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willmounsey

[misc_work] My 205 And Its Progress

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willmounsey

Just thought i would start this tread and let you see how i'm geting on :D

 

After selling my escort, the brother having a 1.6gti a while back and a friend having one for rallying i decided to get one myself.

The first one i got my hands on was a 89 1.6 with a 1.9 engine fitted with 1.6 gearbox, it needed tidying up (more than thought as i found out later :( ) which i didn't mind as was wanting something to keep me busy, it was running sound brakes were good but the suspension was a little worn and the interior too.

So when the time came to start stripping the car down the more i stripped the more feckin surprises it had install for me, front panel, drivers side sill (which i didn't notice till i removed the paint :D ) and the rear panel behind the bumper where rotted through, was rusty holes under back seats and around the front window and in other places whcih i knew about and was planning on fixing but gave up when i realised the extent of the damage.

Anyway a friend had a 92 rolling shell with near everything bar engine gearbox and drivers seat for £250, the shell was very clean underneath but needed a full respray so i took it off him as it was a bargin. :D

To date the car has rallye arches and 309 front valance all been resprayed in a subaru black, new brake lines and flexies,

powerflex wishbone bushes and arb bushes,

baker engine gearbox and rear axle bushings,

rearbeam refurbished with new rear brake calipers fitted,

spax vsx suspension kit wih group N top mounts and rubbers,

morette quad headlights,

and samco hoses.

 

Its been taking a while to build but most of that was due to having no time to work on it and it being 40 mile away at the brothers, but unfortunatly i was laid off there 6 weeks ago so have a wee bit more time on my hands now :)

 

Its mainly a case of putting it back together (apart from the wiring its the only thing I just cant get my head round easy or not) and trying to get it done within the next 6-8weeks.

 

This is the first project ive done before and most of the work ive done myself (apart from the spraying im not very good at it :( )so far so good i think :D .

 

here's a few pics of what it looks like now

DSCF0963.jpg

DSCF0962.jpg

roughly what the front will look like

DSCF0983.jpg

the arches

DSCF0969.jpg

the subaru black i think looks sweet

DSCF0970.jpg

the rear (forgot to say the wiper and lock was already removed when i bought the car still looks nice tho :D )

DSCF0961.jpg

 

Hopefully progress will pick up now ive the time (without the money :( ) and most parts ive already got so i'll try my best to keep this updated but there might be the odd delay :)

 

Cheers

 

Will

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DrSarty

Nice work there.

 

Dunno why you chose Subaru black, because I've given up totally on anything or anyone to do with those cars. :rolleyes:

 

If the car I let out of a side road or something happens to be a Scooby, not a hint of recognition or thanks. Hence me hating everything Subaru. :huh:

 

I also like the way you started your post even writing with an Irish accent. It looks like it's going to be a very interesting 'tread'. :(

 

When will it be on the road?

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djinuk

I like this, i thought about doing a Xs with color coded bumpers to see how tidy it looked

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willmounsey
Nice work there.

 

Dunno why you chose Subaru black, because I've given up totally on anything or anyone to do with those cars. :wacko:

 

If the car I let out of a side road or something happens to be a Scooby, not a hint of recognition or thanks. Hence me hating everything Subaru. :(

 

I also like the way you started your post even writing with an Irish accent. It looks like it's going to be a very interesting 'tread'. :P

 

When will it be on the road?

 

lol im acutally scottish but been in ireland for 6 years now and kind of picked up the patter :lol:

 

When i was getting it resprayed my mate who was doing it for me said why go for the normal black when its a full respray why not a different black and suggested the subaru colour. I didn't know they had this colour in there range its got so many different colours of flake and a red hint in it also looks sweet when the sun hits it :D

 

My brother has a scooby its his feckin pride and joy (sick of hearing about it to be honest ;) ) its not that i dont like them its there toooo expensive to do things with, his front and rear brakes where over £4000 and thats just caliper discs pads and lines thats more than my project to date! :o

 

Hopefully on the road in next 6-8 weeks and that leaving me good time to do all possibly could be before.

 

We'll have to see how it goes B)

 

Will

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willmounsey
I like this, i thought about doing a Xs with color coded bumpers to see how tidy it looked

 

I would say it would depend on the colour, i like the original look of the 205 but my bumpers were a little worse for wear so reason for colour codeing, came out really well i'll get pics up as soon as i get the bumpers and arches back on so you can see how tidy it is.

 

Will

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willmounsey

Few more pics

 

New suspension and brake lines

DSCF0965.jpg

DSCF0966.jpg

 

Under the boot, all sealed with new lines and flexies (still waiing to get he axle back though :wacko: )

DSCF0968.jpg

 

Em.... i'll get round to he interior later ;)

DSCF0960.jpg

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hillbilly

looking good keep up the good work

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Atari Boy

Nice project, I like the black.

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willmounsey

Little annoying update :)

 

Things have been put on hold (once a-fu*king-gain)

 

Rear axle wont be finished till friday (wouldn't mind but he's had it 7months!! :o:angry: )

 

Waiting for the exhaust and manifold to come hopefully this week also.

 

Got hit with an obscure phone bill so what money had aside has now up and fecked off to o2!! :angry::angry:

 

If the axle and exhaust come by friday there's alot i can get on with so hopefully (I say that word tooo much :rolleyes: ) this weekend i'll have a better update :huh:

 

Quick question, I have a transparant pipe which runs down from were the filler pipes are and goes over the tank and along the left side of the car (next to the bake line) and into the engine bay, what's it for??

My car came with no engine in it and this pipe was hanging there.

 

Any help is much appreciated

 

Will

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chocolate_o_brian
Nice work there.

 

Dunno why you chose Subaru black, because I've given up totally on anything or anyone to do with those cars. :rolleyes:

 

If the car I let out of a side road or something happens to be a Scooby, not a hint of recognition or thanks. Hence me hating everything Subaru. :)

 

I also like the way you started your post even writing with an Irish accent. It looks like it's going to be a very interesting 'tread'. :angry:

 

When will it be on the road?

 

You'll find most the early import buckets being driven by chavs with their Burberry caps are like this. Same in Scunny. But to hate all things Subaru for this is a very closed mind point of view.

 

I'm predominantly a Subaru man at heart, and I'd like to point out it's very different with regards to the genuine enthusiasts such as myself. I'm only 24, but had 3 non-chavved-up.com Scoobs and been a sensible driver in all of them. Always courtious on the roads etc, same as I am in the 205 I'm currently driving due to financial constraints.

 

Please don't tar us all with the same brush unless your looking to incite arguments. There are good and bad drivers with all makes, even the hallowed 205GTi :o

 

Willmounsley, personally love the black choice, bugger to keep scratch and rid free, but worth it if you do. Looks a different project to the norm also, but as said, keep lairy paint and bodyparts off (inc. lexarse lights) and you'll have a nice end product.

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willmounsey
You'll find most the early import buckets being driven by chavs with their Burberry caps are like this. Same in Scunny. But to hate all things Subaru for this is a very closed mind point of view.

 

I'm predominantly a Subaru man at heart, and I'd like to point out it's very different with regards to the genuine enthusiasts such as myself. I'm only 24, but had 3 non-chavved-up.com Scoobs and been a sensible driver in all of them. Always courtious on the roads etc, same as I am in the 205 I'm currently driving due to financial constraints.

 

Please don't tar us all with the same brush unless your looking to incite arguments. There are good and bad drivers with all makes, even the hallowed 205GTi ;)

 

Willmounsley, personally love the black choice, bugger to keep scratch and rid free, but worth it if you do. Looks a different project to the norm also, but as said, keep lairy paint and bodyparts off (inc. lexarse lights) and you'll have a nice end product.

 

I agree with you on the subaru side of things its the same here, you ve the chav types (townies what they call them here) who buy these cars with no clue just to abuse and rag around then you get the likes of my bro and one lad who lives a few doors up who have pumped huge amounts of money into thier own cos its there passion (so to say)

It's because of the chav types that all young lads in nice looking motors get treated as 'boy racers' (i fu*king hate this expression) and why insurance is so dear here, alot of insurance companys don't even look at jap imports anymore due to the amount being written off and the cost of repair.

 

I know its lairyer than a standard 205 but the rallye arches and 309 front valance is all that's being changed everything else will be standard, oh aye i feckin hate lexus lights they look so gammy! :) the ones that are on it look the nicest (phase 2 i think they are)

 

Im not taring you all with the same brush mate, i can spot enthusiast when i see one (your def one your cars soooo nice :D )

 

It does annoy me a bit by drifting away from the standard look but when i have it road going it can easly be put back to original look (apart from the paint :) )

 

Time will tell i suppose just need to get the feckin thing finished!! :)

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chocolate_o_brian
Im not taring you all with the same brush mate, i can spot enthusiast when i see one (your def one your cars soooo nice :) )

 

I wasn't have a pop at you dude, nor Dr Sarty, just the closed mind opinion he had re. all Subaru drivers.

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willmounsey

thought i'd update this :D

 

Well the 6-8 week deadline i gave myself was a a bit far fetched with the way things have turned out, only started working again a couple of weeks ago so getting money to get this finished.

 

I havn't many pics i always forget to take them and the ones i do have please excuse the poor quality (feckin i-brick!!).

 

Well so far ive the rear axle back on with new rear brakes, flexi's and copper pipes all round. The rear bumper and arches have been fitted also

 

IMG_0084.jpg

IMG_0085.jpg

 

I dont have a pic of the rear but i'd safely say you all know what it looks like :ph34r:

 

I got the engine back in last week and got the gear linkages drives and all back on

 

IMG_0083.jpg

 

i'll get more pics this weekend when i 'try' and tackle the wiring, i have to admit im very very lost when it comes to wiring i cant make heads or tails of it so one of the lads is gonna be getting a call i think :angry:

 

I will be moving the car closer to home in the next week (brother want his garage back:lol: ) which will make life easyer for me.

 

Not going to give a finish date as it never goes through so it'll be finished when its finished!!

 

more to come

 

Will

 

oh aye one more thing who do i talk to about getting a set of mintex pads? is there anyone on this forum who sell's them?? think its the 1144's. cheers.

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willmounsey

little update:

 

Got the car back on four wheels yesterday and got the bumper and lightes fitted

IMG_0101.jpg

IMG_0102.jpg

I havn't fitted the front arches yet as the bumper has to come off again when i get the car moved this weekend.

Got hold of a guy who's coming to sort this wiring out for me so happy days!! :D

 

Was fitting the samco coolent pipes and to my discovery a year after i bought them i think i've been sent the wrong set, 2 of the pipes dont seem to match

 

IMG_0108.jpg

 

The long skinnier pipe to the left i know goes to the header tank but seems to be too short (unless im routing it wrong i forget tbh), and the one laying on top of the engine is from the back of block to header tank but doesn't seem to be long enough and the size of the opening is too small as it wont fit the bottom fitting on the header tank (sorry not the best at explaining things :D ).

 

There's not much point in trying to take the kit back because of how long i've had it etc etc so most likely give baker a buzz and order the two i need.

 

That's all till the weekend and i'll get more pics up (mental note to self: remember camera!!)

 

Will

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willmounsey

Right had a fun filled weekend working on the car sorting the wiring out (ooh what a bitch that was!!).

It started on sat afternoon when one of the lads called over to give me a hand so we set about getting it done.

 

After a few hours of head-scratching and couple cups of coffee we hit a dead end, on the wiring loom there was 3 extra plugs that we couldn't figure out where they went and it was doing our feckin heads in! 2.30 in the morn came and we said we'll leave it for the night.

 

Next day we set about it again but this time inside the car, we couldn't understand why the fuel pump wasn't working so I seeked out the fuel pump relay next to the ecu.

Now this is where the kick in the balls came, i was looking at the ecu and it had motronic written on it so i grabbed the haynes and had a wee read, next thing i read is that it runs a tdc sensor, then it clicked! I've a feckin phase 1 engine it doesn't have a tdc sensor!! :(:wub:

 

Once i had realised this eveything made sense and when i went and got the wiring loom out the car the engine came out of i could of kicked myself so feckin hard, it was a doddle to fit (took about 2 hours) and could of saved me a day's pay for that lad who was helping me.

 

oh well sh1t happens i suppose but hey least i got the wiring sorted :lol::lol::D:D

 

 

Just a quick question if anyone is reading this: can anyone tell me the type of relay used for the fuel pump? I'm sure its a 7 pin relay but unsure on which one to get.

 

any help is much appreciated

 

thanks

 

Will

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willmounsey

Well i got the relay sorted yesterday and had fun with the caps on the injectors falling in the inlet (dont ask!:))

 

Anyhoo after a half hour i got them out and in the end it was a bad connection with the relay which was the problem, so i turn the key and she started after just a few turns so i was very happy :o (considering the engine had been sat near 2 years)

 

But then when i went to rev her a little i heard this rattleing coming from the cambelt area, so i turned off the engine and went to investigate.

 

Couldn't see nothing wrong so i stared her again and the same thing happend so i turned off and decided to leave it for the night (was late and i had work in the morn)

 

Today took the cambelt covers off and found wee bits of metal around the water pump and a big gash in the cambelt its self

IMG_0116.jpg

 

this is where the metal was broke off

brokenpug-1.jpg

 

and the damage to the pully wheel

IMG_0113.jpg

IMG_0115.jpg

 

luckily enough no other damage was done and the cause was a lad who help me change to cambelt must of left the bolt in the crank when it was locked in place so when staring shattered and made a mess (only way i can think of it happening)

 

so now i need to get a new pully wheel, would one off a 97 106 1.1xn fit?? or would any 205 one do the job??

Parts a feckin nightmare to get here so if there is an alternative would be handy.

 

 

Will

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GLPoomobile
Well i got the relay sorted yesterday and had fun with the caps on the injectors falling in the inlet (dont ask!:))

 

I've done that before. Funny, ain't it? :P Luckily the valve was closed on mine so had to whip the manifold off and then dabbed some grease on the end of a pencil and fished around until I found it.

 

Note for future - if you've taken the caps off in a lame attempt to clean up the injectors a bit, don't then bang on the fuel rail when the injectors are being a bit stubborn to go back in the manifold :o

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willmounsey
I've done that before. Funny, ain't it? B) Luckily the valve was closed on mine so had to whip the manifold off and then dabbed some grease on the end of a pencil and fished around until I found it.

 

Note for future - if you've taken the caps off in a lame attempt to clean up the injectors a bit, don't then bang on the fuel rail when the injectors are being a bit stubborn to go back in the manifold :)

 

greese on a pencil, wish I thought of that!

 

I wasn't trying to clean them but when I had the inlet off to clean and paint on two of the injectors the caps where a little melted so decided to replace them.

 

I was very careful on re-fitting them and I had the engine running ( breifly) so all must be ok there now.

 

Will

 

 

greese on a pencil, wish I had thought of that

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KieranGTI

It will be nice to see her finished, it's nice to be different.

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willmounsey
It will be nice to see her finished, it's nice to be different.

 

Aye can't wait to get her going,

Still having fun with the elec's though, i've ruled the starting problem down to either fuel pump or the tachy relay going to take a voltmeter to it now.

 

Also my dash lights are not working but i'll get to that when i've got the engine running.

 

The joy's :ph34r:

 

Will

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KieranGTI

Any update's will

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willmounsey
Any update's will

 

Unfortunatly no.

 

Money is very tight now (ba humbug!) and since the cars outside well, the weathers not really been on my side. I had a gazebo but the wind took it away and put a nice scratch along the bonnet :D and yes it was tied down to the fence but it broke that too :P

 

Its depressing me now but hopefully i'll have spare cash to do more in the next couple of weeks, wouldn't mind getting it running tbh, ah well we'll see what happens.

 

Will

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Galifrey
greese on a pencil, wish I had thought of that

 

Piece of pipe, blow into the inlet, out they pop.

 

Been there bought the t-shirt

 

:P

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willmounsey

Time for an update.

 

Bad winter and money problems lead to the car sitting for a few months frozen over and neglected, a few jobs where done over jan, feb march but not a huge amount.

 

Fixed my starter motor which was staying on but i'd found that the blue wire going to the starter motor had split so soldered back together and all working fine.

Next it was time to get the engine running, after having problems with it over-fueling and reading through a lot of topics on this forum I went and got a new ECU temp sensor and low and behold first turn of the engine and it sprung into life! I had a very big grin on my face that day :D got up to tempreture and no unusual sounds, fan kicked in and shut off when suppose to so i was very happy.

 

Still having a fuel leak on the bottom flexi pipe from fuel filter i was looking into replacing with braided hose and connections from speedflow, spoke to Miles who put me in the direction of Think Automotive (thanks Miles) who where considerably cheaper, speedflow was about £150-180 in fittings alone :D

Unfortunatly my van packed in and i had to buy a new runaround so what little money i had put aside got spent on a 94 XRAD van i got for £200, then sevice which was needed because the timing belt had not been done since 98.

 

After that i was pretty skint so whilst trawling through numerous topics i found out that a 106 gti filter would work (didn't know this at the time) so off to the autofactors and got one with pipe and fixings for 28euro.

For fixing the new pipe to the solid one i managed to push it over the olive a good bit and fitted a proper clip, then i made this for the filter because the 205 one is a tad too big:

 

IMG_0179.jpg

 

made with a piece of 1.3mm aluminium, very easy to bend and shape i found

IMG_0177.jpg

 

sits tidy i think

IMG_0201.jpg

 

106 and 205 filter side by side

IMG_0176.jpg

 

After that was sorted it sat for a little while longer untill 2 weeks ago when the weather picked up and its mostly been go!

 

I started with getting all the lights working which was fun, when i first tried them it was a bad case of dodgy earths and corroded connections as all the lights apart from the passenger side headlight where spontaneous, depending on either the lights where on or off varied the indicators and brake light also the reverse and fog light refused to work.

 

So after cleaning all connections and earths i got all front lights working spot on, but the back where still the same. I took the rear light clusters apart and cleaned everything

 

This is the drivers side but the passenger side is a lot worse (still causing trouble so will have to replace and sorry i didn't get a pic)

 

IMG_0207.jpg

IMG_0209.jpg

 

This solved most of the problems but the fog and reverse light still were not working, took the casing out and looked at the connections

IMG_0214.jpg

the corrosion was pretty bad, there a bit black looking, and after a clean

IMG_0216.jpg

 

Most of the connections where like this tbh, but still i was happy with myself for sorting it out (its nice when things go to plan :) )

I've had loads of niggley wee bits to sort like dash bulb replacement, tidying wires under the bonnet and under the dash, leak finding (almost sourced them all :) ) and the bloody petrol filler pipe which was a fiddly sod!

old one out

IMG_0264.jpg

 

new one in

IMG_0274.jpg

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willmounsey

IMG_0277.jpg

 

I have more pic's of this being done which i will write up in a topic later on.

 

After that i got a universel washer bottle kit from the bay for i think it was £12 or around that

 

IMG_0237.jpg

 

Found a unused braket behind the battery which was perfect

IMG_0238.jpg

 

made a little bracket for it to mount to

IMG_0240.jpg

IMG_0243.jpg

 

Lovley jubbily

IMG_0244.jpg

 

Also undersealed the rear arches

IMG_0278.jpg

IMG_0272.jpg

 

Still the front to do but i'll get around to that when i refit the front arches.

 

Thats about it really apart from i got new door/boot seals and external weatherstripes for the front doors from autofive, have to say they were really quite helpful as peugoet over here dont supply much for the 205 (or thats what they say).

 

Weathers gone back to usual today though so i'm praying for a couple of good days this week to carry on.

 

More to come

 

Will

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