars, you would not know the difference from the originals.

 

Hubs wise, a bit late now but I would have pressed the bearings out completely before powdercoating, thats how I did my hubs.

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timoth123

Ah brilliant, cheers Merion.

 

The powder coasters said the same Tom. But I didn't want the bearing faces touched. They came out easy enough though, circlip was a little tight but nothing a heavy duty set of circlip pliers couldn't handle. And yeh, your stuff came out lovely! I particularly like the air box bracket. They look factory! Good work on them!

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timoth123

Quick pic of the hubs and fuel lines!!

fe135132dae33f6cd62a09c30f9fdded_zpsbde5

7ae1abcd6e5c01feb04e9e84339bcf27_zpsf83a

 

Also got the front and rear glass fitted

 

9425E9B1-A167-4DCC-9964-1E6F0676BAC8_zps

4342930D-913B-4D0C-90A2-B7BF1CD19C21_zps

Edited by timoth123

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timoth123

Ok, little bit of an update.

 

Got the front end together so it can be moved around easier. Quite handy as I'm moving to a new workshop this week.

d90e385e5b971234d086e0fdb6fcbe53_zps4602

6d5e9d548f81b32cd0690624c59358fa_zpsbf73

 

Looks like a bloody 4x4 now though

4b45325ed7060ea909489e283d5fdcee_zps189e

 

I noticed when fitting the rear wheels that the replacement wheel nuts I got hold of were the wrong type. The original ones were stripped beyond use, I need tapered ones, the replacements were flat. Anyone got a set?

313e90af81c67e24719cd532e44642c9_zps4eba

d16dc32ec0853757763f178eaee34194_zps236d

 

Is it just speed lines that are tapered or is it an early late thing?

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welshpug

that is the correct wheel bolt for that wheel.

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Slo

Looks like some kind of washer is stuck in the recess from an old bolt. Tapered bolts are usually for steel wheels to locate them dead centre.

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welshpug

just looks like its slightly disformed from having tapered bolts used on it in error.

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timoth123

Ah, bugger!!

 

Well at least I've got the right wheel bolts.

There's no washer stuck in there. Like Merion says, they must be deformed.

Hopefully they'll be ok once they're refurbed.

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mrfirepro

didn't know they did a 4x4 205 :lol: really should add some big bumpers to give it that complete 4x4 look :D

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pugsley

Very nice, would love to bareshell mine one day!

 

Nice work!

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timoth123

Ha! And maybe a set of bull bars and chunky tyres ey paul?!

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timoth123

Minor update as this week as I've had to move into a different workshop.

 

Decided to tackle the engine now that I've got a replacement block. Mine had the same issue as mrfirepro's first block, liner seal seat was corroded. Bugger. Still, after abit of searching spoox come up trumps with a very good condition block and only charged me 50 quid. And to make things even better paul, aka mrfirepro was kind enough to pick it up and drop it to my door. Good man!

 

Ok, so I cleaned the engine completely of all dirt, grease and oil. Then got it in a make sift spray bay and spayed some hycote engine enamel on all the bits. Finish looked awesome......

6d9bbd3c087d9b6dc92295b7f87b3b25_zpse5dd

 

But you have to bake it at at least 220degrees for 90 mins. I was a bit concerned about what the heat would do to the finish. Still better it happens now rather than on the car.

 

Enter this bad boy

76f3f1085b4942cf589d8a9be3e67093_zps39af

The metal bashers on camp use it to heat treat various metals. Ideal for fitting everything in there in a oner.

 

So after 2 and half hours at 230 degrees. (I went for longer just incase) this is what I was met with on opening the oven door

a95596f01b0342bd9672cff822183e1d_zpse502

 

The finish is fantastic, really very impressed. How it stands upto real life usage remains to be seen.

 

 

So on with the rebuild, got all the new main shells in and checked the running clearance with plastigauge, all good there. Fitted the new liners and checked protrusion, all good there too!! Just need to check the running clearance of the big ends and we'll have some pistons fitted too!

a5bcf3f0da97a66fb41e376dd47a9b71_zpsa63b

2983b13639d79e8e327c2c537ba04a37_zpse927

 

One question though, I'm using bother the Haines manual and a rebuild guide off the bay. I'm getting conflicting instructions when it comes to the large crank seal. Haines says drift it in to the same depth as the one you removed (how do you know the one fitted was right?), other manual says drift it in fully.

Anyone any idea what's best? Hopefully the pros will be along shortly.

 

 

Also been cleaning the carpeted bits. Center console and drivers foot well were absolutely hanging, but some interior cleaner and some soapy water it made a huge difference. The pics really don't show just how much cleaner and fresher they look now.

 

Dirty side

9b4198748af0e0212554b842a4f62d7a_zpsf774

 

Clean side

d8efed0f5db49f64d04cc704dfc0b79b_zpsd532

 

Dirty carpet

3abdf6ba49a9be031067c989ec4746b9_zps4687

 

Clean carpet

d685518f412218f27d29d2c84170eb81_zpsec8a

 

 

Anyway, hopefully have some more interior bits fitted this week! Just holding out to see if those repro rear quarter seals come to light. Damn I'd be happy if they did!!

Edited by timoth123

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