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ian010778

1989 1.6 cherry red refurbishment

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ian010778

!!ROOKIE MISTAKE ALERT!!

 

So just having a look at the front end bits and bobs that I'll be stripping at the weekend and the rubbers around the wishbone ball joints are split. I reckon I probably damaged them when liberating them from the hubs.

 

The wishbones haven't done many miles and there was no play in them - they've just got a bit of flaking and surface rust on them where the car's been sat so I was going to wire wheel them, paint them up and put new ball joints and rubbers in.

 

And there is the mistake - I hadn't realised that we can't buy ball joints separately! To make things worse I put a big order in to MrAuto last week, without wishbones - I only wanted to order once to save on delivery :angry:

 

I've had a good look through the forums and can see posts about this from 2006 and 2013 with the only conclusion being to buy new wishbones :Facepalm:

 

Ian.

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jackherer

You still can't replace the balljoints but universal rubbers are available on ebay these days.

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ian010778
1 hour ago, jackherer said:

You still can't replace the balljoints but universal rubbers are available on ebay these days.

Sorted - one pair of boots now on the way :-)

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ian010778

Hello everyone – hope all are safe and well. I’ve taken the opportunity to do some work on the 205 while stuck at home and I hit a major milestone this morning… the front end is finished and ready to go back on the shell :D

 

20200509_102617.jpg.4b75851467725725a2abd461a94501e6.jpg  20200509_102645.jpg.17e55881e5efe82e48c3dcf1671a04a3.jpg  20200509_102714.jpg.dd39d2543b8b42250ac2925cc4a4834e.jpg
   

Here’s the story in (lower resolution) pictures.

 

Making sure the tracking isn't too far out for the drive to the MOT station once the new track rod ends are fitted.

20200506_125517.thumb.jpg.84979e50e62ef10000c120c2a8bb6aef.jpg

 

The starting point - although I had pressure washed a lot of the crud off already.

20200419_111640.jpg.50f6d584e5e54374c31fb574d4ec9db0.jpg

 

Before and after testing the wire wheel on one of the lower arms.

20200424_161745.jpg.c777af91ab67aa4010e947dc8f9f2fc1.jpg

 

The stripping station - and not the good kind.

20200425_120804.jpg.1151ca883436b36b7a03f6f108418726.jpg  20200425_120811.jpg.d0bdf471f2126782f77c68de1e136652.jpg

 

One stripped subframe.

20200503_122344.jpg.629fce6b8c15a1b5522a9483db201dc3.jpg

 

Plenty of Metal Prep on all the stripped surfaces.

20200503_104131.jpg.b7d971630676abe453561cdf8246d7b7.jpg

 

First coats of paint going on.

20200503_125254.thumb.jpg.871c1e84f88fa538aa71817b937e9be6.jpg  20200503_125301.jpg.121260a77a2bbf1e425a052f6e2558a0.jpg

 

The painted lower arms and subframe.

20200505_103820.jpg.7eab851b699419733f8307a43344336a.jpg

 

One of the new rubbers.

20200505_115145.jpg.626d246d2d0327f194d1e3e4bf04a9b4.jpg

 

The steering rack components and ARB were next,

20200506_143846.jpg.cf7bb40e276b05288d913e36a8e06eda.jpg  20200506_143853.jpg.820193dca4cfbb399e91977002410ea5.jpg

 

Then the hardware was cleaned - I don't fancy that latte!

20200508_165751.jpg.50404cb94bd1f4a36530e84b4e6798de.jpg  20200508_170110.jpg.b65369a307d921648aa2661b75f53687.jpg

 

All laid out ready for re-assembly - plenty of grease, threadlock and new washers!

20200508_174558.jpg.50731bf5e53a94d6641faf8347e5f533.jpg  20200508_174605.jpg.e5797389d393cce8bb1cab7c4208952c.jpg

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ian010778

Quick update - having made all the recent progress I realised that I really need to get on with getting the shell sorted as my nicely refurbished front-end bits are now sitting undercover going nowhere in the garage and the rear beam is on the workbench ready for strip down; so it won't be long before that is refurbed and ready to go too.

The good news is, I received two independent recommendations for the same bodyshop and the chap came out yesterday to give me an estimate. It was around my expectations having seen how much others here have paid for similar work so once I receive the final quote, assuming it isn't too far over the upper end of the estimate it'll be all systems go in August!

I really liked the chap - he was really interested in the car and he does restoration work alongside his normal bread and butter stuff (he's about to finish an XR3i convertible). This does mean that he'll have the shell until spring next year but he very much gave me the impression he'll treat it like a hobby/project of his own and make sure he doesn't rush it by trying to get all the stages done in one go, which has given me a lot of confidence in him. He also seemed to 'get it' in that he was saying all the right things about quality, preservation of the history and how I plan to use the car once finished. So, the job list is:

  • Strip all paint, stickers and sealant from the outside including engine bay and underneath.

  • New metal on the driver’s side floor where the firewall meets the floor pan as there is a thin but long gap in the original join.

  • Fix the rust on the rear wheel arches.

  • New metal where the hole is in the boot floor.

  • Fix the ding in the front left wing and the ripples in the doors.

  • Re-hang/gap the doors with new hinge pins and check straps.

  • Full exterior re-spray including engine bay, underneath and underseal.

I'm not having the inside painted to the exterior standard but he will finish the boot floor and the floor pan/firewall repairs to a standard similar to the original. Depending how I feel next year I might give the interior a whack over with some red Hammerite or maybe some clear Waxoyl just for a bit of extra protection, before I fit the soundproofing and carpet but I haven't decided just yet.

So I will have a 205 shaped hole on the drive over winter but I'm quite happy about this as keeping it dry has been a mare (especially with the storms in Feb’ and then again this week). And I’m happy knowing it’ll be tucked away in his bodyshop over the winter rather than on my drive (which is going to get a massive clean once the shell has been picked up).

I have a few ‘little’ bits to do before August – mainly removing the sunroof, drilling out a few snapped studs, removing the front and rear glass and removing what's left of the front bumper mounts. I’ll then turn my attention to the rear beam and that’ll probably be it for this year – depending on what happens with lockdown. I’ll be testing and cleaning up stuff like the fuel pump, wiring loom, relays etc. as they are taken out of the garage loft for re-fitting next spring so still plenty to do but lots of progress being made despite the low frequency of updates here. I didn’t think anyone needed to see yet another blow by blow account of a bloke cleaning every single little bit of a standard 205 so I'll be updating here as and when the larger chunks of work are completed.

 

Ian.

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ian010778

Hello all - long time no update, chiefly because of life, the 206cc and lots of other stuff!

 

Although I haven't made much progress my end, I've had some pictures from the bodyshop recently and they are certainly cracking on :D

 

A few more holes and a bit more work than first anticipated but I was warned and I'm just glad they're being thorough rather than rushing it - here's a few of the 21 pic's I received last week - enjoy!

 

Ian.

 

IMG-20210408-WA0005.thumb.jpg.5acccbc74f9680feb63eaa872cc91482.jpg

 

IMG-20210408-WA0007.thumb.jpg.cf0979fe38643718bc1a89fb3a8aae65.jpg

 

IMG-20210408-WA0008.thumb.jpg.33763382618e053481962832a964fd94.jpg

 

IMG-20210408-WA0018.thumb.jpg.8831c653893620a8818f6e59153011ba.jpg

 

IMG-20210408-WA0021.thumb.jpg.c333b866971b013b8619e5fa5caf24bf.jpg

 

IMG-20210408-WA0020.thumb.jpg.cc5e08104e0d512f796de24e41c20a64.jpg

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Telf

not too bad really Ian!

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ian010778

Hi all,

 

Time for another bodywork update - also, those who have been following it will know I've been cracking on with the rear beam recently – see thread here.

 

Progress has been made at the bodyshop – mainly the identification of a rotten driver’s side sill and all the work to source a replacement and get it in place. I ended up sourcing the sill myself (about 60 quid) and having it shipped direct to the bodyshop but it was not an easy task finding one.

 

Not sure if this will play but here’s a video of the crispy old sill and some pictures of the mess it was hiding!

 

 

IMG-20210614-WA0001.thumb.jpg.b3a2e9e23b48f251c0fd4d7ede84400f.jpg

 

IMG-20210614-WA0000.thumb.jpg.12c504cdc7beca87cca0d3be3d78dec9.jpg

 

IMG-20210614-WA0002.thumb.jpg.295a9e29d9572d857bf4392b6e228d3e.jpg

 

Anyway – the new sill arrived and the last picture I have from the bodyshop is with it ready to be welded in. I believe that will be the last bit of cutting and welding before they move on to flatting and straightening everything out.

 

IMG-20210614-WA0003.thumb.jpg.746ddfd1b72d6ddd384f3ee11da101e3.jpg

 

@Telf before you ask, they are keeping me updated with costs and we're making sure the extra work is affordable ;)

 

Ian.

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Telf

Ha ! Looks like a thorough job mate

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