dave_gti 0 Posted July 23, 2011 Its summer and my pug is sat in the garden rotting away. So today I decided to take action and have begun bringing it back to life. Today I have removed the rear beam and fuel tank and have been left with this – Its wasn’t as bad as I thought to be honest I expected there to be a lot of tin work and it to end up looking like a sieve. I have only found one hole so far – From the outside – From inside – And a sorry site of Puggles and my not so fun working conditions – The next plan for tomorrow is to attack it with a wire brush ready for rot treatment and protection, after I decide how is best to patch up the hole . Share this post Link to post Share on other sites
Fox 3 Posted July 23, 2011 How longs it been sat? It does look very sorry for itself! Share this post Link to post Share on other sites
dave_gti 0 Posted July 23, 2011 Approximately two years. Hopefully it’ll soon be restored to its former self and on the track. But the task list is growing by the day. Share this post Link to post Share on other sites
BERTMAN 40 1 Cars Posted July 24, 2011 Approximately two years. Hopefully it’ll soon be restored to its former self and on the track. But the task list is growing by the day. We all know that feeling! Good luck with the build Share this post Link to post Share on other sites
Anthony 1,000 Posted July 24, 2011 Is this the one that you collected the uprated TB/ARB 309 beam off me for last year (or was it the year prior to that?) at Pugfest? To be honest, that doesn't look too bad underneath and should be straight forward enough to sort out - certainly my car was atleast that bad when I tackled it at the tail end of last year, as have most other 205's that I've dropped the tank down on. Of course, I appreciate that the camera doesn't always show the true scale of the problem, and you don't say if you've started poking or not yet... as mine didn't appear to be too bad until I started poking at the rust bubbles Share this post Link to post Share on other sites
dave_gti 0 Posted July 24, 2011 (edited) Hi Anthony, yeah that was me, it was pugfest last year I bought it off you, Just with work and other projects the 205 has been neglected . Hows things? I haven’t started poking about properly yet, I am not looking forward to it to be honest and have been putting it off today . Instead I've done a few small jobs and gathered all the parts needed. 309 Rear Beam Solid Rear Axle Mounting Kit Front calipers removed new discs and pads ready to go on Handbrake cables Rear discs and pads Epoxy Mastic Paint For Underneath I’m in two minds whether or not to buy full braided brake lines and run them through the car along with fuel lines Edited July 24, 2011 by dave_gti Share this post Link to post Share on other sites
Richie 32 Posted July 25, 2011 Best of luck with that, looks like theres enough to keep you busy for a while. Make the most of the sunshine if you're working outside Share this post Link to post Share on other sites
dave_gti 0 Posted July 25, 2011 I found two small holes after attacking it with an angle grinder wire brush today which shouldn’t be too much of a problem. The original hole posted above, do you think it would be ok to fiberglass the hole? Or would it need welding?. I know welding is the best option but I can’t weld Share this post Link to post Share on other sites
dave_gti 0 Posted July 27, 2011 After a final attack with a grinder today inside and out, I managed to get the holes welded up, and this is how it looks after some rot treatment. After some searching I read a few members used and recommended this product – So tomorrow I shall paint the ginger bits with it, ready for painting. While that is drying, I will be making up some new fuel pipes with some 8mm copper pipe I bought today Share this post Link to post Share on other sites
dave_gti 0 Posted August 2, 2011 After realising the rear beam bushes wouldn’t fit and a quick chat with Anthony I discovered just removing the old bushes left the shell behind in the beam, and this is how they came out Using a hacksaw and a bit of encouragment with an old screwdriver. Share this post Link to post Share on other sites
dave_gti 0 Posted August 2, 2011 This is how underneath looked after wire brushing, some rot treatment and protective paint. Share this post Link to post Share on other sites
dave_gti 0 Posted August 2, 2011 The fuel tank and new beam fitted That’s as much as I can do today while I wait for a couple of parts from the pug dealer, should be tomorrow. Share this post Link to post Share on other sites
Fox 3 Posted August 2, 2011 Looks good! What did you use over the rust treatment? Share this post Link to post Share on other sites
dave_gti 0 Posted August 2, 2011 Thanks, its been a nightmare of a task so far, but im getting there. After reading a guide, I used this rust treatment, then painted over it with Rustbuster Epoxy-Mastic 121. Its also possible to paint over the Epoxy-Mastic 121 if you wished. After reading numerous reviews the products are linked above seemed to be the best or among the best. It’s not cheapest but I decided it’s worth spending a little extra than having to do it all again anytime soon. Share this post Link to post Share on other sites
dave_gti 0 Posted August 4, 2011 I got some braided hose and fittings ready to make up brake line. I don’t really fancy doing it myself with it being the braking system so I went to a couple of hydraulic specialists and they said that with health and safety they won’t touch any items customers take in. So I’m going to make them up myself and for a couple of quid they said they would pressure test them. They don’t look too difficult to do, any tips are welcome Share this post Link to post Share on other sites
johnhenry 20 Posted August 4, 2011 looking nice underneath! im looking to do something very similar as so tomorrow and over the weekend. regarding brake lines like that, i would be running them the length of the car and am unsure as to how attach the fitments into their respective ends: 1st'ly master cylinder, 2nd'ly the brake calliper. Any advice/help appreciated mate! Cheers John Share this post Link to post Share on other sites
dave_gti 0 Posted August 4, 2011 Im using male/male fitting on the caliper, and a 90° Elbow attached to it, if that makes sense. If you wait until tomorrow, if I have time to do it, or it will be next week if not, I’ll put a detailed thread up of how I made them and what I used. I’m doing them the length of the car too. Share this post Link to post Share on other sites
johnhenry 20 Posted August 5, 2011 thank you for hyperlinking pictures onto the names! i get what you mean, but yes ill wait on the job if you might be doing a thread on how to do it, ill keep an eye out for it! CHeers JOhn Share this post Link to post Share on other sites
Tom Fenton 1,529 Posted August 5, 2011 I don’t really fancy doing it myself with it being the braking system so I went to a couple of hydraulic specialists and they said that with health and safety they won’t touch any items customers take in. So I’m going to make them up myself and for a couple of quid they said they would pressure test them. They don’t look too difficult to do, any tips are welcome Push the screw on nut first, peel back the overbraid for about 6-7mm so it is splayed out, make sure the inner is cut square and no fash on it, push the olive on fully, insert the rest of the fitting, tighten the clamp nut up fully. There is a tool to insert the olive but to be honest you can do without it. Share this post Link to post Share on other sites
Fox 3 Posted August 5, 2011 Will the hose run from m/c to caliper with no other joins then? Apart from pressure regulators? This seems far simpler than pissing about with copper brake pipe! Share this post Link to post Share on other sites
tdr_1976 41 1 Cars Posted August 13, 2011 Good work so far mate! Keep it up! Share this post Link to post Share on other sites