[trackday_prep] My '89 1.9 Gti Fast Road/track Day Build

[toonz 0]

Ps, how good are trackdays! I joined PSOOC boys over to Llandow in Wales and had an awesome day out. Mate shredded my near side eagle f1 for me:) know what you mean a out power found same thing hence bought engine with a view to dropping it into the pug on Webbers or throttle bodies. Ended up moving and garaging car in end can't wait to get behind wheel again before she goes though...

[mattg 3]

Thanks mate, yes trackdays are superb fun and so addictive. I was slow at the beginning of the day but by the time I got to the end I was pushing hard and wishing for more poke! The Parada's took a pounding! Will let you know on the engine if I decide to go that way

[mattg 3]

I thought I’d put together a bit of a roundup of where I’m at with this, what has been replaced in the rebuild and then a little plan of where this is going from here.

 

Engine

 

Standard 1.9 8v

 

Replacement parts

 

Cambelt

Cambelt rollers

Waterpump

Radiator

BBM silicon hose kit

Alternator

Auxilliary drive belt

Airfilter

Fuel filter

Oil filter

Engine oil

 

To do

 

GTI-6 conversion, engine bay repaint. (engine donor purchased)

 

Chassis

 

Replacement parts

 

Bilstein Dampers (306 GTI6 parts at rear for improved stiffness)

Rear beam fully rebuilt and powder coated. Lowered 40mm

PI -40mm Front springs

Drop links

Top mounts

Yokohama Parada spec 2 tyres all round

Brake pipes

Brake Flexi hoses

Brake rear compensators (Bosch)

Discs all round

Pads all round

 

To do

 

Upgrade to GTI-6 calipers discs and pads up front, upgrade to braided flexis, upgrade to 406 master cylinder, refurbish wheels in original silver, obtain missing wheel centre.

 

Body

 

Standard.

 

Replacement doors (good secondhand) painted to match.

Brand new wings painted to match

Bodykit re-died dark grey, parts replaced where damaged with good secondhand.

Treated and painted underside.

 

To do

 

Get hold of a front bumper red insert.

Full body respray in original colour including door shuts etc.

 

Interior

 

Standard, cleaned as best as I could.

 

To do

 

Undecided, either cage and replace seats with buckets or tidy up the original parts. Either way, any mods will be reversible (bolt in cage, seats will be kept) I’m not going fully stripped out whichever I do.

 

 

 

The plan is to get a few miles on her over winter and then whack a GTI-6 in over a weekend before spring time for next years track day season. After next summers fun I’ll be looking at taking her off of the road for a few months, freshening up the engine bay and refitting the engine after that too has been freshened up. The rest of the jobs will be done as I go along.

 

This isn’t going to be a quick project but at least she’s back on the road and being used again now.

 

Oh yeah, and I’ve just bought a nice low mileage Xsara VTS for the engine….

 

Current pics…

 

 

 

 

 

 

The donor

 

[mattg 3]

Out for a baz this weekend and grabbed this pic. Thinks it sums up what a 205 is all about! Sunshine and a twisty B road! Happy days...

 

[mattg 3]

So, it’s been a while without much in the way of updates. This weekend we decided to get the engine and box out of the Xsara.

 

We pulled the engine and box out.

 

 

 

 

 

Dragged the Xsara’s carcass out of the garage with great care, clearly.

 

 

 

 

Split the engine and box (I’ve decided to use my standard box as it’s in fine fettle)

 

Got the engine on the stand and Pugley in the garage ready for surgery

 

 

So, next weekend I’m going to get the last valuable bits off the Xsara (rear beam, alloys, CD changer, Exhaust, front struts, steering rack) and then it can go. Then it’s a case of selling off the last bits that are in the way and it’s time to crack on with getting the 8v out of the Pug!

 

[mattg 3]

Right, time to get this stripped down and ready for the new heart...

 

 

Want this done by April ready for the spring/summer!

[dcc 855]

Such a shame! Looks like a very neat little motor!

 

Let me know what you do about the silicon hoses - I need 2 or 3 to finish my 8v off! (most fo them need to be changed for the 16v conversion)

[mattg 3]

Such a shame! Looks like a very neat little motor!

 

Let me know what you do about the silicon hoses - I need 2 or 3 to finish my 8v off! (most fo them need to be changed for the 16v conversion)

 

A shame? I saved it from scrap 3 odd years ago and am now making it more suitable for what I use it for so not sure I follow on that one.

 

Hoses will be for sale as a full kit once the lump is out.

[Baz 421]

Out for a baz this weekend...

 

Sorry, what??!

[mattg 3]

 

Sorry, what??!

 

Haha, I love a good Baz

 

I'll be fitting that rad of yours shortly

[FireFly 4]

Nice progress. Nice to see you've gone with the VTS/'6 lump!

[mattg 3]

Nice progress. Nice to see you've gone with the VTS/'6 lump!

 

Thanks mate, should just give it that little lift that I feel it needs.

[mattg 3]

Righty, progress....

So today, I have completed the following..

Sort front of garage to give me space to work.

Up on stands and wheels off.

Bumper off.

Inlet hosing and airfilter off.

Drain Coolant and remove hoses from bulkhead.

Drain engine oil.

Drain gearbox oil.

Disconnect fuel hoses

Disconnect throttle cable

Disconnect clutch cable.

Disconnect speedo drive.

Disconnect wiring from engine.

split ball joints from wishbones.

Leaving me with this....

So next weekend, I plan to remove the driveshafts, disconnect the gear linkages and have a final check before hoiking the 8v out.

Then it's on to engine bay prep!

[samthornton1990 23]

I can't wait for the day that I have the money to own another one of these. Lovely build.

[samthornton1990 23]

One other thing, what springs are they? How much do they drop by?

[mattg 3]

Thanks Sam, they are PI -40mm springs. Handles niceley on them with the rebuilt beam and new bilstein dampers all round. I think it would look good a bit lower but don't want to ruin the handling.

[samthornton1990 23]

Ah... 205s never seem to look that low even with a drop. Still hopinh to have another one in the next few years. Miss mine so much....

[mattg 3]

Well, as much as I love doing my own work on the car, i'm just not getting around to doing this engine conversion and I really want to enjoy the car.

 

I've been exchanging PM's with Miles of Pug Racing this week and have decided to whack the old girl back together and get her down to Miles for a pro-conversion.

 

Quite excited that this is going to be ready for fun this summer!

[mattg 3]

Well, Pugley is heading down to Miles's capable hands on the 27th of this month ready for the conversion to be finished off, cambelt change, a couple of other bits and a fresh MOT (as it's now lapsed)

 

Good stuff!