1.9 Re-Shell And Restoration - The Deathstar

[kyepan 291]

photos are a bit dark, perhaps direct sunlight would have shown it off better, but aside from that, i'm happy that this is a better way to apply plasticare - highly recommended product if used carefully.

[welshpug 1,626]

Quite like the blue stripe

[kyepan 291]

You're not the first person to say that!

[cheesegrater 43 1 Cars]

Tron edition

[cybernck 400 1 Cars]

Misplaced front numberplate always hurts my eyes .

 

Your Plasticare adventures were funny though .

[kyepan 291]

Waterpump changing time.

 

So i've been topping up for the past few weeks, and it was time to do the waterpump... without messing up the cam timing.

Plan was to use a standard pulley to judge which adjustment bolts to remove from the vernier to allow it to be pinned.

 

Plan stood up to about 10 mins of scrutiny, once we had the pulley retaining bolt off, and looked at the position of the adjustment bolts relative to the keyway on a standard pulley, they were no where near the position of the timing pin. Bugger.

 

In the mean time we marked the pulleys up with Tipex, and the straight edge across both pulleys, to get a datum. then at the bottom, then across both of the tensioners.

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The answer was to essentially jam the belt in place, we tried t use Ryans box of cam belt pulley locking tools, to no success, we had one that fitted ish, but we needed more friction.

 

The solution was to use some old hose, fuel hose, slice it along it's length and jam it in between the cam belt and the cover, and at the bottom, between the belt and the casting.

 

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We initially undid the front tensioner, then decided that we didn't need to, and concentrated on the back tensioner.

The belt came off the tensioner, and then off the pump without drama, the belt stayed pretty much exactly where it was. So far so good.

 

‹

 

Pump off, cleaned, gasket on, smear of sealant, pump back on... gently. And tensioned the rear.

The back pulley moved a tiny amount, but when the tension went back on, it shifted back, and the marks lined up.

 

Turned it over, and no bad noises or resistance..Back together with new plugs and it popped into life!

 

So if you need to do an MI Water pump on verneirs, it is possible to do with the belt on, without messing it up.

 

Job Done.

 

Next... DA

[kyepan 291]

Some more....

 

So I bought a DA polisher I got two pads, one fine and one not so fine, two bottles of polish, one fine, and one not so fine. We tried it out on Ant's 306 bonnet, and were quite pleased with the results, so much so i left it at his to finish the car!

 

Took a bit of practice to get the pressure right and keep it rotating at about the right pace.

‹

 

We got rid of a lot of the spider webs, and i'll be using two buckets from now on.

 

 

It didn't burst the microbilsters and in good amibent light you can't see them.. however under directional light you can... but that means it just looks a bit spotty at night.

 

Here are the results.

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the wings came up really well.

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And an arty one from instagram...

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I'm rather pleased, now own a really good looking 205, with sorted chassis, my home built MI-16, on bodies...without water leaks.

 

Little niggle that i need to resolve with the exhaust rattling, but i'm sure that will get sorted.

Time to enjoy it.

 

Cheers

J

[Henry 1.9GTi 36]

nice one

 

always like the look of a clean black 205

[kyepan 291]

Thanks Henry.

[Edp 67 3 Cars]

Very nice!

[kyepan 291]

Drove from london to newquay and back, plug lead popped off twice right near newquay when i had to brake suddenly, also i think the catch tank may need clearing out, as it was sending more oil past the rings than i would like under load.

 

Body count - bank holiday bonus, 40398 dead, including 43 kittens and a puppy named balloo who had his heart broken.

J

[Paul_13 212 1 Cars]

:lol: Edited May 6, 2014 by Paul_13

[feb 47]

Well done it looks the part and must go to I guess!

[kyepan 291]

Big thanks to Tom (cheesegrater) and jamie for helping me weld on the tabs and straps to hold the fanimould together, it's not leaking.

and Batfink ( for allowing us to use the workshop)

[kyepan 291]

Seems sorted too, sounds fab

[cheesegrater 43 1 Cars]

No problem chap!

[kyepan 291]

Thought i had a coilpack dying again, but it turned out to be a water leak onto the coilpack, they don't like water!

 

It sprung a small leak in a pipe by the thermostat housing, stu from baker bm sent me a new hose and that resolved it in time for a round trip from london to llandow wales for a weekend's racing.

 

Didn't skip a beat, sounding great! got lots of love from everyone at racing and everyone on the way there and back, its fair to say it's turning more heads than i expected.

Icelandic chap even stopped last night when i was parked up next to adams shiny new red 205 in holloway london. He proceeded to regail how it was his first car, etc etc, ended up chatting for about 20 mins about cars bikes etc.

 

Cool.

 

Deathstar Bodycount continues to rise, but for some reason it's only killing virgins and chickens... which begs the question which came first, the virgin or the chicken? Plus a wild rabbit which it ordered executed by the Cat squad.

[kyepan 291]

Yet more miles on it without issue.

 

Went up north to Redcar and i learned 2 things.

 

1) people down south do not appreciate the 205 like they do up north, sourfaced stare or a casual point.

2) people up north are not afraid to show their love for the GTI: Bloke in a big 4x4 waving and flashing lights with thumbs up, porka driver pointing out to his passenger, panel van overtook me with the passenger leaning out of the window asking for trumpets... i obliged, and that was all in the space of ten mins!

 

at least 42 pheasents, 12 kittens unfortunately lost their lives, plus several wedding guests were wiped out.

 

Another trip to newquay at the weekend, another 500 odd miles of flawless progress!

No real love for the pug, although some interest from the general diesel motorway mile plodders, especialy a particle expelling smokey BMW with two "youth" in who seemed keen to race on the motorway.. Sorry chaps, my lady is asleep in the passenger seat, i don't think she'll take kindly to waking up with the car doing .5 past light speed making noises closely akin to the death of pornstars from auto erotic overload.. and it's a straight road... sorry again. They gave up after 4 or 5 attempts.

 

 

When the deathstar entered orbit around newquay the entire Boardmasters festival was cancelled due to the hurricane producing throttle bodies, resulting in 42 overturned tents, 24 serious burger van related injuries, and one hundred and eleventy twelve cases of fatal chemical comedown.

 

Went to the beach and watched the surf contest, head high, onshore wind, with plenty of very rough water made for some challenging conditions! awesome to watch, especially the longboards, massive ariel off the lip on a longboard, much respect.

 

Need to polish the car, sort the leather trim, replace the rear wiper, and fix the boot leak! before it rots out the boot floor!

[Weser 30]

Great right up! That post really made me chuckle. Especially this:

 

When the deathstar entered orbit around newquay the entire Boardmasters festival was cancelled due to the hurricane producing throttle bodies, resulting in 42 overturned tents, 24 serious burger van related injuries, and one hundred and eleventy twelve cases of fatal chemical comedown.

 

[kyepan 291]

A quick update.

 

Still chasing boot leaks - more pics to follow

Cleaned off and resprayed the boot floor inside

Changed a coil pack - OMG different car.

New struts at the front as i've blown the left one

Braided hoses, bias valve and it now stops seriously well.

 

and some wheels, decent pictures to follow.