Project Puggles

[dave_gti 0]

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 .

[Fox 3]

How longs it been sat? It does look very sorry for itself!

[dave_gti 0]

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.

[BERTMAN 40 1 Cars]

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

[Anthony 1,000]

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

[dave_gti 0]

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

[Richie 32]

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

[dave_gti 0]

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

[dave_gti 0]

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

[dave_gti 0]

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.

[dave_gti 0]

This is how underneath looked after wire brushing, some rot treatment and protective paint.

 

 

[dave_gti 0]

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.

[Fox 3]

Looks good! What did you use over the rust treatment?

[dave_gti 0]

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.

[dave_gti 0]

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

[johnhenry 20]

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

[dave_gti 0]

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.

[johnhenry 20]

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

[Tom Fenton 1,526]

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.

[Fox 3]

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!

[tdr_1976 41 1 Cars]

Good work so far mate! Keep it up!