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timoth123

[Car_Restoration] 1.9 Restoration

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timoth123

Been a few weeks since I've updated this. And I don't really have loads to report on really as I've been away for a month. Back this Friday though so full steam ahead.

 

I finally got round to sorting out the rear beam issue that Tom Fenton pointed out that I'd put a bolt through the wrong way. Also when I set the dummy shocks I drilled them at 330mm I think it was, a standard 205. Thank you Haynes manual. But on the advice of the gurus on here lowered it back down to 322mm, much better. Also put the torsion bars on the right side. I got them mixed up when I built the beam. Bit embarrassing. Anyway, it now sits level and doesn't feel harder on one side to compress.

 

One thing this has highlighted even more though is the after market 'standard' springs are jacking the front up waaaaaay too high, I'm not convinced even the engine weight is going to compress them enough. Will have to see on that one but I can see me getting a 2nd hand set of standard springs powder coated in the end.

 

 

Also got a brand new set of genuine rear clusters and fitted them, damn they make a difference.

Loads of bits came back from the zinc platers. Used a different firm this time as the last firm were just messing me around.

Electroplating uk ltd, absolutely fantastic. They have a set rate of £35 for car enthusiasts, I sent them everything in the pics below plus a sump and got it all back within 3 days, hell of a turn around.

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Not the best pic but they came out pretty good!

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So got back one weekend and fitted a few brackets to the bulk head. Naff naff stuff getting there now. Including new master cylinder and new brake lines. Also got the gear mechanism fitted with updated rods.

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I completely lucked out with an original stereo too, moved into the new workshop, and what was sitting there in the back of a cupboard but a standard 205 clarion head unit. No code, but nothing a 12v battery, a beer and a movie in the living room would sort. So I started at 1111 and work my way up. Got there eventually. So stripped it down cleaned everything, painted the buttons with a tamiya model paint that matched the original colour and hey presto, looks and works as good as new.

 

Decoding in process, haven't got a pic of it completed.

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Once that was installed in the car I hooked up the battery to test some of the electrics and the new jvc speakers. Speakers were good, some other electrics not so much. Electric windows were working but only down and the dial lights weren't all lit. Bugger. Window problem turned out to be dirty switch contacts. And the dial lights were blown bulbs. Strip the dash again. Got there in the end though and now all works.

 

But can I hell work out where the cigeratte light goes. It doesn't seem to clip into anything. Anyone any ideas?

 

Interior wise, I dyed the carpet a bright red, came out really well! But then mrfirepro came up with a brand new one. I couldn't pass up that opportunity! Naff pics sorry.

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Also the engine is coming on nicely. Got all the pistons fitted, head fitted after getting a new head filter, old one wasn't really doing anything anymore.

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And that's all I've got upto really, sorry for not getting more pics of interesting bits of the build. But hopefully will be getting a large delivery of some genuine bits soon so will have some exciting stuff to show then.

Cheers

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carmike

awesome work. :)

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Rock Lobster

Great work mate

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timoth123

Well over due an update! Not that there's much to report on. Some good, some very bad! :(

 

I'll start with the bad!!

I'm having some serious bad luck with this body work, this time all my fault! I managed to scratch the rear quarter! Very badly! F¥$!!!

I'm no going to say how I did it as to be honest I'm embarrassed about it!

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Once I'd finished crying, swearing and shouting I phoned the bodyshop, after called me an arse they assured me not to worry and they'll sort it. But told me to get the engine in incase any more scratches appear.

 

Ok, not got loads on the car done, mostly interior and external niff naff stuff. And some new bits arriving!

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The new carpet is awesome, transforms the interior I think!

 

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Slow and steady!

 

Also just about finished the gearbox rebuild! Just waiting for a shim for the diff/speedo housing.

 

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Also just about done the engine, just need a clutch and were good to go to mate the two up and get it in the car!

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And that's where I'm upto really! Should be getting a few more interesting bits from farmer soon too! :)

Edited by timoth123

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acox99

Wow it looks better than factory. Good work

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Slo

Top notch that mate, bad luck on the scratch though. Did you get that compressor from our favourite shepherd by any chance? :lol:

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mrfirepro

Nice work, carpet looks grrrrrrrrreat.

 

Scratch will be no problem to Dave the magician :D , I could think of worse things you could have done....... ;)

 

Nice gearbox work as well.

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timoth123

Ok, little bit of an update...

 

I received an exciting package from Farmer again, this time with two brand new quarter seals, new gti badges and a few other hard to comeby tid bits!

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I fitted the quarter seals, good god they're a pig to get in when they haven't shrunk, there is no way these are going to leak!!

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One of the seals is a 'mink' colour on the internal trim part. I need to dye it a suitable colour. Anyone have any ideas on that one? Plasticare just rubs off.

 

Not the best pic but you can see on the pic where I've applied a little bit to the corner, it comes off quite easily with my thumb rubbing it.

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Hit a solid mile stone after 16 months after starting this project. The engine is in :)

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And so was the bonnet, which I'd found out someone at work had propped a bike up against the bonnet and scrapped it slightly, bang in the middle of it! Grrrrrr!

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Then it was time to get these nicks and scratches sorted before I went any further with the exterior. So loaded her up on the trailer to head back to the bodyshop in Woodall spa.

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Then driving away with her left outside in the sun part finished, felt like I'd abandoned her. :(

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But I picked her up a week later, and good god she looks bloody fantastic now!! I never got any pics though so you'll have to wait to see the outcome!

 

 

And, finally got one seat from the upholsterers after months of me badgering them, I'm happy with how it's came out actually. Was a little concerned when I saw it part don't that the colour was off, I still think it is. But it looks great. Apparently it has to settle with use too. We'll see what happens there. The trimmer has promised I get the rest at the end of the month. (He said that last month though)

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Managed to pick up some bits I've been after at pugfest too, bbm eom rubber coolant hose kit, very good bit of kit. And a few trim bits I've been needed to finish the exterior. Also arranged some refurbed wheels from gti distinction, I collect them at the end of the month. Need some tyres now!

 

Anyway, that's it for now. Next couple of weeks will be getting engine ancillaries in so can fire her up.

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eddie bullit

Fantastic job and nice choice of colour.

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ALEX

Not had much luck with the original air horn in the past. I spent a fortune on a new pump and trumpet and it only lasted about a year before it started to sound gay!

Just at the point where were having a horn off...(I was a boy racer at the time) and thinking I'd win having spent loads on a new horn. It came out with a sound like it was attached to the noddy mobile.

I go for the twin set up (high and low pitch) found on the 1.6 Gti's now. The horns can be bought at your local motor factors for a couple of quid which are the same ones peugeot sell.

I've seen second hand ones on ebay go for stupid money :wacko: crazy.

 

edit.

If it makes you feel any better I scratched mine fitting the door back on after having to remove it to repair the door swing catch on the chassie.

there's also a few nics and scratches that I've caught by moving around in my tight garage.

 

It'll never stay perfect if you plan on driving and it looks like the trim will cover most of your scratch anyway.

Edited by ALEX

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timoth123

It'll never stay perfect if you plan on driving and it looks like the trim will cover most of your scratch anyway.

I'll definetly be driving it! Just only when it's sunny! And unfortunetly the trim didn't cover any of the scratch. That was the first thing I checked!

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Juttie205

One word stunning seeing all these mint 205's going back together really got to pull my finger out with the dimma.

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timoth123

Minor update here as I just seem to be getting to certain points and missing a small little bit.

 

Got my gear linkages hooked up and obviously couldn't resist selecting all the gears. Bugger...... Won't go in reverse. It just wouldn't pull back into gear.

I was adamant it was all working on the bench, how could it not be now???

Disconnected the selector rods and tried it by hand, still wouldn't go in. After a few hours of more and more swearing and getting more and more heavy handed. I grumpily called it a night and resided on pulling the box out in the morning and stripping it down again to see what was wrong.

 

Then lying in bed that night I had an apifiny, the reverse switch. It's the only thing that was new after testing it on the bench. I pulled it out tried to go for reverse. Boom!! Straight in! You f@£cker!

 

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As you can see, it's a lot longer and was stopping the selector from moving to select reverse.

Think the switch was £2.50, and it caused me to lose hours of time.

Oh well, glad I found it now

 

Also got my wheels from Tony at Gti Distinction. Damn they look good. I'm very impressed!

 

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Bloody good deal for a set of 5 too!

 

 

Found an issue with one of the hub bearings too when I put the naff wheels on, the inner has separated from the outer. Can only assume it's from when I stropped the car for it to go to the bodyshop. :( new bearing on route.

 

Also was told yesterday by my trimmer that all the seats are finished!! :) can't wait to get them tomorrow!

Exciting times, now all I need is some time to put it all together!

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jackherer

The longer switch is for an earlier (BE1) gearbox with lift up reverse by first gear as opposed to the late (BE3) 'box with reverse below fifth.

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timoth123

The longer switch is for an earlier (BE1) gearbox with lift up reverse by first gear as opposed to the late (BE3) 'box with reverse below fifth.

Yup! I assumed they would be the same. Obviously not!!

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ALEX

Something id do that!

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timoth123

Little update.

 

Got most of the seats in, just waiting for a few spacers from Anthony to get the passenger seat in.

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Got the rear bumper and rear arch trims

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StArted on a job I've been avoiding! The engine ancillaries, it didn't last long, oil in and wanted to turn the engine over to check I'm getting oil to the head. Direct wire to the motor, just a click. Check the voltage all fine. Try 2 other batteries all the same. Stripped the motor cleaned it all, back together now turns but only just, it's knackered! Typical! Time to just give in and buy a new one.

Anyone any idea which slimline one fits?

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ALEX

I've found that the solenoid click without the motor turning is down to the multi-plug from the ignition barrel to the loom found near the ecu near the drivers right knee.

By unplugging and plugging it back together usually fixes it.

 

if not make sure the earth wire bolted to the top of the gear box is clean or even connected.

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timoth123

Bit of an update.

 

Turns out I was being an arse with the starter motor. I won't go into details buts it's working fine now!

 

After being sent away for a few weeks I managed to get on a fair bit.

The wheels and new tyres are fitted. Forgot to get a pic of them.

Pas seat and parcel shelf fitted. That's the interior finished now apart from rear windows. I'm waiting for some that aren't etched to be delivered.

 

Got on and got the brakes all bled and buttoned up!

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Dirty finger prints were cleaned off don't worry!

 

Then it was crunch time, I have been putting off working on the engine. Just too nervous incase it went bang.

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I've ordered a replacement alloy oil cooler from spoox as this one is trashed. Their website said in stock but that's a lie. They are waiting on the manufacturer to make another one and can't tell me when he's going to even start it. That's British customer service for you :(

 

So for testing purposes mine will be cable tied up. Not ideal, but I needed to push on.

 

So with oil in, and plugs out and rocker cover off, I turned the engine over to make sure I'm getting oil out of the spray bar. Success, after filling the filter and I assume the oil cooler, it came pouring out! :)

 

Ok, then rocker cover on, plugs in. And see if it fires..... Turnin, turning, turning, nothing then bang. It back fired. If I wasn't feeling nervous enough as it was, now this. My heart was in my throat. Had a quick look around, couldn't see anything untoward. Checked the caps were pushed in, check. Check the leads position on the dizzy, WTF, how the hell have I done that??? Fitted them completely wrong. Swapped them round to what they should be, turn the key! IT LIVES,!!

 

I think I cried, laughed and passed out all at once!

 

So then carried on putting the cooling system on to run it for longer than 10 seconds.

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Ran her up again, a lot more confident this time. And with a vacuum hose attached that I missed off for the servo. She sounds pretty good. Bit of twist of the dizzy and she sounds ok. Idles around 1200.

 

Now, I know there's massive room for improvement on the setup. And I am no way up to speed with pugs to start attempting it, I want someone who knows what they are doing. Time to start looking!!

 

That's it for now. Mrs is away in Spain, you'd think prime opportunity to get on. Not according to her and the DIY list left for me!

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timoth123

Bit of a minor update, but, a bloody big one in my head!!!

 

After completing a few niggly jobs that were annoying me like replacing the oil filler hose, slam to filter hose and a while host of other bits all thanks to farmer. (This car wouldn't be half of what it is if it wasn't for his help). New clutch cable, complete nut and bolt check of the drive chain, suspension and brakes.

 

There was no putting it off, I took it for a 3 mile test drive. Good god I was pooping my pants. 19 months ago I started this project and I was about to drive it properly for the first time. Damn it felt good!!!! :)

 

Left her outside to bask a little. I'm dying to clean her, but no point as the workshop I'm using to rebuild her is so dusty it would be dirty again in a day.

 

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Fitted the refurbished spoiler that Paul has done for me, (I owe you a few drinks there mate) what a difference it's made. Absolutely lovely!!!

 

I'm not overly happy with the wheels, the lacquer is peeling off in strips on the mating surface of the bolts and the center hub. So that will be another job to get redone in the future.

 

Still no sign of the new oil cooler too, had an email today though telling me it's been dispatched: so once that's fitted, can put the front end together properly and that's it done.

Clean.

MOT

Tax drive on road.

 

Them lay it up for the winter! :(

Edited by timoth123

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mrfirepro

Cant wait to see her, and experience a bit of pant popping myself :lol: , looking really good.

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timoth123

Well it's been ages since an update.

 

She went through her mot in December and then sat hiding inside for a while from the weather.

At the mot station after using the same road as a farmer :(

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Then decided to get her professionally detailed, was over the moon with the results. Also highlighted a few things I wasn't happy about!!

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18 months of dust and finger prints were hiding lovely paintwork.

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And I thought hat would be it, but things are never done.

I've been running the engine in and now its at 500 miles its revving lovely, haven't taken it passed 4500 yet but it just wants to keep going.

Our regular Shepard located a new AFM which absolutely transformed how the car runs. I thought it was good before. But this seems to have smoothed everything off, it idles lovely, off the throttle is the most improved, as well as holding a slow speed in town. Just lovely.

 

But now I really want to get it on a rolling road and get everything dialled in perfectly!

 

Couple of outstanding jobs, farmer found me some original carpet pieces for the boot wheel arches so need to get them cut up. But have no originals to copy.

Got a replacement top fuel hose from bbm as mine is just a generic bit of hose with two banjos jubileed at each end.

The fad fan is always on after a journey, I'm sure I got the right one from Mr auto but now I'm not so sure. Will have to pull it out and check!!

 

But, the biggest job I need to do now. And it makes me grrrrr just thinking about it.

I have to pull the gearbox out. The top fork arm bush has dropped inside the box. I noticed a while ago that one of the lugs had snapped but it seemed secure enough so left it. Now the form arm just flops around and has generated a little wobbling sound so I assume a thrust bearing is needed also. Just hope it hasn't done any other damage.

So they're next weekends jobs, then all will be right in the world ready for pugfest!

 

I hope!!!!!

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mrfirepro

Looking good mate... :)

 

I've got a template for the boot carpet I've emailed it to your googlemail account.

Edited by mrfirepro

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farmer

Are they not ready to go on straight away from out the packet?

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timoth123

Craig your right, already pre cut carpet pieces! Makes things easier!!

 

Got the gearbox sorted too! Replaced the fork arm bushes, what a pain in the backside that is leaving everything else in situ. Got it done though, but not before the engine slipped on the jack ripping the top engine mount, bugger. Teplaced it with a spare BBM one i had. They must be a hell of alot stiffer as the vibrations are alot more now!!!

Replacement standard unit fitted asap!!

After that just a few little jobs and its off to pugfest!! :)

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