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bigearmuffs

[Body_Work] 205 Wide Arch / T16 Project

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bigearmuffs

okie doke, if the arches are staying as is, then I suggest the following:

thicker torsion bars and anti roll bar and stiffer shocks for the rear (salvage from a gti)

that will prevent loads of movement

solid rear beam mounts will prevent any slopiness there also.

 

and (I'll get flamed for saying this again) maybe drop a tyre size on the back as i doesnt affect the gearing and speedo reading like it would on the front.

e.g instead of 195/50/15, go for 195 45 15

same width just 10mm extra clearance, and 10mm can be the difference between no scraping and ripping off your new bodykit!

 

Fantastic, exactly what I want, keep thinking and posting, your help is really of value to me(first 205 project) thanks again

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johnnyboy666

No probs. I feel the urge to take you under my wing lol.

I'm not really one to go with the flock either, so I've made plenty of cock ups, but at the end of the day, if you havent tried it yourself youve only got somebody elses opinion to go on, and will always wonder.

 

A problem you might find when matching the front supension height to the back, is that a lot of stiffer springs are shorter rather than longer. But if you go for 306 lowering springs on your 205 that may actually raise the ride height.

 

In fairness there is plenty of suspension travel there at the moment, and I think you should leave the ride height settings untill the interior is in and youve got a full tank. then see whats what

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bigearmuffs

Took front wings off, fitted fiberglass ones, drilled out indicator points, still some work to do on the inner wings and tidying it up, test fitted front bumper (on bricks), looks pants as it is supposed to look like an escort cosworth bumper

 

1z6rtwk.jpg

 

Tested fitted it, looks worse from this angle

 

16hqbyv.jpg

 

Took the saw to it, thinking ken block gymkhana 3 as the inspiration, so went for big mouth which will have mesh and two air scoops meshed rather than spotlights

 

4v5qau.jpg

 

No further than this at present fiber glassed and filled roughly

 

2qtimmg.jpg

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bigearmuffs

As you can see back bumper a shocker, don't really know how it was meant to fit as it came out miles on the sides

 

2wokbx3.jpg

 

Decided to splice it with the existing bumper (riveted it on to the existing cut down bumper), this makes for far better fixings, cut both sides to fit

 

1e2w6t.jpg

 

2crot4h.jpg

 

After quite a bit of fiber glass and filler it is something like, fits really well as it is on the existing mounts

 

xamvs.jpg

 

Need more work around the finish as I was keen to etch prime it and then use a white primer to test it, turns out the white primer is pants as it is already flaking

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bigearmuffs

Forgot to show interior stripped out, just need buckets and cage

 

2ns6tdf.jpg

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bigearmuffs

Managed to seam seal under the rear arches and paint in hammerite, still loads to do but cannot find the time during the week due to work, by the end of this weekend I want to have completed both rear arches and back bumper & have the lot in etch primer. :blink:

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Daniel185

keep up the good work. Exhaust backbox came up trumps

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bigearmuffs

thanks for the comment, this weather is shocking, every time I get free in the evening to do an hour it is raining, fortunately the etch primer looks like it is waterproof as in areas were i have rubbed through to metal i have sprayed over and rust has not come through. I am sure primer of old was porous and would rust through..

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bigearmuffs

Disastrous weekend as far as progress goes, all the little jobs are time sapping, I had to do some filling on the skirts to blend into the body and get level (got as far as the filling, still to do the sanding). Fiber glass both front wings inner arches, and the inside of the back bumper which had been cut multiple times to fit. To look at the car you would think that I had done nothing. After a bit of ebay surfing tonight I found a UPOL matt black paint, might consider this as the final colour, anyway for what it's worth some pics

 

Inner rear bumper fiber glassed:

dgp6x5.jpg

 

2e38o4w.jpg

 

Side skirts filled:

2cse6iu.jpg

 

2zqrehs.jpg

 

Inner arch fiber glassed:

 

vsjj85.jpg

 

4sfhtw.jpg

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pugmarshall

I'm very eager to see you progress with this! Do you have any experience in a body shop or the like?

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bigearmuffs

Hi, thanks for the comment, I do not have any formal experience, my background is electrical. I previously did (as a hobby) a mk1 fiesta in porsche continental orange, this was harder though as the fiesta was a rot box so it was welding and spraying (did have a compressor and welder then - all borrowed off my dad). Fortunately with the 205 the body is perfect (no rust at all). Hope to get more updates done this weekend -

 

veci9s.jpg

 

24pgbj6.jpg

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bigearmuffs

Gave up on Fords shortly after this as I could not find non rusty examples (did own a 3 door cossy before giving up and that was the only non rusty one of the lot)

 

kbbq05.jpg

 

dpgsqf.jpg

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bigearmuffs

Fingers crossed for good weather this weekend, my recent internet purchases turned up today:

 

34ycpz5.jpg

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DaveW

Bumper looks good, tho exhaust not so maybe centre exit might look better?

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bigearmuffs

Bumper looks good, tho exhaust not so maybe centre exit might look better?

 

Cheers for the comments, not sure how else I can do the exhaust as I am using the original exhaust up to the back box which runs down a channel under the car, also the spare wheel sits in the middle, I've took another picture to see if it was the angle, I've seen a few others on line with a similar style exhaust. The back box itself is different because the tail pipes are angled up and to the right (slightly), so it may look even odder in the middle. Thanks for looking and the thoughts.

 

119chg3.jpg

 

2qcmmnq.jpg

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bigearmuffs

Looks a mess because the back box is now splattered by rubbing filler down and the back bumper has black paint on because I painted the inside with hammerite (not sure why with it being fiber glass it's not as though it will rust - I might have ocd)

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bigearmuffs

Took doors off to get better access to where the front wing joins the car, also easier to do the side skirts:

 

73ckco.jpg

 

Started the rough filling:

 

t8rvpu.jpg

 

This is where you start to lose the will to live, miles to go filling sanding filling sanding:

 

2prch91.jpg

 

o8t6xi.jpg

 

In between waiting for filler to dry decided to solve the problem of the gap between the wing and the car. The wing is solid so this just needs to be filled, decided seam sealer was the easiest way:

 

wkgqvl.jpg

 

Looks ok when done, and you cannot really see it when the door is back on:

 

2ch82kh.jpg

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bigearmuffs

Another job while waiting, put extra rivets at the top of the wing and seam sealed:

 

2j5o210.jpg

 

ig90l2.jpg

 

More filling more sanding:

 

oidd3l.jpg

 

2n2kie.jpg

 

20r4w1.jpg

 

Giving up for the night, put the drivers side in etch primer just to avoid any rust as its through to metal on the sill, doesn't look to far away now, just need the motivation to get back on it tomorrow:

 

6qi3r8.jpg

 

2jg45ld.jpg

 

rlcob6.jpg

 

Will try and do more tomorrow and update

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cybernck

Superb work! And it's not the first time I've been impressed by someone doing great amounts of fiberglass-work on the forum.

 

I am now sure I won't be getting a cheapo Dimma kit of any sort though - my only option would be to bin it :rolleyes:.

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bigearmuffs

Todays job, current drivers side sill shown from below already done some work need to get it smoother, also passenger side sill loads to do:

 

ayq87o.jpg

 

26vs2.jpg

 

Inner wheel arch needs a bit more work:

 

n6t9j7.jpg

 

2il0dw8.jpg

 

Drivers sill done again looks better and feels smoother:

 

24kgl.jpg

 

Passenger front arch taking shape:

 

2emgzyd.jpg

 

Looks better now:

 

24ned82.jpg

 

Passenger sill, very rough but a start:

 

spvrza.jpg

 

When fitting the back bumper I noticed the rear quarter did not have enough shape, just need to bring it out a bit:

 

28k79js.jpg

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bigearmuffs

Overall pictures of car as it stands at present:

 

qp0wvk.jpg

 

34i45tg.jpg

 

2hrogo2.jpg

 

63t091.jpg

 

2ik5oh5.jpg

 

2j1ospw.jpg

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bigearmuffs

Superb work! And it's not the first time I've been impressed by someone doing great amounts of fiberglass-work on the forum.

 

I am now sure I won't be getting a cheapo Dimma kit of any sort though - my only option would be to bin it :rolleyes:.

 

Thanks for the comment, it really helps with getting back out and motivation when you get feedback, rubbing down under the sills on a wet drive saps you of energy, I am still determined to get most of this in primer tomorrow.

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chipstick

Good work. There's a lot of filler being used. I just hope it doesn't start to crack and look nasty after a short period of being in paint.

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bigearmuffs

Good work. There's a lot of filler being used. I just hope it doesn't start to crack and look nasty after a short period of being in paint.

 

You are not wrong there, I am particularly bad at applying it so I have to put plenty on and then sand it off, for every 30 mins I fill I then spend 4hrs sanding, so most of it ends up on the drive. In one instance when sanding an arch I went through the filler and even through the body kit to make a hole, it is similar to plastering (which I also cannot do) the better you are at applying it the least work you have there on finishing it. I am now tired of the process and exasperated with my overall lack of skill in this area, hopefully soon I can move onto suspension and wheels, thanks for commenting.

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bigearmuffs

Masked out ready for spraying in etch primer:

 

2j5kkco.jpg

 

2rzc5di.jpg

 

In etch primer (u-pol matte grey/black):

 

dg2qvr.jpg

 

2q9c7eo.jpg

 

k4upno.jpg

 

qrizyo.jpg

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