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Rostle1984

My 1991 Peugeot 205 Gti Long Term Project

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Rostle1984
Well after searching for quite a substantial time I came across this nearly a year ago, Whilst she look pretty clean (to be fair it is for 23 years old) it does need some TLC. But I'am the right guy for this.
so this will be an on going project not to be done asap just as and when as I plan never to sell it like the previous one I let go 4 years ago.
This car will make the odd appearance at shows, but more importantly I hope it turns some heads.
so here goes.
The Cars history from Day one, Owned by 7 people in its life, seems a few but each and every one has documented every part of its life Now to me this means everything, Infact to complete the history I bought the original Sales brochure for £17 :shock:
I have every MOT certificate, I have every tax disc but 1992. and every single receipt for work and services etc and some history a previous owner had documented. More importantly I have the orginal Book Pack that came with the car fully stamped & the original Lion AA Guide.
15039732818_f36513c8a8_c.jpgThe gti by Rostle84, on Flickr
The car has covered a Genuine 95k Approx since new & is backed up by the national Mileage register and HPI
15039941838_856932e690_c.jpgThe gti by Rostle84, on Flickr
The interior of the car is completely standard And this is how it left the factory apart from the radio has been changed to a pioneer unit, The Mats never came with this car However these are Genuine GTI mats from Peugeot which came with the limited edition 1.9's back in the day., Kindly Given to me on long term loan from My Mother a previous gti owner in 1990.
15203541626_8b37e65d12_c.jpgThe gti by Rostle84, on Flickr
15223442701_72f13f600d_c.jpgThe gti by Rostle84, on Flickr
The Paint work is finished In Sorrento Green and complimented with the Original Speedline alloys, this will be getting re painted at some point due to age its suffered a fe knocks in its time plus some bubling in the paint means it needs doing
15039752978_d03ee5d16c_c.jpgThe gti by Rostle84, on Flickr
The engine on the car is completely standard Apart from a couple of blue hoses which wont be staying on the car. 130bhp XU series engine with everything as it left the factory, Missing at present is the Jack.
15226586735_232bf4163d_c.jpgThe gti by Rostle84, on Flickr
Still has the original speedline alloy spare with Michelin tyre fitted to it, bumper needs new Irons fitted to secure it further & the tail gate badges need refreshed
15039875690_0a2bf99dc2_c.jpgThe gti by Rostle84, on Flickr
15039928598_d74b4f36d4_c.jpgThe gti by Rostle84, on Flickr
The Iconic 1.9 badges speak volumes
15039809160_99e4fe513d_c.jpgThe gti by Rostle84, on Flickr
15039676380_d23b7eddf1_c.jpgThe gti by Rostle84, on Flickr
General Body condition overall isn't too bad, some corrosion to deal with but that's easy sorted
15203534266_4c9d501631_c.jpgThe gti by Rostle84, on Flickr
15226549075_8c0a8c6fbf_c.jpgThe gti by Rostle84, on Flickr
Meets the rest of the fleet of vehicles. Looks well at home
15039797640_303cb5d310_c.jpgThe gti by Rostle84, on Flickr
15039723980_a562518dbd_c.jpgThe gti by Rostle84, on Flickr
15039791737_49a286e41a_c.jpgThe gti by Rostle84, on Flickr
15223293471_7c8df45584_c.jpgThe gti by Rostle84, on Flickr

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Rostle1984

Time to go play in the garage.

This is what I had presented to me once I'd removed the front end of the car. 23 years of use has taken its told or its had a minor bump at some point and a crap repair.
Passenger side headlamp surround pretty much the same.
So with both front wings removed and the top section of the headlamp surrounds removed this is what was hiding behind it
15319620699_f6f37d95f6_c.jpgCutting out the tin worm on project gti by Rostle84, on Flickr
So I took the plunge and ordered some new panels last week, I had to go down the route of pattern parts for it. I'm pleased I got two new front wings as this is what was lurking under the passenger one
The inner wings on both sides were remarkably spotless which was a huge relief
As to can see easily on the drivers inner section where the jack sits its literally holed its that rotted through, But never fear that's nothing major and I will crack on with the next bit.
Washer bottle and battery removed from the passenger side, Looks better than the drivers but I always say the only way to deal with rust is to cut it out back to good metal and replace.
First piece on that side cut out, the bottom section I wasn't happy with so cut that out later too.
As above but the corner piece was cut out too as It was starting to rot. the rest is minor surface rust which will mop off with a wire wheel attachment and sort out later.
as per the otherside, the only way was to cut the whole lot back to good metal
as you'll agree, they sections removed are pretty much buggered, These will be used to make up copys on new zinc coated metal.

Both sides cut out, photo taken before the section removed on the passenger inner section
Well heres the old section ready for the scrap vs the new galavnised front section.
Quick offer up of the new panel, with it being a pattern part and not an original I thought it may be a bit out in places, But its pretty sweet.

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Rostle1984
So I bought a brand new Mig Welder and Big Hobbyweld Tri mix cylinder, no messing around with disposable ones.
10407596_10154735989220157_4392397849032
10363083_10154837624940157_5204965535299
So armed with new sheets of steel My dewalt Grinder and a box of grinding and cutting discs and a few Panel beating tools Kindly Loaned from martin (Cheers Mate) I set too with the repairs to the boot floor section.
Heres what I'm talking about. Rotton and holed, Most common areas, Plus two holes in the center.
15556716247_2890f4dd31_c.jpg20140915_183609 by Rostle84, on Flickr
Only a small Hole but the rust where it joins the rear arch was going to come through at some point so that was cut out too.
15741890795_b548fc8f42_c.jpg20140915_183619 by Rostle84, on Flickr
First piece in the middle of the floor removed and a plate made up, Weld magnets are ace for this no more trying to juggle metal.
15122163983_fe67639b28_c.jpg20141108_151503 by Rostle84, on Flickr
15717845826_6e74a2f3ca_c.jpg20141108_151511 by Rostle84, on Flickr
15739621691_95d0f7bf12_c.jpg20141108_155658 by Rostle84, on Flickr
First section ground back and primed with Acid etch
15121570664_56eec6708a_c.jpg20141108_181643 by Rostle84, on Flickr
Second section ground back and primed
15556078208_c55f2e4d11_c.jpg20141108_182612 by Rostle84, on Flickr
Corner piece all cut back to solid metal and a dummy plate cut but needing trimmed is offered up
15739637141_5752a8344d_c.jpg20141108_153128 by Rostle84, on Flickr
Welded in and drilled down to the chassis and welded through to give rigidity
15743085552_344a381f43_c.jpg20141108_155651 by Rostle84, on Flickr
Not bad, slight overlap no huge lumps uniform in size, I think that will suffice.
15743070622_699c208619_c.jpg20141108_161015 by Rostle84, on Flickr
all ground back and wire brushed, Bit shiney really.

15739592691_7a3fefa2d6_c.jpg20141108_185000 by Rostle84, on Flickr
Now etch primed up
15121551474_9bc54f3564_c.jpg20141108_185333 by Rostle84, on Flickr
That's one side down, One to go
15122098153_f1c3bb7977_c.jpg20141108_185438 by Rostle84, on Flickr
The other side cut out plated ground and primed.
15555613119_79cb795fba_c.jpg20141108_185450 by Rostle84, on Flickr
15556345767_8ddb20a56b_c.jpg20141108_183633 by Rostle84, on Flickr
That's all for today, Next instalment is Inner wing repair to outter wing plates and bumper mounts.

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Rostle1984
Front panel fitted and clamped into place ready to be welded on Bonnet fitted and catch setup to front panel. Both front wings fitted. Osf needed manipulated into place to sit right as the forming wasn't quite right plus had been bent a little at some point compared to the nsf. Doesn't look much of an update but I can assure you it took a while to achieve.

Small progress report today on Project GTI. The fiddly bits that everyone hates doing. Inner wing sections were the sunroof drains run we're literally rotted away to nothing. This means the rear bumper has no corner support (bumper supports to make at a later date). Anyhow cut the inner arches away to good metal with the plasma cutter and the took the shape to a new sheet of steel and cut to the exact shape enabling me to butt weld in the new steel making it sit flush. These bits will never be seen but I like things done right. After welding those in there was the little task of making a new rear tow eye. This was literally hanging on by a wing and a prayer. So cut that off and the supposed support brackets to the rear body. I then set about fabricating a new tow eye using the original pressed loop. Easy enough but took a while to shape etc. once done offered it to the car were it became apparent I needed to add a support for extra strength. I then welded a small section over the top then cut down and welded. 90 Deb section so it would weld onto the chassis rail. Easy enough. Job done. Etch primed and painted. Next update coming soon.

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arbor

Some nice work there, keep the updates coming.

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welshpug

indeed, very good, surprising what lurks under a nice looking car too!

 

What's the subaru?

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Rostle1984

​

 

indeed, very good, surprising what lurks under a nice looking car too!

 

What's the subaru?

 

Your quite right about what lurks under the car.

Fuel tank is ready to drop out after a bit of persistence with the long bolts at the rear of the tank. Couple of holes under the rear seats which need seen too Plus looking from under the car in front of the tank it looks quite nasty under there. I spotted a few threads before I was able to register where you had kindly commented about taking the fuel tank out etc :)

 

Also the front outriggers had to be cut off as I'd guess its been jacked up in the wrong place and crushed the metal leading to the tin worm setting in.

 

Enjoying the challenge that's for sure.

 

 

The Subaru was my old daily driver, Built the engine and tinkered with it a touch, 460bhp 500ft/lbs it could certainly shift on. Sadly been replaced as I'd had enough of it.

 

Heres a couple of pictures of them both

 

10413433_10154599465435157_3943634091609

 

15687_10154587104160157_4237327036549507

 

11013039_10156044650065157_7235425315650

 

11202966_10155678746600157_8982759732183

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Telf

Top Work.

 

After picking up my second Pug Ive realized I need to buy a welder - so I have! Its posts like this that have made me think I can do that too!

 

Keep the updates coming

 

Nice Subaru - I prefer old school tin though :D

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Rostle1984

​

 

Top Work.

 

After picking up my second Pug Ive realized I need to buy a welder - so I have! Its posts like this that have made me think I can do that too!

 

Keep the updates coming

 

Nice Subaru - I prefer old school tin though :D

 

I was lucky with my previous 1.6 GTI as the body was pretty good, Shame I sold it really.

I don't mind a bit of welding, least once its done I'll know the shell is rust free & the satisfaction of knowing I repaired it.

 

Your quite right as nice as my new cars are I still prefer old school cars better. I work on the new stuff day in day out and its boring and can be quite complex, So it's good to get back to simpler things with the GTI

I bought this one as a 30th birthday gift for myself quite fitting really as the GTI was also celebrating 30 years too. This one wont be getting sold once its rebuilt that's for sure :)

 

Quite a wealth of knowledge on this forum which is brilliant.

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JamPug

This looks really great ! It's motivating me to get on with my problems as they are literally the exact same aha.

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Rostle1984

​

 

This looks really great ! It's motivating me to get on with my problems as they are literally the exact same aha.

 

haha, I'm glad I'm not the only one that's for sure, after reading a few threads it seems to be the norm with a few of them. Good luck with yours. :D

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Hobbyweld

Hi Rob,

 

I'd love to feature your 205 welding work on the Hobbyweld website - drop us a line when you get a moment - info@hobbyweld.co.uk - we'll hook you up with a free fill of gas in exchange for your story :) Look forward to hearing from you!

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Rostle1984

​

 

Hi Rob,

 

I'd love to feature your 205 welding work on the Hobbyweld website - drop us a line when you get a moment - info@hobbyweld.co.uk - we'll hook you up with a free fill of gas in exchange for your story :) Look forward to hearing from you!

 

That would be absolutely fantastic, I'll be sure to drop you an email with my story on for your website. Thanks again that's a truly brilliant offer :)

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Rostle1984

Small Update for tonight, I bought some new tools for the Job at hand. I need to make new sections for the front inner wings as basically they have seen better days so I cut them out back to good metal with no rust on.

New vice and a clarke Metal folder and some panel beating hammers& dollies.

 

Excuse the state of My garage there are tools lying everywere at the moment.

 

21280004055_ea7e5c4938_c.jpgUntitled by Rob Ostle, on Flickr

 

Started with cutting the basic shape with the Plasma Cutter and popping it into the folder to get the nice smooth folded edge to weld back onto the wing section, Old one on the right as you can see has seen better days

 

20657231924_e30e3c1b5b_c.jpgUntitled by Rob Ostle, on Flickr

 

The next bit was to figure out how to get the curve in the center to match up to that of the front panel.

 

20657295554_d23499fe4b_c.jpgUntitled by Rob Ostle, on Flickr

 

Easy enough once I got my head around it. Slight cut in the center with the Plasma cutter then with the use of the Hammers and dollies made the basic shape needed to match the front panel Then welded the center up and edge piece & flattened back

 

21253671606_14e52f208b_c.jpgUntitled by Rob Ostle, on Flickr

 

21280004215_c64ebcec50_c.jpgUntitled by Rob Ostle, on Flickr

 

Job done for tonight, Coated with Galvanised Zinc primer, Ready to weld in.

 

21253672996_0e3ec4d99a_c.jpgUntitled by Rob Ostle, on Flickr

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Rostle1984

​

 

DA in the background of the last picture?

 

Yes indeed, I do the odd bit of paint correction now and again.

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Rostle1984
Something has been annoying me for a while and now I saw the ideal chance to do something about it.
You can tell that in the 1990's folk really couldn't be bothered with there jobs. Alarm and immobiliser to be removed
21304508345_10d2d16094_c.jpgRemoving the faulty alarm & immobiliser by Rob Ostle, on Flickr
I don't think they should be on a classic car unless its factory fitted.

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Rostle1984

​

Went to fire up the GTI today. A complete no go-er.
Engine would crank but refused to start, didn't even hint to want to start.
Few checks of the Tachometric relay indicated no power from the ECU to the relay.
Enough is Enough, Not knowing the brand of alarm or engine immobiliser the only option was to rip it all out and re-wire the fuse board.
With all the crap pulled out and re-wired, first flick of the key we had engine starter signal & fuel pump relay clicking and energising, Quick check at the fuel pump end we have power this is good but no noise & power returning down the earth line.

Quick check at the distribution block at the rear lights became apparent that I'd not bolted it back to the body. Bolted it on and hey presto she lives
21176284380_be1ecc2e84_c.jpgUntitled by Rob Ostle, on Flickr
21176287700_99283a06bb_c.jpgUntitled by Rob Ostle, on Flickr

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jackherer

 

I don't think they should be on a classic car unless its factory fitted.

 

 

Insurance companies used to insist on at least an aftermarket immobiliser before they'd cover a 205 GTI unfortunately.

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Rostle1984

​

 

 

Insurance companies used to insist on at least an aftermarket immobiliser before they'd cover a 205 GTI unfortunately.

 

Yes your right there, My previous 1.6 gti the insurance company insisted it had one fitted and required proof of fitting.

My current insurer has never asked for such proof and neither have I declared one as I don't know what the make or model was. I couldn't even start it with it fitted it cut the starter and fuel pump circuits.

If there comes a point they ask I'll buy something like a Cobra 8510 and try to discreetly fit it some were allot neater than the previous install

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Rostle1984
After playing around with the Immobiliser and getting inside of the brain I found the cause of the issues I was having. One of the wires onto the main board had come adrift. Also found out its a genuine Peugeot 96721t unit so I happily repaired the unit and refitted it to the cars electronics. The alarm remains in the bin. Cheap fix all in all.
Anyhow Garage door shut, tunes on, Heating on I decided to start making the offside front inner wing section.
First off when I removed the sections from the car I still don't know why I cut them into two pieces but nevermind.
I offered the two sections onto the sheet steel and drew around them to get the basic shape I needed with the additions of two pieces that needed folds applied so I can affix them to the front panel and wing sections.
21402436191_c0af78e121_c.jpgOffside front inner wing fabrication by Rob Ostle, on Flickr
Cut out the basic shape with the added on sections which needed folded.
20772983003_d08ef0aa76_c.jpgOffside front inner wing fabrication by Rob Ostle, on Flickr
Section applied into the folder and folded to shape.
20771314484_88d455bdf2_c.jpgOffside front inner wing fabrication by Rob Ostle, on Flickr
Nice and tidy Fold, quite like that machine.
21402376301_8b73344ac5_c.jpgOffside front inner wing fabrication by Rob Ostle, on Flickr
The front edge however after the main fold couldn't be fitted in the folder so, Out with the Hammers and dollies, I had to run a cutter up the center as it needed to fold a bit further in the middle.
21367851366_e06b12524f_c.jpgOffside front inner wing fabrication by Rob Ostle, on Flickr
After a little alterations and dressing with the grinder I offered it into place on the car & pleased with the fit its very snug
21207102669_bb437b3917_c.jpgOffside front inner wing fabrication by Rob Ostle, on Flickr

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Rostle1984

​

Bit more tinkering. With yesterday's panel. I realised I hadn't fitted the jack mount on it. DOH. Hole cut with plasma and smoothed off with the grinder. Cut the old insert out of the old panel and welded it in place. Just need a jack now since it didn't come with one haha. Primed up in zinc ready to weld the pair in now. also refilled the cooling system with corrosion inhibitor & antifreeze for winter
20797236704_e5b311317f_c.jpgUntitled by Rob Ostle, on Flickr
20798876913_a72d5cd4c6_c.jpgUntitled by Rob Ostle, on Flickr
21233045329_bb34979bfe_c.jpgUntitled by Rob Ostle, on Flickr
20797232874_34722dd3c1_c.jpgUntitled by Rob Ostle, on Flickr

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arbor

Great work and some nice tools for the job. Cracking stuff.

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