- fitted fully adjustable front wishbones

- moved top strut mount back for more caster

- fitted pedal box

- removed rear torsion bars

- replaced 350lb rear springs with 500lb springs

- fitted dry sump tank over LH rear wheel

- fitted full width full tank & surge tank

- fitted flex sensor and fuel lines ready for E85

We're hoping there will be a lot more weight over the LH rear wheel now. Previously we were at 138Kg & 189Kg, left and right rear wheels respectively.

Firstly, it's been a long-term project/hobbie to have a separate track car not compromised by being a daily driver as well.

Mechanically, it is 1927cc, big valve head rebuilt by PeterT, t/bodies, forged high CR pistons, close ratio box, Quaife & aftermarket management making 165hp at the wheels.

Sitting in the shed & soon to be fitted are GAZ coilovers, 400lb springs, 23mm rear t/bars, 24mm rear arb, Brembos, bigger cams & 8V rods/ARP bolts.

The cage was made by a company in Melb. called Fabriacations who make cages for many of the Targa cars, open wheelers, etc & are highly regarded in motorsport circles. Well pleased with the result 'tho it looks like I'll need a smaller steering wheel as it's a tight fit getting in & out.

I want to do away with the huge heater box & blower, so does anyone know of a compact type or another way of demisting the screen? The touring car heated screens are no longer available unfortunately.

1) Are all XU10 Top Engine mounts the same, ie do they all bolt to the front of the block?! Has anyone got any good photos of the Mounts?!

2) Sump spacing, obviously im goingt o have some clearence issues at the bottom of the engine as i am removing a 88mm stroke crank and fitting a 96mm stroke. The XUD9 has no sump spacers etc. I would like to utilise my XU9 Sump Baffle from Shenpar Motorsport but how do i extend the sump and more importantly the Oil Pump Pick Up?!

Best Regards

Simon

It is a E Reg red 205 Gti that I converted to a gti-6 a couple of years ago.

The car was given a lot of attention at that time.

This is a short list of some of the jobs done the 1st time but the main thing was I never got the car painted properly.

Xsara VTS engine and box conversion. Original engine was on it last legs when I brought it.

I repainted the engine bay (With rattle cans) not bad but not great.

I made a new engine wiring harness as I could not find a GTI,6 loom good enough and while I was at it made a custom loom for the whole front end.

The front suspension was striped,rebuilt, painted and new bolts ect.

The rear beam was scrap so another was brought and fully rebuilt with grease nipples added.

All new brake lines in Kunfer,braided flexes, Rebuilt and sealed callipers.

Battery into the boot with a fia master switch in the dash.

The body work on the car was in good condition except for a bit of bubbling on the drivers rear arch and the front panel where it joined the wing. The rot was cut out and new metal welded in.

This was were I got a bit lost with the way I wanted the car to look. I made the mistake of painting the bottom half of the passenger side and rear valance dark grey (Anthracite). This was done because I did not want to have to try to match the red when I got round to the drivers side. It looked crap in my eyes but I had done it and all I wanted to do was get it on the road and try my lovely 6 engine out. So the drivers side bottom half was done with red rattle cans. Which looked OK but it is not a great paint match and has suffered with stone chips. Serves my right for cutting corners and not getting the car painted professionally.

So after a few years using the car and doing a few track days the car is now being stripped for a full shell respray.

During this time its also getting a roll cage, Xsara vts rack, Adjustable pedal box. Flocked dash. Polly windows. Race seats and harness and any thing else the the funds allow.

Photo's to follow.

Cheers

Neil

An on going track car build project!

Started life a few years ago as a standard 205 XL, I basically stripped everything off the car, to start fresh with a 3 door non sunroof shell to work from. Hope its an interesting build, photos jump a lot as its been on going for a couple of years.

The project is about a year old now and came about as a result of noisey valve shims.The car had been off to a so called expert at a local garage who promised the usual stuff,you know - 42000 bhp @ twelve rpm rising steadily all the way to 12 grand.All that actualy came back was a car that was noisey and slower with a big bill.

I had a good long look and think and decided the thing to do was to start again but this time with a plan.So my mate and I (the owner),(I'm just the wrench by the way) thought hill climbing and a bit of drag racing sounded fun and I've got a bit of drag racing practice under my belt anyway.

From the outset we both decided that we would try to incorporate some forward thinking ideas into it,so I got on with planing the power plant and my mate took up the rains on the chassis.

The motor is a 205gti 1.9 unit,the c.r. has been droped to 7.95:1 using a combination of chamber reworking and a decompresion plate of 1mm thick,the bottom end is as stock with the adition of new rod bolts,ballancing,oil pump drive,blah blah blah.The reason for keeping it stock down there is because its so Tonka to start with.

After finishing the chamber work I set to with the inlet and exhaust ports giving the exhausts a more 'D' shape to speed up the gas flow round the bottom of the port,the inlets have had basicaly a straightening and enlargment idea.There's a cam installed and three angle job on the valve seats,although I've widened the contact face on the exhausts a little more than normal to aid in heat dissipation.The turbo is to be set at 15psi.

The ignition system is my baby realy.I didnt want to just buy the usual maped ecu because its to easy,boring,and limiting as your soley relient on somone else's ideas of what windows of operation your motor would like.Sure your gona get a good bit of kit that works but what have you learned-Nothing!!!.So I took a bunch of micrcontrollers and some other bits and bobs ad started building one.I wanted a system that would fire the coils sequentialy in the firing order allowing me to run one coil per plug giving me the opportunity for large plug gaps.The system is being equiped with a multiple spark discharge circuit and ignition timing with feedback from a boost sensor.

From the outset I wanted to use optical sensors so the rotor arm has been removed to make way for an optical interuptor wheel to trigger the optical sensors which ultimatley fire the coils.I have to say the code that I've writen for the project has been chalenging and although the firing sequence part is up and runing and the multiple discharge section is ok,the timing section is much more complex but I love it and its well underway.

Anyway enough babeling from me here's some pics.

Ok like I said new here.How do I get my pics on anyone help,I'm gona need it.

Cheers

O.T.

apologies in advance for my text and explanation of things, lets just say its not a strong point of mine, so I'll be using lots of pics it its place

Peugeot Project

205 Gti 1.9 Mi16

Bought-

21st February 2004

Paid-

£825

Spec-

Standard 205 1.9gti apart from

Koni suspension and rear beam lowered (two splines)

1991 405 1.9 Mi16 engine and gearbox

Mi16 ECU

Momo race steering wheel and gear knob

Guttmann rear spoiler

Bad points-

missing red trim (pic)

crunching in 3rd gear

6x9 holes in parcel shelf

Chicken mesh front valence

Rusty o/s wing

And a hole load of other bits and pieces that I’ll sort it the future

The car was bought as a cheap fun daily runabout to replace my 2yr old Audi A4 se sport 115 tdi

Tidied the car up and dealt with much of the bad points from above, as I was also using the car daily to commute it was doing about 350miles a week so lots of little things kept coming up and needing replaced, things like starter motor, water pipes, linkages, dodgy wiring etc

Had it put on the rolling road at McDonald Racing to get a bit of an idea of how well it was running

I finally got round to getting myself down to Santa pod for the retro cars show and to have a bit play in the Mi on the ¼ mile strip, my best time of 15.8sec was maybe a bit poor

On the way home the mi16 gearbox which still had the crunchy 3rd finally gave up, my mate had to hold it in 5th half way bk (about 130miles) then I lost 5th and 3rd and did the next 170miles in 4th

Got back and went in search of a complete 205 1.6 gti for the box and few other bits, after couple of days I found one with knackered bottom end for the sum of £300

lots more to come

Hi all,

Been poping in and out of the site for a while now as its the 1st place I head to on fact finding missions

I had a 1600 8v back in 95-97 and still remember the fun I had in it.

So when a mate wanted to start some sort of motorsport a Pug was top of the list.

We decided that Hills & Sprint would be a god place to start as we could both drive the car and costs would be a lot less than rallying.

The wee car below was bought in 05 as a 1900 8v and we gave it a bit of a tidy up and replaced all the suspension/brakes.

We ran the car for 3 years (06-08) and fixed things as they broke lol, this is the main reasion for the 09 rebuild.

The car as we got it

Then after the tidy up + new brakes susp

There is more pics in the link below of the tidy up and I will upload more pics from the 09 rebuild as

I go

http://s298.photobucket.com/albums/mm280/G.../Pug/?start=all

Over the 09 winter it's getting a rebuild and a 1600 8v droped in, due to changing class.

The spec below is as the car sits now, all this has been done over the last 2 years, only the engine and box have been done in the past few weeks.

Shell

Omp Cage

Plated Sunroof

Striped Interior

Battery In Boot

Plumbed In Extinguisher

Areoquip Fuel/Brake Lines Incar

Cobra Monaco Seats

Trs Belts

Battery Cut-Off

Suspension Brakes

Bilstein Struts

Eibach Springs

309 Bottom Arms

WMMS Rebuilt Rear Beam Solid Mounts

Upper Strut Brace

Lower Strut Brace

Tarox G88 Discs

Mintex 1144 Pads

Engine GearBox

Rebuilt Std 1600 8v

K&N

WMMS Down Pipe

WMMS Single Pipe System GP N

Rebuilt BE1

Quaife Diff 4.4 CWP

Wheels & Tyres

15" 1900 Rims Yoko A048's White

15" 1900 Rims Toyo R888's Bronze

14" 1600 Rims Road Tyres

14" Steel Rims Gravel Tyres

Thanks for looking more to upload as the winter 09 rebuild gets under way.

.

I tried starting a project thread but it wouldnt let me!

Ive had the car just over a month now, and have bought a rollcage and an xs engine for it

The car has been used for hillclimbs and sprints in the past so is part prepared.

My friend Ricky P swapped me the car for a MK1 escort I had. He had owned the car for 3 years or so.

I currently race a mk1 Toyota MR2 but its becoming so expensive to race now, I think that hillclimbing is the way forward for me, and my bank manager!!!

Once I can create a thread in the project section I will do as i would like to show what im doing with the car over the next few years.

Matt

GTI6 engine

306XSI gearbox

Pair of PeterT solid cams with solid lifter conversion

40mm ITB's (trying to retain midrange powerband and driveability)

Lightweight flywheel

305mm 4 pots up front (406 discs with CL500 brembo calipers), gti 180 calipers on rear

Suspension yet to be decided

Wheels to be decided but most likely 16 or 17 with R888 rubber.

MS management

6 point cage with harness bar and door bars

1 seat, no dash, fire extinguisher and a small control panel. Probably stack dash if funds stretch, or a coupe of small gauges for temp and revs.

Swirl pot and external pump.

PC windows and no door internals or front lights etc.

This is the car that will become a new toy.

The story begins with the purchase of one 1989 Peugeot 205 XS back in September 2009.

I purchased the car from a chap who had already competed in the car, and had done various types of events ranging from Auto tests to PCT's (production Car trials) as well as numerous Road Rallies and Endurance rallies, all with a fantastic reliability record.

The car came with a lot of safety features fitted such as Full Roll Cage, Racing seats and harnesses etc.

When I drove the car, I noticed right away that there were quite a few things that I wanted to sort out. Things like the drive shafts, gear linkages and a fair amount of other things that needed my attention.

As you can see, it needed a LOT of TLC body-Wise!

I'm currently going through all of the pictures I have taken and will be posting more info on the project to where I am at with it at the moment!

Anyway, to cut a long story short I started doing trackdays in my diablo red 306 gti6 years ago and got the bug, but the car at the time was my daily and far too nice to turn into a track car, so after a bit of saving up and picking up bargain parts I found a local-ish gti6 with engine problems. It was a pretty good price for the car at the time and if I hadn't bought it it would have been destined to being broken for spares.

Here it is when I got it home.

IMG_0322 by Steve Count, on Flickr

Not my cup of tea but it was affordable and just what I wanted as a base to start a project.

It wasn't long before I had stripped and sold pretty much everything I could that would be of no use to me, the car then effectively owed me nothing.

It soon looked like this:

IMG_0523 by Steve Count, on Flickr

IMG_0498 by Steve Count, on Flickr

I took the engine in to work and stripped it down, I bought the car knowing the head gasket had gone but upon looking at the stripped engine I decided that rebuilding that engine wouldn't have been cost effective, the block needed boring out, the head was as good as scrap and everything else had seen better days.

IMG_0668 by Steve Count, on Flickr

In the end I bought a second hand engine from someone in Southampton for £300.

With the old engine out I tackled the engine bay rust and gave it a fresh coat of paint.

IMG_0708 by Steve Count, on Flickr

IMG_0839 by Steve Count, on Flickr

IMG_0846 by Steve Count, on Flickr

IMG_0853 by Steve Count, on Flickr

I also treated the wheel areas to some stone chip.

IMG_0840 by Steve Count, on Flickr

With the front end sorted I could then start to fit the new bits to it, one of the first things to get replaced was the front dampers, I fitted some KW V2's that I'd purchased in preparation for getting a track car.

IMG_0369 by Steve Count, on Flickr

Wiring for moving the battery to under the boot floor, and brake line for fresh lines all round and removing the ABS.

IMG_0847 by Steve Count, on Flickr

Roller bearing wishbone bushes.

IMG_0848 by Steve Count, on Flickr

Smaller/lighter alternator.

IMG_0837 by Steve Count, on Flickr

Had some brackets laser cut to hold the power steering pump and allow for manual tensioning of the aux belt.

IMG_0884 by Steve Count, on Flickr

IMG_0885 by Steve Count, on Flickr

Fitted a billet flywheel to the replacement engine.

IMG_0935 by Steve Count, on Flickr

IMG_0929 by Steve Count, on Flickr

Engine and gearbox back in.

IMG_0937 by Steve Count, on Flickr

Decided to paint the block fluorescent orange in a moment of madness.

IMG_0943 by Steve Count, on Flickr

Fitted a lower strut brace to go with the seam welded subframe.

IMG_0842 by Steve Count, on Flickr

Front end starting to come together now.

IMG_0960 by Steve Count, on Flickr

More new parts arrived.

IMG_0850 by Steve Count, on Flickr

IMG_0818 by Steve Count, on Flickr

IMG_0869 by Steve Count, on Flickr

I'd had problems with overheating brakes in the past so I decided to fit some ducting directing cold air from the foglight holes in the bumper to the back face of the discs.

IMG_0965 by Steve Count, on Flickr

IMG_0967 by Steve Count, on Flickr

IMG_0968 by Steve Count, on Flickr

IMG_0970 by Steve Count, on Flickr

New nissens radiator and two 13 row oil coolers fitted.

IMG_0985 by Steve Count, on Flickr

IMG_0993 by Steve Count, on Flickr

The new battery mounted under the boot floor.

IMG_0988 by Steve Count, on Flickr

After a mis-hap on a test drive involving losing a lot of petrol I decided to fit a fire extinguisher. Also visible is the bias valve and braided lines which are short lengths just to get under the car where they mate with the copper-nickel lines running to the rear brakes.

IMG_1004 by Steve Count, on Flickr

I think around this time I took the car to the nurburgring, and in classic Peugeot style it broke down, several times.

254446_10150275412767154_6080765_n by Steve Count, on Flickr

First time the clutch cable auto adjuster gave up the ghost whilst stuck in Belgian motorway traffic. Face palm moment! I had a spare though so got that fitted in record time but ended up soaking from laying on the wet road.

Next problem:

247911_10150275425287154_6536589_n by Steve Count, on Flickr

Fortunately it was a relatively easy fix, the crank position sensor had gone, but finding one of them on a German bank holiday weekend and the ferry booked for early the next morning added a bit of stress. Fortunately a mate in Luxembourg had one on his brothers car that I could borrow to get me home with, so a late night trek over to his to get the sensor, then the drive back to the campsite to fit the sensor. I think it was about 2am by the time I'd fitted the replacement, started the car and it ran so I got a couple of hours sleep before the drive home.

Just to prove it did get a lap in whilst over there:

248290_10150223868952472_7012345_n by Steve Count, on Flickr

Once back it was time to progress a bit more. I got Phillipm/Rippthrough to make a cage for me. My order started out as a simple 6 point cage but he could sell sand to an arab and before I knew it I'd agreed to all sorts of extras. A few weeks later I got the car back.

IMG_1551 by Steve Count, on Flickr

IMG_1554 by Steve Count, on Flickr

All painted with a copious amount of rattle cans!

IMG_1594 by Steve Count, on Flickr

IMG_1626 by Steve Count, on Flickr

IMG_1627 by Steve Count, on Flickr

I decided to save some more weight by removing the heater, so looped the coolant hoses on the back of the thermostat housing.

IMG_1603 by Steve Count, on Flickr

I ditched the bonnet release mechanism as the cage now lived where the cable lever would be, plus I got a good deal on some Aerocatches.

IMG_1610 by Steve Count, on Flickr

IMG_1615 by Steve Count, on Flickr

IMG_1631 by Steve Count, on Flickr

I also fitted aerocatches to the boot as there was no other way of securing it after ditching the central locking. (Weight saving once again)

IMG_1642 by Steve Count, on Flickr

IMG_1643 by Steve Count, on Flickr

I fitted all new BakerBM engine mounts and Miles gear linkages.

IMG_1646 by Steve Count, on Flickr

I got some Lexan sheet and made some new side windows, used the glass items as a template then went round with a jigsaw before smoothing off the edges on a linisher.

IMG_1649 by Steve Count, on Flickr

IMG_1673 by Steve Count, on Flickr

Came across a cheap Pipercross Viper filter so snapped it up and fitted that.

IMG_1738 by Steve Count, on Flickr

I got some corrugated plastic and made an undertray to sit under the boot floor, the aim was to reduce the air dam effect in the big void between the fuel tank and rear bumper, and to provide a bit of protection for the battery.

IMG_1684 by Steve Count, on Flickr

IMG_1698 by Steve Count, on Flickr

I also made a new centre dash panel with an oil pressure gauge, and several switches for various things since getting rid of all the original switches etc.

IMG_1662 by Steve Count, on Flickr

I fitted some seat bars, bucket seats and harnesses.

IMG_1535 by Steve Count, on Flickr

Morris guarding one for me

IMG_1561 by Steve Count, on Flickr

IMG_1630 by Steve Count, on Flickr

IMG_1636 by Steve Count, on Flickr

I fitted some borders to the rear windows in an effort to make them slightly more o.e.

IMG_1768 by Steve Count, on Flickr

And a new heated front screen to combat the removal of the heaters.

IMG_1769 by Steve Count, on Flickr

I thought I'd start a new topic on my engine build and it's progress.

The aim is an engine to go into my base model 205 GT to have a right hoot at weekends and on trackdays. Origianlly I was going to go with an ally 1360 block and 106 Rallye head, but finding a bottom end with the parts I needed was starting to get hard.... Then I got offered a TU5 bottom end for free.

Current build spec is:

Totally rebuilt TU5J2 (From a 106 XSi 1.6) bottom end

106 Rallye head (Also TU5J2)

4900645 CatCam (280 degree, 11.25mm lift) and CatCam Vernier Pulley

Standard compression (For now... long story)

45mm Jenvey SF Throttle Bodies

Custom inlet manifold made by Sandy

Custom right hand engine mount to clear manifolds

Modified 4-2-1 Exhaust Manifold (From 106 to 205 fitment)

KMS ECU

For pictures of this little lot see: http://smg.photobucket.com/albums/v727/ros...Engine%20build/

I chose the TU5 head as it has the largest valves you can get on a TU Blacktop head and seems to flow reasonably well in standard form. For it's first incarnation, this head will be standard, i.e No flow work.

The camshaft was a bit of a lottery. It came recommended from Matt at QEP. Sandy seems to recommend the 615 or 646 profiles for TU engines, so typical of me I chose the one he hadn't used yet

The Throttle bodies and manifold came from Sam on this forum who is now building a monster XU turbo build. I got the mount from Jrod but again this originally came through Sam too.

All the rebuild parts, the cam and vernier came from Matt at QEP. Top guy and very competitive prices.

The aim is ultimatly for 150bhp and about 115 - 120 lb/ft Torque. Not much by todays hot hatch standards, but in a 750kg 205 I reckon it will keep up with a lot of other machinery

Current progress is that the cylinder head is now built and ready to go onto the block. The block has been painted, and the crank is in and torqued up. Next step is re-ring the pistons, install into block and then the head can be attached to the block. (See the sub album in the above link for latest pics)

Been to the stealers today and ordered some new con rod bolts, pick those up tomorrow.

You can follow progress here: Rossy.org.uk, its just a simple webpage I have cobbled together so I can record the progress it makes.

So thats it for now!

Keep it TU and keep it 8v!

This is my project which I picked up on Sunday:

The main aim for the time being is to make it as light as possible hence keeping the costs down to a minimum.

I will post up pictures as I go but the first job is to drain all the fuel out and put fresh in and fire her up.

Thanks

Jon

I've driven 205 Gti's since I was 18 and unfortunately have sent one to a scrap yard, converted one nearly to MI16 that I sold to a mate cheap which he easily got working and I hope is still on the road somewhere.

I had a small period of a few years without owning one before I decided I needed one in my life again. A bit of an impulse buy I must admit but knabbed this one off ebay.

image5 (1) by simsk, on Flickr

It is running a Xsara engine on jenvey throttle bodies and K6 management which was too hard for me to ignore since I wanted a XU10 engined car. It seemed to have a good spec with some money spent on it so seemed a good deal.

Basically as I bought the car it had:

Xsara engine with throttle bodies and K6 managment and made something like 167bhp at the wheels on the map though I'll have to double check. It was mapped at Janspeed.

Xsara 5 speed box

Willwood dynalite brakes with braided hoses

Gaz suspension

Grp N engine mounts

Swirl pot in the back with fuel line ran in the car.

OMP 6 point cage

Cobra Imola bucket seats and 4 point harnesses

Stainless steel custom exhaust

Bad points where:

Cage and seats where barely welded in...

Has wheel spacers all round

Sits too low so probably needs rasing by 20mm or so

Had no filter on the throttle bodies

Bad fuel lines and tyres.

Well at least that's what I've found wrong so far after owning the car a couple years.

It has had a couple problems both where the crank sensor. First time was a straight swap and up and running again though I never drove the car much as It had no air filter and then It started to become hard to start and got worse over time. What I didn't expect was the new crank sensor to break down slowly and cause this to happen which left me scratching my head for a long time and waiting for some people that never helped and In the end it clicked one day. Finally with that fixed and now an air filter fitted on the front I could at least drive the car though not fast as the seats and cage where a joke quite frankly...

So next year I want to drive around europe in it. Hit SPA, Nurburg, alps, monaco, le man and some other roads etc in a loop. I've always wanted to do this and only ever driven the ring in other peoples cars and never my own yet unfortunately. So the game is on to get it ready for next summer.

So I have a few jobs to do and a couple things I'm a little unsure on atm, regarding the rear beam and overall suspension setup. What to go for?? thinking 21mm torsion bars, 22-23mm ARB and a full rebuild with possibly xsara arms.

Here's some pics so far, I'll update with any little jobs etc on my way...

image3 (1) by simsk, on Flickr

Cosmetic wise I didn't like the orange wheels, badgeless grill or raised bonnet, so wheels are now ford grey fitted with new tyres, Continental PremiumContact5 185/50/15 and speedlines all round that I had in the garage with all my other bits and fitted a grill that wasn't badgeless though it does have carbon stickers on it :/ still I like the colour and having a badge!

I fitted a IFM filter onto the bodies...

image1 by simsk, on Flickr

image2 by simsk, on Flickr

Then I wanted to get the seats in properly though I don't think it'll quite meet MSA spec quite as the 3mm plates that attach in the middle aren't quite big enough. A wrong calc on my part... Though I'm pretty sure they are in there good and I'm happy with it. It was hard getting the seats low enough to keep your helmet away from the cage and I don't ever plan on competing myself though safety is always first.

image4 by simsk, on Flickr

image5 by simsk, on Flickr

Floor is just zinc primed until i get the cage in properly then i'll go over it all with a better finish paint.

That's where I am a now but hopefully I should be able to get some time over xmas to make some progress.

Any advice greatly appreciated, I do try to use the search function as much as possible on here.

About 2006 Colin decided that any further development would really need a new base shell and engine, to do what he wanted to do. He sold the car to a customer (it's still in occasional use) and that was that. Since we've been working together, we've had many ideas and ambitions we wanted to invest in another car; initially a 106, which we made some progress with, but the 205 had more ultimate potential for the Modified Production classes and we decided this had to be a car we just built for our own satisfaction, more than anything.

Colin had prepared a 205 shell to near completion for one of our customers, with a Honda H22 engine, but when the customer offered to sell it back to Colin, it seemed the obvious opportunity to quit talking about it and make a start!

First stage was to undo all the modifications to the shell for the Honda engine/box. This included a section of bulkhead that had been modified and would need to be put back to original. One of the biggest changes from the old car, would be to mount the engine and box much lower, nearer to vertical, to lower CG, improve the driveshaft angles and enable the subframe to be solid mounted to the engine and use it to carry suspension loads.

Here it is at the mocking up stage, wheel location is vague and the original cage is still in there:

With the workload we have, time to spend on this project is limited, so Colin has employed a couple of able friends to do alot of the work, under our supervision. I had a few things I wanted to do differently with the engine, to my previous XU 16 valvers, I toyed with the idea of using the EW head, but in the end I heavily re-worked an XU7J4 head to an entirely new inlet port shape, it took 3 heads to get right and I used the new head on a customer's engine, which produced a fantastically wide torque band, so I was heartened that my efforts were worthwhile! I ported a near copy of that head, but with subtle differences to suit the cams I'll be using in this. A big part of this project is that doing it for our own entertainment, we can go a bit wilder here and there, in a way the responsibility of building for a customer doesn't allow!

The tilted engine would allow the exhaust manifold to be mostly in the engine bay, which helped alot with packaging and where bump steer would dictate the rack needed to be. Normally I farm out exhaust manifolds, but Colin fancied trying his arm at it and based on my dimensions, figured out what bends were needed, acquired them and got on with it. Manifold making is a skill all of its own, knowing how and where to cut and weld, but we're pretty happy with it and once tidied, it'll do the business I'm sure:

Colin was not satisfied with the cage already in the car, so it was cut out and binned. He bought in the main hoop and legs, but fabricated all the other sections in the appropriate tube and with the seating position lowered and moved in slightly for safety (with the confirmed approval of scrutineer), the steering column and general controls could take shape:

hope you enjoy.

removal of the old Mi/gti6 hybrid engine.

after most of it was stripped down i took it to work and pressure washed the whole car down

before

after

I’m sure some of you know of my last car, Red track spec 205gti6. (In the avatar!)

Well I’ve decided to start racing properly now so the track day 205 has gone, being replaced with a newer eligible car.

I will be competing in the Castle Combe Saloon Car Championship in 2008. Class C (1400 – 1800cc)

After going through the feasibilities and costs of many cars I narrowed my choice down to a 1.8 16v Peugeot 306 XS.

But finding the model spec I wanted with a decent shell etc wasn’t so easy!

But just at the right time (last July) a white 3 door non sunroof 306 gti-6 came up for sale. As it’ll be stripped right back to the shell and all new stuff including engine will be going in anyway, the model difference wasn’t a problem.

So a bank holiday trip down to the tip of Cornwall armed with a tent to pick it up. (The other half took some convincing that this was a great idea though!)

After a couple of weeks stored on my parents drive (Thanks!) while I cleared room on my drive for yet another pug I parked it up and started attacking it.

Out came the engine first. Which has gone to a good home in a friends 205 (Spikey).

Then I stripped out everything that isn’t vitally essential; ABS, Air conditioning, Power steering etc. And some other heavy bits that will be replaced with smaller/lighter equivalents.

Then gave it a good clean and shine up.

It was originally built to be a track car and no expense had been spared by the previous owner. The cage had been fitted by Phillip (Rippthrough) and had Colin Satchell solid engine mounts fitted. The plan was simple, replace and fit the bits required to get it through log-booking and get out on the stages. Unfortunately that did not happen and 14 months later it is still sat in the garage on axle stands.

a few pictures before work began:

The bucket seats and harnesses were out of date so they were sold. I already had a brand new pair of Ricco Racing harnesses from the 205 so after a quick phone call to Motordrive a pair of bucket seats arrived:

and drivers side was fitted after having to buy a new pair of side mounts:

Next I moved onto sorting out my suspension. I decided started with the rear beam and as Andy (jord294) is local, I ask him to build it for me. Some negative camber on the back was in order so I sent a pair of trailing arms off to Martin (CRF450) at Bridgecraft Engineering to work his magic. A cheap 30mm arb was up for grabs on the GTi6 forum so I snapped that up and placed an order with Anthony for some 23.5mm torsion bars. A few weeks later everything had arrived and as I already had a set of solid rear mounts I took a trip up to Andy's to drop everything off. Once the parts had arrived back from powdercoating it only took Andy a few hours to put it all together. The following weekend I took the car up there to get it fitted.

I ended up with AVO mono-tube fronts and two-ways on the back as I was trying to stick to a budget, looking back now I could have spent a bit more but was happy with what I had. The after-sale service from AVO seems highly rated so if I do have any problems I should be able to get them sorted pretty quickly.

well I was happy with the rears until something else popped up for sale the AVO two-way rears were sold on to buy these:

After waiting ages for a decent set of 4 pots to come up for sale I bit the bullet and got a pair of AP Racing CP6562 6 pot calipers

they are of a solid one piece alloy construction, fitted with titanium pistons with ceramic caps to stop heat transfer into the fluid. Next up to buy was a pair of Carbone Lorraine RC6 pads, as these calipers run a smaller size pad they had to be ordered in. Here is a picture of the caliper and pads on the kitchen scales:

Choosing what size rotor I was going to use would be a difficult decision. As I have 2 sets of Pro Race 2's, 1 set of Pro Race 1.2's and 3 Pro Race 1's all in 15" size and direct fit (ET15) I wanted to make sure all the alloys fitted over with no problems. I was very tempted to go with 310mm but the TD 1.2's really are p**s poor for clearance compared to the TD 1's and 2's. After much thought I went with a pair of 300x28mm rotors from Hi-Spec. I just need to get some bells and brackets made for them now.

more to follow.....

Unfortunately the car came to a sad end in March 2009

A pic of what the front drivers side corner of it looked like after:

I was just after buying a white 205 1.6 GTi not long before this which I was planning on just keeping origional for maybe an every day car.

Here is a pic of the two of them together:

http://img818.imageshack.us/img818/6424/s013.jpg

So after this I decided you use the white 205 to rebuild the rally car. So this then got stripped to pretty much a bare shell. The cage was fitted. Strengthening plates fitted to strut tops,rear axle mounts,engine mount and towing eyes/sump guard mounting points. The car was also seam welded just around the seams on the inside. Plated over sunroof. etc...

When this was all done I then cleaned it all down and painted it just the engine bay and interior.The outside of the car was pretty much spotless.

It all started when me and my other half deceided that we would fancy having a go at rallying. I knew that road rallies are popular in our area and is probably the cheapest and easiest way to get into the sport so we deceided that would be our path. We went to Finland in July to watch the Finish round of the WRC and started our search for a car when we came back.

The original plan was for a Saxo vtr or 106, so we went to a garage to see about a Saxo and got talking to the sales man and it turned out that he used to do a bit of road rallying in the past, what happened next was amazing. He told us to forget about a Saxo and buy a 1.9 205 GTi, so he talked himself out of a possible sale and gave us some great advice, dont get that from many salesmen eh??

So thats what we did. In august we put an offer in on ebay for a Gti and got it. We travelled from sunny Wales to Poole and brought it home. Tax and Mot for £800. It needed a little bit of work but was perfect for what we wanted it for, It was pretty solid and even though its over 150k on the clock it still goes and sounds great.

So far its had a new airflow meter, track control arm each side, sorted rust on bottom of the rear quater, stuck on a Green cotton induction kit, sportex exhaust from the manifold back and group N engine mounts. We also serviced him so he runs pretty well now. Oh and currently has one white wheel that we ve refurbed. We have 9 wheels altogether which will be going white soon. So here is Pugsley as he stands at the moment

In the new year it'll be set up as its a bit rich at the moment, also a knocking from the rear which will hopefully go away when it gets new suspensipon all round too, failing that it could well be a new beam time. Also there'll be a cage on order and these will go in at the same time.

Seats were had off ebay for a steal and their virtually like new, TRS 4 point harnesses from Peter LLoyd Rallying.

So there we are for now. More updates in the new year

Merry Christmas and a Happy New Year

Arwel + Claire.

I present M556 BOT :

As being picked up with lots of help from my mate Will Diclaudio - thanks Buddy

then pictures taken today.

Few things to be sorted out but thats what lists are for !! comments below most welcome !! thanks for looking and will keep updated on the progress!

1st thing is to raise the ride height a touch

sort the gear shift out as its running be3 lever but with be1 box !! not good !

sort the wiring out and strip what isnt required - ie the ECU etc.

Get it properly rolling Roaded so its set up properly

then go from there I have lots of plans but want to use this on track and enjoy it and not be working on it all the time like the last one !

It took a knock last time out and being sat up for a while.

I bought it a few weeks back with the hope of running it in the Irish Rallycross Championship 12/13.

Engine out last week, ready to go off to the repair shop at the weekend,

Ill keep it updated as I get it back to its former glory!

So after rolling my 205 at Cadwell Park, so the rebuild begins....

Damaged Car

Although not looking terrible from the picture, the rear impact into the barriers had made a real mess of the boot floor, and otherwise there wasn't a straight panel left on the car. It was also not a great shame to be able to get rid of the sunroof!

Donor Car

Donor Car + cage, next to my tidy 1900

Donor Car - engine/box/susp etc removed.

Found some rusty bits

EEK.

After some time away (tracking Impreza's) I've decided to build another Pug 205, The plan is to build something that will be the equal of my old impreza around Cadwell. If I can acheive that I will be a happy man as my best lap was around 1min 45sec. Who knows how much Ill spend chasing that.............

I will try to give regular updates but as with all projects time, money and family commitments always have some bearing on the outcome.

Any input/advice is always welcome as I dont like making costly mistakes. LOL

The plan;

Multipoint weld in cage

Big brakes

Bilstein Tarmac suspension

mi16 motor

plated diff

Custom loom

Plastic windows

Serious weight loss (well anything that doesnt cost the earth, I cant afford unobtainium)

Track tyres/slicks of some sort

I bought YEE as an unfinished project, rough around the edges but had most of the main parts for the transformation and importantly only one small path of rot (passenger side footwell)

It took a weekend to strip to nigh on a bre shell ready for the cage

Cage arrived yesterday, very surprised given the snow..........................!

I made a start on the trial fit but given it was -5C outside I didnt get much done

Cheers

Stu