[Car_Upgrade] 1.9 Gti Rust Repairs And Bodywork

[johniban 59 1 Cars]

more parts through the post,

 

got the fuel lines tidied up

 

 

 

will no doubt be changing the fuel line set up soon as want to buy one of miles inlet manifolds when funds allow and run 8 injectors

[johniban 59 1 Cars]

Little update, decided to sell the 205 rallye as it was just sitting at the back of the lock up gathering dust and i cant even get this project finished let alone that one, so sadly that went, but has given me a bit of money to buy some decent parts for this.

 

So thanks to Miles i have a satchel engineering inlet mani, i was never too happy with the previous mani, it never fitted well and the trumpets wouldn't clear the bonnet.

This one sits perfect, im over the moon with the quality, now i can run 8 injectors too,

 

 

Not too happy with where the fuel reg is sitting, its ok but doesn't look too neat

[welshpug 1,620]

if you plan to run 8 injectors you can do away with that aftermarket regulator totally and use the standard gti6 one.

[johniban 59 1 Cars]

i really don't like the look of the standard fuel rail, looks really nasty in place ontop of the inlet mani, im trying to find an alternative, i have tried the jenvey rail in place but obviously the mounting holes don't line up. must be a way around it

[welshpug 1,620]

Lol, works well enough for however many thousands of xu 16v engines psa have made.

 

wont look any different to anything else that fits and does the job as well.

[johniban 59 1 Cars]

yes it may do, but im already running four injectors in the bodies with AN fittings, i cant see that the standard fuel rail will really work i need one with fittings on either end

[johniban 59 1 Cars]

Thanks to Colin at pug performance i now have a sexy looking exhaust manifold that fits perfectly, saves me alot of hassling about with the reangled manifold and making up a down pipe

 

[johniban 59 1 Cars]

exits out a 2.25 inch so not too big of a bore,

 

pain in the arse trying to remove the old one

 

 

new manifold fitted

 

clears everything nicely

[johniban 59 1 Cars]

New radiator purchased, some reason its came through gold! doesn't look too bad, added two 12 inch slim line fans to it, probably a bit over kill

 

[Miles 331 1 Cars]

Interesting to see your manifold fitted OK, joys of 205 build, the 1 I fitted was right up against the seem on the exhaust tunnel and a mates one hung down too low so he had to shorten it, One reason why I doing my own later in the month.

Rad wise I'd send it back if you can, that type of rad is pretty poor, the Nissens types are by far the best for cooling, I;ve always known quite a few issues with the fine fin ones

[2052NV 24]

its probably the body on your 205, i know with mi16 conversions some bodys you dont even need to reangle the manifold at all..... i believe in the 80's/90's french body manufactoring tollerances were very loose

[johniban 59 1 Cars]

Interesting to see your manifold fitted OK, joys of 205 build, the 1 I fitted was right up against the seem on the exhaust tunnel and a mates one hung down too low so he had to shorten it, One reason why I doing my own later in the month.

Rad wise I'd send it back if you can, that type of rad is pretty poor, the Nissens types are by far the best for cooling, I;ve always known quite a few issues with the fine fin ones

 

 

Yeah seems ok so far, currently awaiting exhaust tube and welding gas to make up the rest of it.

 

As for the rad it was only £30 so will do for now for mocking up

[johniban 59 1 Cars]

started on my wiring loom, stripped down and took off what i dont need as will be using omex,

[johniban 59 1 Cars]

ran the loom back into the car to work out the lengths between sensors so i dont have a load of spare wire all over the place, all mocked up and nearly ready to be soldered and heatshrinked

 

 

the wiring will be attached to the bulkhead where its near the exhaust mani and relevant heat shielding will be added

[johniban 59 1 Cars]

Now on to the front end, radiator needs to be lower so made up a new lower cross member,

[johniban 59 1 Cars]

mocked up a new slam panel

 

[johniban 59 1 Cars]

obviously needs welding fully, cleaning up and painting, ideally i would like to be able to find someone to copy it into ally but im not to bothered

[welshpug 1,620]

I personally would not run the wiring there, given I have seen the standard grommet get melted by a gti6 manifold...

[johniban 59 1 Cars]

I had thought about moving it to the nearside but the new manifold is miles away from the grommet compared to the original mani and I'm going to be using a heat shield

[jamie_1992 66 1 Cars]

will an air filter still fit in there looks quite tight

[johniban 59 1 Cars]

if i use smaller trumpets it will but the car wont be an everyday car and alot of people dont run a filter so i dout i will

[johniban 59 1 Cars]

Slowly doing bits to this as and when i can witch at the moment ive not been able to touch it due to other commitments,

 

Have been trying to collect parts to get the brakes plumbed in, and first on the cards i needed a pair of rear calipers, after searching most places, calipers were either in worse condition that mine of they want a ridiculous amount of money for them so i have decided to just pull my finger out and refurbish mind,

 

Started with the strip down on one caliper

 

All came apart ok, nothing seized and nipple came out fine,

Pistons and sliders will be going in the bin and replaced with fresh new ones

 

[johniban 59 1 Cars]

Quick coat of mercedes silver

 

[johniban 59 1 Cars]

Well no pics of the calipers built up, but they are on and bled,

 

Been busy trying to get it run this weekend,

 

made up a coil pack mount, maybe not the prettiest of things but it does the job well, bolted to the head with some hardish rubber washers to try take out some vibration,

 

Bought some vauxhall cavalier HT leads that fit perfectly,

 

Then after damaging one of the o rings on the fuel rail i decided to get it welded so i wont have any future problems with leaks

 

[johniban 59 1 Cars]

Time to do a job i was dreading as im pretty useless at measuring and cutting steel..

 

 

Used a hole cutter and then a die grinder to get the holes perfect