[car_upgrade] Project Pug, 205 Rallye (my First Project!)

[tomcolinjones 26]

Well done ali! now you can have fun putting it all back together! mine hasnt moved in a while, i have 2 weeks off soon so we can compare progress then!

 

BTW tht gearbox looks familiar

[allye 530 3 Cars]

BTW tht gearbox looks familiar

 

Haha, tis a good box. Its been a while since you did anything with yours! Get your arse into gear, I'm going to be finished way before you

[tomcolinjones 26]

Haha, tis a good box. Its been a while since you did anything with yours! Get your arse into gear, I'm going to be finished way before you

 

I will be! tho i do have the tu-vts aswell as a sorrento mi16 to do now! paint starts next week. will be ordering it on monday. then I'm back in the race

[allye 530 3 Cars]

Getting there.

 

got both front and rear valances and bumpers on the car, makes it look a million times better and makes me think I'm closer than I am to finishing

 

Then I thought I would get the master cyclinder 'fun' out the way, some grinding to the cambelt cover and losened off the servo and it went on, duct tape is a right bodge but I didn't like having a hole where crap could get into the belt. Prob won't last long.

 

Couple of question about the hoses, the header tank > metal hose, hose is very close to the gear linkages is that alright or should I just cut the hose alittle shorter?

 

The matrix>thermostat hose seems to have a un-needed bend in it? just cut it off?

 

Ramp makes life very easy

 

How she sitting now. Work to carry on tomorrow!

[allye 530 3 Cars]

Also forgot to ask, you guys think these hoses are ok? or would you suggest heat wrapping them or somerthing!?

[tomcolinjones 26]

Going well my friend! nothing more satisfying than gettin the engine in there , its like a milestone, and you can start rebuilding around it! i felt the same before i changed my mind and got the xsara! now ive had to start over!

Good luck with the rest.

[allye 530 3 Cars]

Going well my friend! nothing more satisfying than gettin the engine in there , its like a milestone, and you can start rebuilding around it! i felt the same before i changed my mind and got the xsara! now ive had to start over!

Good luck with the rest.

 

It feels good to get things like the valances and bumpers on, makes it look like a car again after it being in bits since september. Can't wait to send it down to miles for the wiring so I can put the interior in and drive it!

[rallyeash 155]

nice one mate, yeah that 90 degree end just needs cutting off and popped onto the thermostat housing. think it has the end on it for an mi16.

 

other pipe looks abit close to the linkage, remember you have the gear linkage rod to go on there also (which moves).

[allye 530 3 Cars]

other pipe looks abit close to the linkage, remember you have the gear linkage rod to go on there also (which moves).

 

Yer I thought it was a bit close, will cut some off the end so it doesn't sit as near, plenty of pipe to play with. Should be done in a few weeks, will bring it over to show you!

[rallyeash 155]

sounds good, mines tax'd and mot'd now, did a few miles in it last night. love being able to drive it again on the road

[shalmaneser 26]

See my post here to for the answers to almost all of your questions!!!

 

http://forum.205gtidrivers.com/index.php?showtopic=128408&st=0&p=1157509entry1157509

 

Good luck with the swap!

 

Adam.

[allye 530 3 Cars]

See my post here to for the answers to almost all of your questions!!!

 

http://forum.205gtid...9

 

Good luck with the swap!

 

Adam.

 

Nice one, cheers for that. I trimmed them back today and fit perfectly now

[Stolton 0]

Great looking rallye mate.

[allye 530 3 Cars]

No photos Forgot the camera as I'v been fairly flat out in the last few days.

 

Got all the brake lines in, cleaning up and thr braided hoses on the wire wheel as well, then got all the fuel lines on and mounted the 106 fuel filter. Popped down to Miles yesturday and got the GTI tank and gear linkages so the tank went in today and got all the plumbed in apart from the fuel hoses - on the GTI tank which outlet is the feed and which is the return? I would assume the feed is the outlet is the middle, closest to the back and the return is the one on the edge, closest to the front of the car - is that right???

 

Then set about the radiator, I robbed twin fan setup from an STDT at the scrap yard along with a GTI radiator, just needed some 'encouragement' to fit made up some brackets to drop the rad and trimmed back some of the fan cowling as it went in, although very close to the rad - will keep an eye on it, stiff mounts will help. Got all the collant hoses on as well.

 

These little jobs are taking longer than I thought, they always do! I got a L bracket for the gear linkages but it was a TU one so too long , might trim it down or get hold of a GTI one. Also I need to get hold of a 205 clutch cable arm, I had one but binned it because I thought it was the same as the VTS one, it really isn't New one from pug is about £60, robbing bastards.

 

Anyway, couple of little bits to do but I move to weymouth tomorrow so progress will be on weekends! Its about ready to go to Miles in 2 weeks, then its interior in, MOT......fun times

[welshpug 1,661]

the last gti pump I remember looking at was marked with arrows.

 

re-clutch arm, it'd be the same as any BE3 push clutch, so tons of vehicles out there will have one suitable.

[allye 530 3 Cars]

the last gti pump I remember looking at was marked with arrows.

 

re-clutch arm, it'd be the same as any BE3 push clutch, so tons of vehicles out there will have one suitable.

 

I gave it a wipe off but couldn't see any arrows. I spent quite a while trying to get the arm of 2 diesels and GTI in the scrap yard. But it just won't happen with a 20 year old car wih the gearbox in the car! They are just rusted in.

[welshpug 1,661]

doesn't have to be a 205

 

306, xsara, belingo, partner, 406, Xantia....

[SurGie 54]

Your rallye looks very well put together

 

When i get round to it i'm going to try and modify a GTI6 heat shield between the pipes and manifold.

[allye 530 3 Cars]

Your rallye looks very well put together

 

When i get round to it i'm going to try and modify a GTI6 heat shield between the pipes and manifold.

 

Thanks Surgie! The idea behind this conversion for me was to do it bloody well first time round to ensure its reliable and just a driving car not a fixing one

 

(PS start a project thread!!!! I want to see yours)

[allye 530 3 Cars]

Spent the afternoon on the car and got a few bits done,

 

here are some pictures of what I did last week! Phones pictures again

 

I'm using full length rubber lines for now and see how I get one, if it smells to much then I will run some copper oner or something

 

Today I did the rear brakes, I'v been putting it off really as I'v never done anything with drum brakes but found it actually quite easy if you take it apart logically and place them in order, my mechanic friend then walked me through setting up the h/b correctly. I put ne shoes and cyclinders on it, the ones that came off were nearly new and cyclinders weren't leaking but hey, peace of mine!

 

Also new nut and cap makes it look pretty! also the hut gets a a hard life

 

As I lowered the rad an am using a stainless bottom water hose I had to make up some little brackets, looks pikey but is bloody firm does the job well.

 

been trying to get the front up together as well but ran out of time

 

Slowly getting there!

[lukesaddy 0]

absolutely love your car mate, makes me crave for a rallye

 

your workmanship looks to a very high standard too, cant wait to see it finished

[rallyeash 155]

good work mate, just make sure them rubber fuel hose's don't come to close to the centre box on the exhaust

[Wes 86 1 Cars]

looking good mate. will you be taking it to weymouth with you during the summer? mine is with miles at the moment getting the xsara lump fitted. would be good to have a mini meet at the coast.

[allye 530 3 Cars]

looking good mate. will you be taking it to weymouth with you during the summer? mine is with miles at the moment getting the xsara lump fitted. would be good to have a mini meet at the coast.

 

yer I will, hopefully in about 3 weeks time! I'm on chickerell road if you know, i'v got my xs here at the moment.

[allye 530 3 Cars]

Productive day! I bought the ready converted exhaust from the laser Spikey was breaking, I was very worried about it being too loud but he assures me its not too bad, but of modifying to the centre exhaust mount so it sat low enough not to foul on the gear linkages (read: hitting it with a hammer in a vice ) Fits perfect now though, new fitting kit and clamp does the job nicely.

 

 

I think it looks quite nice, a little bigger than I thought it would be! Also finished messing around with the alternator set up and got the new brake pads in and will bleed it tomorrow, new plan is to buy a ready converted loom from someone to get it running then take it to Miles to get the gauges working.