[Body_Work] 1991 Gti Steel Grey Detailing Progress Thread

[mrfirepro 127 1 Cars]

looking good Alex....

 

Red could be your next project....

[acox99 71 1 Cars]

Finishing touches like this make a car. Cracking job sir.

[ATK 137 1 Cars]

So this arrived the other day - a brand new OEM boot seal! Super hard to find so was pretty chuffed with this one. Nice tight seal so fingers crossed for a non-leaky boot!

[ATK 137 1 Cars]

Fitted a set of Osram Nightbreaker Plus Headlamp and Driving Lamp Bulbs this week - a massive improvement on standard bulbs. Highly recommended, thanks to those who recommended them!

[Henry Yorke 269 3 Cars]

You have probably seen this, but I was browsing through and old copy of Torque magazine and found this pic from when the late Don Louth had it and used it to support an article I wrote

 

 

I guess you have already got the Classic and Sports Car mag with it in.

[ATK 137 1 Cars]

Cheers Henry, I've got both mags which came with the car. I think Don Louth owned it from '99 before selling it for £5250 around 2002 according to the papers I had with the car. Really cool bit of history. Those extra front lamps are long gone though hah hah.

[ATK 137 1 Cars]

So after a few weeks of doing bugger all, did a few things today with varying success!

 

Firstly these brand new OEM phase 2 door seals arrived from a supplier I found in Greece (all gone now!) and one from farmer on here so these were fitted.

 

 

Doors take a good shove to close now so hopefully it'll be nice and air tight for winter . Pain in the arse to fit, lots of swearing and use of a rubber mallet.

 

[ATK 137 1 Cars]

Also fitted a new TPS and new HT Leads, but this caused my idle speed to shoot up to 3000rpm. Might have adjusted the TPS too far so will be stripping it back down and having a good look tomorow.

 

I also ditched my PSCUK driving lamp protectors. This was prompted by the fact I managed to buy a near mint used Siem from Ebay France for £25 as a spare incase mine crack. Really liked the driving lamp protectors to begin with but as my Siems are new, I prefer the car without as the nice bright Siems really set the front end off.

 

Other plans for tomorow, time and weather permitting:

 

1. Fit new Rear Quarter window seals. I did a shedload of internet and dealer searching and found that the original part number for these for a Phase 2 is 857197 rather than what is shown on Servicebox (857225). I passed the part number to farmer and lo and behold, a week or so later two brand new rear quarter seals were at my door! With the new door seals, new boot seal that I fitted a while back, and these rear quarter seals the car should be completely water tight.

 

2. Fit new genuine black rear slatted tailboard. Looked for one of these for ages and there was one left in a French supplier so I snapped it up and have only just got round to fitting. New fixings and badges being applied to the back at the same time.

 

3. New spark plugs. Easy job.

 

4. New O-ring for throttle body, and new gasket for AFM to air intake. Just to make sure all the intake system is completely airtight and solid.

 

5. Clean up earth and washer motor as it's a little sticky.

 

6. Do a complete idle setup as per the Haynes manual.

 

 

I've said a number of times since having the car (Jan 31st 2014) that "I'm done", but after the above jobs are complete, I really am finished and just plan to get on with racking up the miles to reach 200,000 (184,000 miles at the moment) . Cheers to all who have helped throughout, especially farmer for the parts sourcing and general assistance.

[ATK 137 1 Cars]

Productive Sunday for once! Changed the plugs and then tackled my high idle. Turns out the TPS was indeed holding the throttle butterfly. Stripped it all back, cleaned all the intake system and fitted new o-ring to throttle body and AFM to air filter gasket. Then sarted from scratch and did a full setup as per Haynes manual and now she's running lovely...for now!

 

Next job was to fit the brand new rear quarter window seals which farmer sourced for me.

 

 

Wasn't too bad a job, it looks at first like they won't fit as they are so large, but if you put each corner in first then even out the excess, it then all lines up with lots and lots of hitting with a rubber mallet.

 

First one done!

 

 

 

Seals are very, very tight in the windows and the windows feel tight. Passed the hose pipe test with flying colours - no leaks!

 

Next job was to fit my genuine Peugeot black tailboard slatted panel. Easyish job as this is the third (and final) panel I've fitted to the car!

 

Mid way through

 

 

Finished off with brand new badges.

 

 

The finish on the OEM boards is definately better than the aftermarket ones, not by much though, to my suprise.

[ATK 137 1 Cars]

Finished off by giving the car a good clean inside and out, and another coat of wax for the winter. Some finished shots:

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

[iPlod999 143 1 Cars]

Shiny shiny. ????

[ATK 137 1 Cars]

Collinite 476 for winter

[ATK 137 1 Cars]

Bit boring but also got a spreadsheet outling in date order everything that has ever been done to the car since the 2nd owner. All backed up with a thick folder with receipts and printouts for every penny spent!

 

Makes for quite a list:

 

PREVIOUS OWNERS:

 

Scorpion Alarm Check
Pirelli Tyre
Scorpion Alarm Check
SERVICE - Oil, Plugs, New Radiator, New Starter Motor, Dizzy Cap, Rotor Arm
Pirelli Tyres x 3
Front Pipe Kit
Rear Discs, Rear Pads, Front Brake Hoses
SERVICE - Oil, Plugs
Rear Exhaust Silencer
Engine Tuning
Gaiters x 2
CAMBELT
FULL MAJOR SERVICE
Front Mudflaps
Scorpion Alarm Check
FULL SERVICE
Front Exhaust Pipe
FULL SERVICE inc Front & Rear Discs & Pads, Water Sender
Front Windscreen
FULL SERVICE inc Clutch
CV Gaiter, Track Rod End, Handbrake Cable
Handbrake Cable, Coolant Pipe
FULL SERVICE
Number Plates
Paint Spoiler & Bumper
Rear Exhaust Silencer
Suspension Check & General Check for MOT & sale
Alternator
Starter Motor
Rear Suspension Renewed
REAR BEAM REFURBISHED
Scorpion Alarm Repaired
Timing Belt & Tension Roller, Switches
Timing Belt & micro V Belt
New n/side Headlight
Oil & Filter
Reversing Switch
RADIATOR
Steering Bushes
Bushes
Water Pipe, Gearshift & Selection Linkages
Oil & Filter, Spark Plugs
Tyre
Misc Tubing Parts etc
Handbrake Cables
Brake Discs & Pads, Fan Switch. Brake Hoses
BRAKE MASTER CYLINDER
Brake Pads
Tyres x 2
Passenger Door Repair & Paint Respray, Suspension Wishbone
SERVICE - Oil & Filter, Fuel Filter, Air Filter
Wiper Blades
Front Exhaust Pipe, Relay Box
HT Leads
Exhaust Pipe
Various clips, pipes etc
Discs & Pads
Bumper Trim, Side Trim etc
Bumper Clips etc
Screws
Brake Calipers
Car Cover
Inidicator Assemblies
Front Brake Discs
Water Pump & Timing Belt
Glaser Head Bolt
Thermostat
Trim Inserts etc
TOP 1/2 ENGINE REBUILD - Head Skimmed, Gaskets, Cambelt, Waterpump etc
Timing Belt
Engine Tune & Injectors Cleaned, new SAD Valve, Inlet Manifold Gasket
Front Silencer
Downpipe Fitting Kit, Rear 1/4 n/side Badges
Oil Dipstick
Power Distribution Box, Battery Cable
Installed Scorpion SA30 Alarm/Immobiliser System (but no receipts available)
ARB Bushes
Gear Linkages
Coolant Temperature Sensor/ECU Temp Guage Sender Unit
Tachnometric Relay
Coolant Temperature Sensor/ECU Temp Guage Sender Unit
Door Hinge Pins
Coolant Temperature Sender Unit
AVO Front Dampers & Springs
K&N 57i Air Induction System
N/Side Driveshaft
Driveshaft Oil Seals
AFM
Petrol Treatment, cables etc
Baker Bushings & Mounts
Cambelt & Tensioner replaced (no receipts available)
Starter Motor
Starter Motor
Front Wheel bearings


MY OWNERSHIP:


Haynes Manual of course
Front Indicators
Headlights
Brake & Clutch Pedal Rubbers
Boot Inner Trim
Full Set of Car Mats & Boot Mat
Driving / Fog Lamps (Denji)
Rear Window Seals x 2 (used)
Dash Switches & Trim Surround
Refurbished Alloy Wheels x 4
Fog Lamp Surrounds
Two Toyo proxy TR1 Tyres (Front)
LCD Clock
Parcel Shelf Clips
Boot Trim Clips
205 Rear Boot Badge
Rear Wiper Arm
Stone Chip Paint - Paint Code M0TA
Front Mudflaps
Rear Washer Jet
2 Day Full Bodywork Detailing, Machine polish, Bonnet wetsanded etc, Fitting new lights
Rear Quarter Window o/side & Fixing nuts
Door Hinge Pins
Window Fixing Nuts
Front Lamp Brackets
Numberplates, Tax Disc Holder, Rear Screen Decal
Peugeot Rear Boot Badge
Rear Quarter GTI Badge o/side
FULL SERVICE - Oil & Plugs, HT Leads, Door Pins, Lamps Adjusted, Full New Exhaust, Track Rod Ends & Tracking, New Clutch
Rear Light Lense o/side
Interior Black Arch Trims
Rear Quarter 1.9 Badge
Original Clarion Radio Cassette Unit
Standard Exhaust Backbox
Heater Blower Rheostat Resistor Unit
Exterior Trim Clips
Dash Trim
Rear Light Lenses x 2
Deposit for New Seats x 4
Exhaust Manifold Gaskets x 4, Downpipe Fitting Kit
Bilstein B4 Dampers x 4, Grp A Solid Rear Mounts, Eibach 7001 Front Springs
Rear Quarter 1.9 Badge
REFURBISHED REAR BEAM
Set of AXO Rear Light Lenses x 2
Rear Quarter GTI Badges x 2
Bosh Vaccum Advance Unit
Balance Payment for New Seats x 4
Ream Beam, Dampers all round, Front Eibach Springs, Solid GrpA Rear Mounts all fitted, new Exhaust Manifold gasket & downpipe fitting kit
LCD Clock
Aerial Cable
Boot Spoiler
Rear Valance/Bumper Clips
Mudflap Badges x 2
Handbrake Cable Clips (Trailing Arm)
New Set of Rear Quarter Badges
Bumper/Valance Clips
Wiring Loom
2 x GTI Mudflap Badges
Bosch ECU Temperature Sensor
1 x 1.9 Rear Quarter Badge
Spoiler Retaining Clips & Screws
Bosch Ignition Amplifer
Durite Tachymetric Relay
Supplementary Air Device (new)
Rear Screen Decal
Air Flow Meter(new)
SAD Hoses
Front & Rear Brake Pads - EBC Redstuff
Rear GTI Boot Badge
Full Set of Car Mats
Lucas Near Side Headlamp
Head Skimmed, Head Gasket, New Throttle Body, New Thermostat, New Lower Arms (Wishbones etc), New Front Brake Pads (Standard)
New Battery
Bosch Ignition Coil
Distributor Cap
Rotor Arm
New Steering Rack, New Rear Brake Pads (Standard)
Electric Window Switch
Driver Side Electric Window Regulator/Motor
Headlamp Connectors & Wiring x 2
Gearstick Leather Gaitor
New alternator, starter motor, fuel filter & fuel pump
Boot Seal
Boot Bump Stops x 2
Brand New SAD & CTS
GTI Near Side Badge - New
New Windscreen
Rolling Road Engine Tune etc
Wind Deflector
Fuel Pump gasket, Speedo Cable
Offside Headlamp, Indicator Mounting Bracket, Headlamp Adjuster Bracket, Front Grill, All Fitings
Fuel Pump Ring Clamp
Driving Lamp Support Brackets
SIEM Driving Lamps - OEM
Fuel Sender Screw Ring
SIEM Driving Lamp Backing Shells/Holders
Fuel Sender Seal
Dash Clips
GTI Boot Badge & Book
Green Check Door Cards
Upper Dash Board
Steering Column Trim
205 Boot Badge
Upper Dash Board
205 Boot Badge
Upper Cam Cover & Bolts
MOT, 2 x Rear Tyres (Toyo Proxy T1R), Welding to Offside Inner Sill, CV Boot Gaiter Repair/Replacement
Full Correction Detail to paintwork
Wiper Nut Covers x 3
Mudflaps
New Wiper Nut Covers x 2
Clarion Radio Cassette Player
Rear Saddle Mat
Upper Dash Board
Rear Tailboard Clips x 4
Peugeot Rear Boot Badge
Driving Lamp Surrounds - New
GTI Boot Badge & 30th Anniversary Poster Print
Rear Black Slatted Boot Panel & Fixings
Rear Black Slatted Boot Panel
Rear Speaker Grill, 2 x Door Pockets, 2 x A-Pillar Trims and fixings
AXO Rear Lenses - New
Sunroof Trim
Mudflap Badges - New
Rear Black Slatted Boot Panel
Nearside Window Scraper/Weatherstrip - New
Rear Black Slatted Boot Panel
Rear Black Slatted Boot Panel, Inlet Seal, Handbrake Trim Screw Covers
Handbrake Cables x 2, 8 x Handbrake Clips (2 types)
Boot Light Switch
Alpine Speakers - Front Set
Alpine Speakers - Rear Set
Rear Boot Spoiler
U-Pol Black Texture Paint for Spoiler
Rear Boot Rubber Seal
Fuel Pump Relay
Rear Black Slatted Boot Panel
Fitting of Handbrake Cables x 2 and replacement Klarius Backbox (backbox replaced under warranty)
Nearside Window Scraper/Weatherstrip - New
Interior Mirror Cover
Rear Black Slatted Panel
Exhaust Mounts
Fan Resistor
Radiator Fan Switch
Headlight Resistor Clip
Thermostat Gasket Seal
Thermostat
AXO New OEM Rear Lenses x 3
Rear Black Slatted Panel
New Parcel Shelf Fixings & Cord
Rear Black Slatted Tailgate Panel
New NOS Boot Seal
New NOS Offside Weatherstrip & Heater Resistor Clip
New NOS Rear Tailgate Window Seal
Osram Nightbreaker Headlight Bulbs
New NOS Door Seal
Siem Driving Lamp (Spare)
Prospark HT Leads
NGK Spark Plugs
2 x NOS New Door Seals
Bosch TPS New
GTI Boot Badge - New
Gearknob Tops x 2 Reproduction
2 x new 205 GTI Rear Quarter Window Seals, Door Seal, Idle Screw O-Ring, 4 x Siem Screws, Rear Board Fixing Clips, Foam Ring and Fixing Clip
New Rear Quarter Window Seals x 2
New AFM Gasket Seal
New Door Seal

[Juttie205 123 2 Cars]

stunning car cannot wait for my dimma to be the same colour

[Alan77 78 1 Cars]

Love it... possibly my favourite car on here.

[ATK 137 1 Cars]

Replaced my FPR yesterday, all went well aside from having to cut the piping back a little. Now my misfire on cold startup is gone and the car starts strong instantly. Also stripped the entire intake system back and cleaned it all back thoroughly and did a full setup again.

 

My cold idle is now spot on with no dropping of revs/hunting on initial startup! Finally after a year of tweaking! Starts properly straight off the key. Well pleased

[lightflow 59 1 Cars]

FPR?

 

As an aside - does your air horn work well? I am looking to share some postage costs on new old stock OEM FIAMM horn and compressor. Looking at around £40.00 all-in. New compressors are scarce/NFP so it's a good deal...

[ATK 137 1 Cars]

Sorry, FPR = Fuel Pressure Regulator.

 

Dan (DCC) suggested my misfire when cold might be caused by this, and it would appear that my FPR was indeed at fault - definately one worth checking, welshpug did a thread on how to test to see if it is holding pressure.

 

Replaced mine and all is well, frustrating as I wish I had replaced it earlier but nevermind All sorted now.

 

My air horn is fine ta

[2052NV 24]

god damn that make me feel better about my stack of receipts hahaha

[dcc 855]

happy days!

[Reebmit 51 4 Cars]

stunning car cannot wait for my dimma to be the same colour

Yeah stunning, it is just the perfect colour

[ATK 137 1 Cars]

Thanks guys

 

Spent yesterday ripping the roof apart as my headling was soaking. Sunroof drains were completely clogged with rust and debris. And the drain pipes were utterly f*cked. Repaired using some copper couplers, piping and tigerseal. Hopefully all sorted now!

Suprisingly, the front drains were pretty much ok!

[ATK 137 1 Cars]

Result! Lots of rain today and last night and headlining is nice and dry

[ATK 137 1 Cars]

After having a very wet rear footwell managed to sort it, sealed up the rear arch abd unblocked the rear quarter panel area sill drain. Also sealed seatbelt lower mount bolt and checked sill drains were clear. Lots if rain last couple of days and she's all dry throughout again...for now!! Pretty sure another water leak will show up at some point though.

 

Also had the car on an exhaust analyser a couple of days ago as I changed the fuel pressure regulator. Was running lean at 0.8% CO so adjusted CO to 1.5% and it's running spot on - even when freezing cold it's starting without needing throttle assistance. Finally!

[ATK 137 1 Cars]

Nothing further to report other than it's 1 year to the day I picked up H853 DBD on a rainy Friday! Here's the first pic when I first picked her up!