[car_overhaul] Bam Bam's (Mi16) Refurb Project

[BamBamGTI 0]

Old BE1 taken off as I had the old crunch in 2nd starting to piss me off, but had a spare luckily. Anyone here want an old gearbox that they wanna rebuild?? Also removed all the old rubber hoses, some of which hadnt been changed in 20 years, Some I found leaking or about to fail.

 

 

Changing them to these nice new silicone lovelys in red... Ebay £175 for 10

 

[BamBamGTI 0]

Gearbox before... Cleaned with Gunk Oil remover and a wire brush and power sprayed, then painted with Hammerite metal paint smooth silver £10 B&Q

 

 

And Now

 

 

Replaced the Driveshaft seals as one side had a leak...

[BamBamGTI 0]

Subframe and VU removed, disassembled, Stripped (only the VU) then painted with U-Pol Etch Primer (£10 Halfords) and Halfords Matt Black Paint (£8)

 

 

Unfortunately, one of the bolts broke on the Anti-roll bar, Anyone got a replacement bracket???

 

[EdCherry 34 1 Cars]

some of the terms you use a rather wierd, big end liner? VU?

[BamBamGTI 0]

Big end liner? Did I say that?? I might have meant the liner nearest the big end cap... VU = Vacuum servo unit

[EdCherry 34 1 Cars]

All the liners will be near a big end cap as thats what is on the end of a conrod. The small end being the piston end of the rod.

[BamBamGTI 0]

Ohhhhhhhhhhhhhhhhhhhhh

[BamBamGTI 0]

Block now repainted in Hammerite

 

 

All bolts have been replated in zinc, including Pulley and other brackets = Jackson Plating Hounslow £60

 

 

Sump De-oiled, stripped and repainted in Matt Black

 

 

More shiny painted bits

 

[BamBamGTI 0]

Box arrived from Autofive today with New gasket sets, SAD, Coil, Thermo

 

[GLPoomobile 958]

Box arrived from Autofive today with New gasket sets, SAD, Coil, Thermo

 

 

Bet you paid through the nose for that lot!

 

Someone on eBay is selling brand new SADs for about £30 at the moment. How much did Autofist, err I mean Autofive charge you?

[welshpug 1,661]

especially with GSF own brand stuff in there too!!!

[BamBamGTI 0]

I know, I saw those f***ing SADs on ebay after I bought it - gutted. GSF dont do all the part im after, I need some new piston rings and GSF dont do them. Dont fancy paying £80 for a set off Autofive. Any suggestions where I can get some cheaper? I cant think peugeot would be cheaper would it?

[welshpug 1,661]

I think Peugeot do them for about £100.

 

As for GSF, have you asked or just looked in the catalogue?

 

Most motorfactors can supply decent quality items, or try QEP, they may well have them on the shelf being an engine specialist.

[BamBamGTI 0]

Yeah, I asked GSF in store and they didnt do them. Their catalogue doesnt even have 205s in anymore - shame really, getting more difficult to get parts these days. As I have my head being reconditioned with QEP Ill give them a ring and see if they do them.

 

Still after some other bits and bobs... Any ideas?

 

- Lower steering column - Peugeot do them but there are 2 different types one £70 the other £130. My PAS rack is off a '90, but no idea which to buy. People have the parts, but usually are unwilling to sell the column without the pump and rack included. Bah.

- A few replacement bolts with allen key heads on them that sheared off when I removed the engine. E.g Lower Gearbox bolt (to the block) and Upper alternator bracket bolt, as well as one of the bolts for the thermo housing.

- PAS low pressure hoses - I guess a motor factor can do these

[Ryan_B 2 2 Cars]

Great project fella. Keep up the good work.

 

Ryan

[Mongo 0]

Got two coats of paint on all but one of the alloys now, I think Ill give them one last light wet&dry before the laquer coats (2)...

 

Decided on the rubber for the wheels and just bought some new centre caps off ebay which need painting too. Im also gonna buy some wheels nuts so I can paint them, to complete the look...

 

Decided on the Michelin Pilot Exalto PE2's. Bit dear at £100 a corner, but Ill do some shopping around.

 

http://www.michelinman.com/tires/ultra-hig...lot-exalto-pe2/

 

in 195/50/15 Costco do them for about £45 a corner.

 

I got htem in the 25% discount deal for the 306, and ended up paying £152 or so, including fitting.

[BamBamGTI 0]

Quick update:

 

Engine bay cleaned

Bits of rust in engine bay treated and re-painted

Loom removed and all plastic pipe protectors replaced or cleaned

Liners being honed and new rings from QEP

Head refurbed by QEP

Suspension mounts renewed

Rubber stop and protector for D/S renewed as there was a hole in the protector and the rubber stop had disintegrated

New wishbone rubbers and boots fitted

Wishbones stripped and painted

New droplinks fitted

New clamps and Anti-roll bar bushes fitted

New sensors for Oil and water

[BamBamGTI 0]

Still need:

 

New lower steering column for PAS upgrade. Still cant work out which to buy. There are 2 types and I cant work out which I need. The rack is off a 90 GTI but I need the VIN or reg to find out which I need. Had a look on servicebox and found the diagram but as I dont have the upper part of the steering column from the original car I cant work out which I need. Peugeot said I am obligated to buy the part even if its wrong, and I really dont want a £70 lower column I dont need. The differences in the two racks are to do with the top column and the distance between the unions (450mm and 550mm I think) Has anyone got a '90 GTI with PAS? Can you measure the top column unions for me!!!!?

 

Terminals for the engine loom. Replacing all the terminals off everthing apart from the special connections like injectors and AFM as they are still in perfect condition. Servicebox doesnt seem to list them and I only have the part numbers for the spades on the brown multiplug, but there maybe other part numbers I need.

 

Earth blocks next to the headlights - not on servicebox either. Cleaned them up with a jar of vinegar and worked better than I thought, although I would prefer new ones if they are available.

 

Bleed screw for thermo housing. On order at pug, the old one broke in the pipe

 

Rubber hoses for PAS and unions.

[BamBamGTI 0]

Update

 

Finally got a lower steering column off a bloke selling a rack on ebay £20. All I need now is the hoses. I went to peugeot but they came up at £60 a set and the special jubilees are a 50 pack!!! So Im just gonna go to an autofactors for that stuff.

 

Managed to track down the part numbers for all the loom terminals and completed the new multiplug which has rubber seals so the water cant get to them (£7.50 from Simtek) but you need some good ratchet crimpers (£38 motor factor) - a wise investment, they crimp to a near pro standard and all the terminals survived the pull-test

 

Before

 

cut off the old plug and seals added...

 

crimped

 

 

 

Stuck in the new plug

 

Looking good...

 

Clip to keep the terminals straight

 

Female side

 

Done!

[BamBamGTI 0]

Suspension mounts have now been replaced on both sides, as I had a nasty creaking noise coming from the passenger side when turning... £45 a side (peugeot). Found the problem to be the bearing on the top had disintegrated with the rubber buffer which had fallen apart.

 

 

Compressing the spring is much easier when the strut is removed from the car...

 

New buffer

 

Old manky mount

 

Nice new mount

 

Liners honed, (QEP) and new rings fitted

 

 

Head test fitted

 

 

Suspension back on the car with new drop links...

 

Now just gotta put the gearbox on and finish the loom connections, then Im nearly done!!!!

[sport1901966 8]

Nice project chap keep up the good work!

 

I'm only round the corner from you over in epsom and I'm working through my first Mi conversion, I've got a project thread in the members works section, when you come to doing the conversion yourself if you get stuck I'd be more than happy to try giving you some help!

[BamBamGTI 0]

Thanks mate, I may need your help in the next couple of weeks if you have time... I gotta get this engine back in the car. You got a crane???

[BamBamGTI 0]

Update

 

Just a few pics from the project. After waiting ages for parts I'm finally nearing the finish line, got some refurbed alloys to replace my amateur effort courtesy of A1 Alloys... decided on the Goodwoods - nice and shiny

 

Side mouldings have been taken off as I want to cut the paintwork properly as I can't afford £2000 for a re-spray, although most of the metal clips have turned into dust, so I've got to change those too now. Hopefully the cut and polish as well as the alloys should make the car look alot tidier.

 

I'm currently waiting for some silicone SAD and oil filler hoses from a bulk buy off stew205 \/ link

 

http://forum.205gtidrivers.com/index.php?s...mp;#entry992419

 

Goodwoods

 

 

Engine work

 

 

The motor

 

[BamBamGTI 0]

Any ideas on what I can do for this little problem?

 

 

The bolt for the fuel lines and brake line sheared off so I had to tie the lot together with a few cable ties to the clutch cable to keep them away from the exhaust manifold... Doesn't look great.

[BamBamGTI 0]

update