205 Xr Charity Rally Project Help

[decoc182 0]

Ive recently picked up a 205 xr with a shot gearbox.Im going to enter it into a charity rally, where the winner gets £1000. Ive got lots of bits kicking about from doing up peugeots and citroens in the past. So this is a big post, and please excuse the nooobness. Ive decided to go for a stripped out 2.5 dirt basic rally monster. Im up against some friends entering in some big engine 130bhp saloons and need to beat them over the 4000 mile race to the end. The race has lots of windy bits and hills.

 

 

I firstly need a gearbox to drive EEEK... so which is it to be:-

 

106 1.1 gearbox

106 1.4 gearbox

saxo vtr gearbox

any 306 TU gearbox

 

Also need a new clutch, which clutch would fit the 1.4 SPI Flywheel, and offer decent performance. (VTR ones fit??)

 

Got the exhaust sorted, patched together some spear SS silencers kicking about from the older cars. Ive got a 3.5 ich straight cut silencer fixed up to a SS middlebox with SS piping. I just need a 4 branch to fit it, as the manifold on it has cracked. Will the raceland ones on ebay for the 1.4 1.6 TU engine fit?? Dont mind a bit of welding to make fit.

 

Its got SPI throttle body on it, I think it makes 63 bhp stock. Not sure if its the 75 bhp model. Basically which is the best option to add some power. :-

 

Go Carb from xs gt/Go bike carbs/Go webber carbs, and rig up an ignition system and fuelling from an early model carb model. (is there any threads on this)

 

OR

 

Go MPI TB/Bike Boddies/Custom TB and wireup the ECU and igntion/fuelling system from an MPI TU model.

 

Ive got the interior sorted, stripped it out and fitted some recaros from an old escort. Fitted map reader lamps.

 

Suspension, Ive got some xsara/306 60mm springs and some xsara/306 dampers to with them. These should fit the 205 right, with the 205 top mounts?? How much would 60mm 306 springs lower by>? will they be stiffer ride

 

Should I change the rear beam?? Its in good nick, not collapsed, or should I upgrade to GTI beam?? Obviously going to lower to match front and fit 306 dampers.

 

I have some xsara vts tornados to fit the car, and a spare set of fox evo 03's fitted with tyres as a spare set to go on the roof rack. Both 15's painted white.

 

I have got hella spots on the front, for the night time driving. I and hard wired the front fog lamps with a full beam cluster from a spare 306 cluster and wired it inline with the full beam lights. I got lotsa light on the front

 

I have 266mm discs and callpers to match from a xsara hdi to fit to the front.

 

I have rigged a Xsara HDI radiator and oil cooler to the engine. Engine will have new headgasket

 

Exterior, 3 door white, I have got some 205 rallye arch extension to fit, and gti front and rear bumpers. It has been repainted in ford frozen white

 

Right sorry for the blabber. The car has to make it to end 4000 hard miles away. 4 days solid driving day and night over bumpy windy mountain roads across europe. I need it fast and reliable, and unfortunately has to be this car. Cant afford engine conversion, so Im stuck with what I have engine wise. Money is not to important, as I have a grandish sponsored to do the engine and gearbox work.

 

Thanks guys, after loads of info and help on this, as Im the only 205 entering, and Im up against a wide array of vehicles, including some big 2.0 fast salloons. Also some tips on driving these bad boys hard and fast would be much appreciated. Hoping to have some forum adverts made up if thats ok to stick on the windows. Pics will be on there way this week.

 

Edited December 24, 2008 by decoc182

[RossD 43]

The 306 box wont fit as they have an odd gear linkage setup, but most of the others are pretty much the same bar the ratios and final drives.

If its the singlepoint injection, they were rated at 75bhp from the factory in 1.4 form, about 60bhp in 1.1 form.

The raceland should fit any TU 8v engine as the exhaust stud patterns are all the same.

 

Really you need to build to the regs of the rallye, find out what they are and then build to those - thats if there are any!!

 

Good luck and keep us updated

Edited December 24, 2008 by RossD

[welshpug 1,626]

don't lower the front, if its going to be rough you will need the extra travel, similarly with the back, leave it at a standard height, fitting gti torsion bars will improve the handling though.

[GazRallye 0]

Yeah I'd leave it as far as lowering goes if you're going over rough surfaces.

Gearbox wise, don't go for a saxo vtr one as the gearing is very long, go for the 1.1 or 1.4 for better acceleration.

 

I think you need to aim for reliability really and also be sure to have a good navigator that you trust. Over that kind of distance the winner is more likely to be determined by who has the more reliable car and navigator, rather than outright speed.

 

Sounds like fun anyway! Good luck.

[bren_1.3 1]

Also need a new clutch, which clutch would fit the 1.4 SPI Flywheel, and offer decent performance. (VTR ones fit??)

 

VTR clutch plates are 200mm i think. your 205 SPi flywheel is 180mm, they can be machined though to accept the larger VTR clutch plate.

 

The raceland should fit any TU 8v engine as the exhaust stud patterns are all the same.

 

raceland will fit the block but doesnt have the bends in it to go up and over the top of the 205 subframe. you'll have to knock something up to suit.

[RossD 43]

Indeed, I forgot you had to modify the raceland, wasn't thinking that clearly this morning!! I just cut and shut the raceland with a standard downpipe.

[decoc182 0]

Indeed, I forgot you had to modify the raceland, wasn't thinking that clearly this morning!! I just cut and shut the raceland with a standard downpipe.

 

 

Ok kool, I think I got a gearbox on the way now, carb and head from an ax gt.What job should I do to rebuilt/check it. Should I just replace the seals. Is there anything else??

 

With the carbs and head, I will fit head off the gt with the carb, but does anyone know how to, or got a guide or link , to rigging up the carb fuelling and timing electronics?? Anyone got any ideas.

 

With the exhaust, I have an SS downpipe, could that be made to fit to the manifold???

 

Ive been told, the roads are no worse than english country lanes, so a drop could still be down. Does anyone know how much 60mm 306 springs will drop the car?? Will these be better than 205 springs??

 

As for the project, I have started stripping the enterior. Going to Paint wheels white this week. Will get pics up this week

[decoc182 0]

Started work on the car this week got some pics of the progress and what she looks like

 

 

 

 

Gearbox is well and trully buggered, engine runs however, and it drives ok (got towed at 50mph on a rope!!)

 

Ive bought an ax gti pre-cat engine (100bhp) with a sportex manifold from a chap off the ax owners club. Ive also picked up a straight through replacement mild steel straight through pipe from a new 1.4xr and an old ashely backbox off VTR. Exhaust sorted once the engine arrives.

 

Got some momo seat subframes for £9.99 off ebay. Will get pics up tommorrow for them.

 

Swapped my pepperpots for a set of s1 steelies off a mate on pug106.net

 

Just a matter of finding a be4 gearbox and finding out how to get setup..

[decoc182 0]

Ive done some more work on the 205 this weekend. Will get some pics up later. The shell is solid, with only some surface rust. The boot floor is rotten though. So I will need to cut out the boot floor pan and weld a sheet of steel in to replace. Its no where near the Beam mounts, so shouldnt be structural.

 

I have had a look around the forums and asked a phew people about the be4 gearbox conversion. Some people mentioned I need the gti subframe etc etc.

 

I have managed to pick up any parts I need from a 205 diesel. I believe these have the subframes as the gti, so does the spare car have all the parts I need realisticly for the be4 gearbox conversion.

[decoc182 0]

Hi dudes. My 205 project has hit another brick wall when the engine i was buying was deemed "no longer for sale". So stuck in a bit of a pickle. I have a 205 1.4 xr and would like to stick an XU10 in there. I know they dont fit straight up and needs some fiddling to fit. The thing is, I can get my hands on a 205 diesel for £70 complete. I was thinking of using the subframe,mounts,driveshafts,suspension from the diesel and put them on my TU shell. Will this suffice, or will I need a GTI subframe?What else is needed to fit?