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Nobbly

'Box of bits' 1.6 GTI restoration

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Nobbly

Hi 205'ers,

 

I have been meaning to do this for a while having gone through the same process with my old VW camper a couple of years ago ( http://forum.earlybay.com/viewtopic.php?f=2&t=69499 ), I found it a great way of recording what I'd achieved and the help and advice received made a huge difference!

 

I always wanted a 205 when I was a 'yoof' in the early 1990's, but (working in a Ford dealership) tended toward the blue oval (RS1600i, 2 x S1 RS Turbo, Capri Mk2... wish I still had them, I'd be well off now!).  Even then I knew the Pug was a better car than the Escort, but I wouldn't admit it, even to myself.

 

So, I stumbled on a bit of a 205 project about a year ago, a chap had started the resto  but needed space for other projects (RS2000 Mk2, De Tomaso Pantera,...).  It was quite local and at a price I was happy with to get me into 205 land.  Basically it was:

 

  • A 1.6 phase 2 from 1991, 79k with no history.  (However, looking at the condition of the interior, engine and gbx internals and the body I'm as sure as you can be this is genuine)
  • It had had a bump in 2004 and was written off Cat C  - the damage was minimal and limited to the o/s/r 1/4 panel and rear bumper.  The tailgate fitted was non-GTI.
  • Engine, front suspension and interior already stripped out.
  • Engine had been stripped, vapour blasted, all new parts (cylinder liners, bearings, gaskets) were supplied.  Crank had been checked/polished and the head fully rebuilt.
  • Gearbox not touched.
  • Rear beam (seized), also not touched.
  • Front suspension had been overhauled with new brakes, wheel bearings and the subframe p/coated.
  • The shell was in good condition, tiny bit of corrosion on the n/s inner wing and boot floor needed 2 x 5cm square patches. 
  • The guy had already wire-wheeled the underside - which i was very happy about!

 

Here she is as bought...

 

IMG_0703.JPG

IMG_0811.JPG

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Nobbly

So I got it home and started tearing bits off, fixing the rust on the inner wing and boot floor.  I found a bit under the rear seat too that when prodded was a bit 'soft', so fixed that.

 

All in the welding and making good took about a day - light relief after a VW camper I can tell you!!

IMG_1982.JPG

IMG_2012.JPG

IMG_2022.JPG

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Nobbly

After a bit of scraping and wire-wheeling I could see progress in the engine bay and under the back-end :)

 

IMG_2038.JPG

IMG_2043.JPG

IMG_2044.JPG

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Nobbly

Then the front suspension went back in so I can get her to the paintshop where the experts can sort the minor dings and the dents in the 1/4 panel - it's hilarious that this could write the car off!

 

41922819944_89bae7bee7.jpgIMG_1997 by David Noble, on Flickr

 

While I get cracking on with this...

 

42641396831_0daf8523d1.jpgB9F125F7-96D4-4673-8051-7139987CF373 by David Noble, on Flickr

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Nobbly

So, we're nearly up to date.

 

Car is at the bodyshop, looking like this...

 

40833727080_91a582da86.jpgIMG_2225 by David Noble, on Flickr

 

40833727790_60d6fd179e.jpgIMG_2226 by David Noble, on Flickr

 

... and I'm just about to build the gearbox after the casing comes back from the vapour blasters.

 

Stay tuned!

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Nobbly

Bodyshop update... now in primer!

 

42649660801_4dcf5662e0.jpgDJ6 by David Noble, on Flickr

 

:D:D:D

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pugdamo

I love these sort of write ups, it goes from start to finish really quick, loads of decent pictures and all the work to a really high standard. Hope it's finished soon so you can enjoy it through summer. 

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forbeslongden

It's great when someone buys one to put back on the road again! 

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Richie-Van-GTi

Nobbly, do you mind saying how much the paint job is costing you? Looking real good so far, hoping mine will be going through these stages in early August

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Leslie green

Going to be very nice when finished 

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Telf

looks great- have you painted or treated your block?

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Nobbly
On 6/8/2018 at 4:21 PM, Richie-Van-GTi said:

Nobbly, do you mind saying how much the paint job is costing you? Looking real good so far, hoping mine will be going through these stages in early August

I'd rather not say :unsure:...

 

 

                                       .... well, actually I don't know...   

 

                       

                                                                                              ... until it's done...            :blush:

 

 

I trust the guy and we've agreed a ball park figure based on his hourly rate - but a good job is cheaper than a cheap job.  I want a good job.       

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Nobbly
Posted (edited)

Gearbox night tonight...

 

Bearings from various sources (Brammer, BRT, Peugeot) all seals and other bits from Pug too.  Plus a nice tube of Loctite 518 to seal the case.

 

Cheap diff bearings!  Ford wheel bearing kit of some sort has them in - £24 for the pair from BRT :D

28888641218_5019606f31.jpgIMG_2270 by David Noble, on Flickr

 

Genuine US made Timken bearings too..

 

42044858484_bd632f9828.jpgIMG_2271 by David Noble, on Flickr

 

The paint dot is so I keep the bearing with it's cup (i.e don't mix them up between now and putting the diff in). :excl:

 

Diff bearings on...

28888639908_7ba1382b4c.jpgIMG_2267 by David Noble, on Flickr

 

Bearings on the shafts...

28888638578_e4c8c2345e.jpgIMG_2266 by David Noble, on Flickr

 

Nice clean casings 

27893013907_9697509345.jpgIMG_2268 by David Noble, on Flickr

 

Clusters in - and out about 3 times.  Bit of a faff with the selectors (not done one of these before) :blush:

42044858944_dfd4d6575e.jpgIMG_2272 by David Noble, on Flickr

 

Getting late now, I'll do 5th gear another day!

42044859284_0e1e6fdc50.jpgIMG_2274 by David Noble, on Flickr

Edited by Nobbly
photo duplicated

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Nobbly
On 6/9/2018 at 8:00 AM, Telf said:

looks great- have you painted or treated your block?

Hi Telf,

 

Not done anything to the block so far, I have seen that some folk just give it a coat of WD40 from time to time.  I'm more partial to GT85 as:

  1. It doesn't eat all your rubber and silicon parts
  2. It smells better - I sometimes use it instead of deodorant ^_^

Nobbly

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Nobbly

Gearbox finished tonight :D

 

42753291612_3a3b6d0614.jpgIMG_2281 by David Noble, on Flickr

 

28929226668_c6ae66208a.jpgIMG_2282 by David Noble, on Flickr

 

... and no parts left over!

 

Well, apart from the shim pack for the diff that [apparently] you don't need in a late 'box. Didn't do my homework there now, did I?

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ian010778
On 6/8/2018 at 7:18 AM, pugdamo said:

I love these sort of write ups, it goes from start to finish really quick, loads of decent pictures and all the work to a really high standard. Hope it's finished soon so you can enjoy it through summer. 

Wish mine was going this quick ;-)

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Nobbly

Exciting day yesterday... picked her up from the paintshop :D.

 

This is us popping in by the house for lunch on the way home...

 

42988921841_c2560aeb5d.jpgIMG_2372 by David Noble, on Flickr

 

Then up to the workshop...

 

42270496124_08cfb47075.jpgIMG_2378 by David Noble, on Flickr

 

And onto the ramp to get the axle out for refurb and start putting twinkly bits back on 

 

42270496194_383b3b63cf.jpg36bbd93f-4caf-488f-8a28-bb0a9c3cb5a8 by David Noble, on Flickr

 

42270496224_145b74993c.jpgff0d650d-5116-4f03-847b-97425a4c75ac by David Noble, on Flickr

 

42270496684_9d890032c9.jpgIMG_2382 by David Noble, on Flickr

 

42087500405_8a8e5da57f.jpgIMG_2383 by David Noble, on Flickr

 

Loving the brightness of the red!

 

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Nobbly

Question?  See this stabiliser arm thing on the beam...

 

28120685947_65569e4ab8.jpgIMG_2422 by David Noble, on Flickr

 

Should there be a bush or something in the eye where it attaches to the bracket on the tube??

 

 

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Telf

nope that's how it comes- no bush

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Tom Fenton

That is how it is. To be honest the purpose of that strap is somewhat vague as to what it actually achieves. On my standard cars I have retained it for originality sake, but on my modified ones it gets removed and left off with no ill effects.

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205Rallee

Car is looking brilliant. Will have to meet up when you've finished. Mines MOTD and insured and in mothers garage as Rallye is getting used this year. Moving later in the summer and will have two garages so I'll be able to keep the two together for the first time ever.

 

 

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