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

[allye 530 3 Cars]

I'v been meaning to type a final (for now ) spec list and what I'v done during this part of the build, so here it goes!

 

Original 1992 Rallye - engine bay resprayed

1.6GTI rear beam (rebuilt by Anthony)

GTI sub frame - new ARB bushes + drop links + new wish bones

1.6GTI hubs - new bearing + Baz's bolts

1.9GTI Rebuilt Girling calipers + mintex pads

Braided hoses all round

Spax shocks all round + Peugeot sport springs + Group N top mounts

73,000 mile XU10J4RS engine, new HG, water pump, cambelt, inlet/exhaut gaskets, new plugs

Ph2 GTI header tank, 306 battery box, Spikey converted loom, gti dash +engine/lights looms

Xsara VTS gearbox, 205 BE3 diff, clutch arm, lever arm, clutch cable + new bushes

1.6 GTI drive shafts + new seals

K+N air filter

BBM Group N engine mounts

GTI radiator + STDT twin fan

New 1.9 GTI master cyclinder + new brake lines

1 year old manual rack with new TRE

Near new drums, new shoes + cyclinders

BBM hose set + gear linkage bush

Miles gear linkages

GTI fuel tank + all new fuel lines

106 GTI fuel filter

1.6GTI cloth seats + red carpet

GTI clocks (reset to original millage of shell)

106 Rallye ph2 steel wheels + spare

Aero catches

 

Waiting to go on

Euro Rallye arches

Full UK decal set

 

Think thats about it for now! I like to think I'v done a thorough job.

Edited September 2, 2011 by allye

[burr_2000 1]

cars looking good and loving the tripod look. the euro arches dont do it! not sure how you will apply uk decals once arches on and how it will look.

[allye 530 3 Cars]

cars looking good and loving the tripod look. the euro arches dont do it! not sure how you will apply uk decals once arches on and how it will look.

 

Cheers! I know what you mean about the arches but the front wheels poke out a little + I need to cut the rear metal back as the wheels catch at the moment. Decisions decisions.

[allye 530 3 Cars]

Looking back I never added the photos of when I was rear ended last sumer by a lovely man in a transit......with bull bars......towing a massive trailer It got completely repaired by their insurance to a good standard, the cost of the repairs came to nearly £2k so it should never of really been repaired but I stomped my feet loads and got it fixed! I came out of it with a better car in the end (plus I rinsed the nuts off the matiz hire car )

 

 

[allye 530 3 Cars]

Rallye is now parked up for the winter as my new job is a 36mile round trip so bought a 309 diesel to commute in.

 

I'v been umming and arring for ages as to whether to supercharge it, even watched a lynx fitting kit sell for under £600 on ebay and a new supercharger go for about £700 but then I would need better brakes, intercooler, pipeworks etc etc. Even on a very tight 2nd hand budget min would be £2k. As at current I never intend on selling it so thats a plan for the future

 

Plan for the winter is to do all the little jobs I never got round to doing whilst enjoing it in the summer

-get all the guages working

-buy a new standard exhaust system

-one cv boot has split

-fit stickers and arches

-ditch twin fan cowling for slim lines

-fit oil cooler (I know I know, but I want one and it will be on a thermostat)

-powdercoat inlet, maybe cam covers, strut brace

-put some heat reflective stuff on bulkhead

-fit solid fuel lines under the car

-new injectors as one of min is ticking

 

If I can find some for a reasonable price some compomotive th's prob in the 14x5.5 size

[Jarrus 3]

Mate, that's a really tidy motor you've got there, I would love this.....

 

Personally though, I would stick with the steelies and leave off the arches and just put the decals on.... gives the car a much cleaner look...

[allye 530 3 Cars]

I used to think the 106 steeles looked the best and would never change but secretly would love some TH's, stollen from custard rallye's thread

 

 

I would leave the arches off but the front wheels stick out and I'v trimmed the rear arches so they need to go on unfortunatly, still looks good though!

 

 

(thats back in early summer 2010, old engine standard rear height)

[rallyeash 155]

nah, i had comp th's and also the OZ rare versions but still prefer S2 steel's hence why i run them now

[custard-rallye 25]

I have 2 spare but one is buckled they even have rallye engraved on em but don't think I could bring myself to sell them. I might know of some though

[allye 530 3 Cars]

I have 2 spare but one is buckled they even have rallye engraved on em but don't think I could bring myself to sell them. I might know of some though

 

You know you want to sell me yours! or if you do know of any tell me! I noticed the Rallye ones but would never get 2 more,

[allye 530 3 Cars]

Empty you inbox custard rallye!

[custard-rallye 25]

It's emptied now dude send away :-)

[ash mi16 0]

nice blog dude your rallye is looking so tidy now i would love a rallye i just cant find a tidy one forsale :/ keep up the good work

[allye 530 3 Cars]

Took it out for a quick spin today and got it up to temp etc, roads are a little dirty last time it'll be out before the engine is dropped for a few little jobs to get it ready to go back on the road start of March

 

[Russ_T 1]

Car looks ace, looking forward to reading this thread properly next lunch break

 

Cheers

[allye 530 3 Cars]

Car looks ace, looking forward to reading this thread properly next lunch break

 

Cheers

 

Cheers Mate!

 

Well today this happened

 

 

In the engine bay shot you can see the bulkhead bung that melted! The reason for dropping the engine is to replace the bungs with metal plates and to add some heat refelctive stuff to the bulkhead. Also whilst the engine is on the floor thought I scratch my 6 speed itch....

 

 

You can see the difference in size, so I'll see how I get on with it. Talking of gearboxes, whilst I was living away in the summer I had a local garage change the box oil as it had been sitting for ages and I though it was leaking a little (it wasn't) so I came to drain it today and it came out like this.

 

 

Would seem they have put engine oil in monkeys.

[BenC 6]

 

Would seem they have put engine oil in monkeys.

 

 

Haha nice! Won't be trusting anyone else with your baby from now on...

[Anthony 1,003]

The smell should give it away - gearbox oil smells very different to engine oil.

[dcc 855]

"smells very different!"

 

too fecking right! I walked into a pub after doing my gearbox on my OLD OLD OLD gti6, and was told i smelt like a crazy cat woman!

 

In other news, Me and george did 2-3k miles with 1ltr of 15w-40 oil in a ML box, and that had a few minutes at max speed / max rpm! It was fiiiiiiiiiiiiiiiiiiine...

 

Gear changes became a bit more fun as the trip went on!

[Daviewonder 533 3 Cars]

Pour some of the oil onto your T shirt. If it still smells in a years time, after 30 washes, then it's gear oil

[allye 530 3 Cars]

No good to put back in the as its only done about 1500miles

[allye 530 3 Cars]

Gave the bay a quick clean and put on some heat reflective stuff, during the summer the bulkhead got really quite warm. I could put my foot up behind the dash and feel it. May even reduce noise........maybe

 

 

Got the 6 speed on, also got lift up sleeve and cable ready to fit onto my extended lever.

 

 

Engine will be going back in next Tuesday/Wednesday when I get bits back from powder coating.

[allye 530 3 Cars]

Got some bits back from powder coating today, very pleased they are going to look great when I put them on tomorrow!

 

 

Also got my OMP strut brace coated white and the battery tray done in black.

 

Finally got round to fitting the oil pressure adaptor I've had for ages and the sender I got a couple days ago, Quick question regarding that, do I use the 306 oil pressure warning switch or the the 205 one which was on the adaptor when I bought it?

 

 

I changed servo's to the original (slightly smaller) one because I had painted it all lovely and the GTI one loooked horrible

 

 

Will the size difference in the servo make a large difference in braking? I've seen a couple people change to smaller ones from GTI items.

 

Got tomorrow and weekend off work so engine should be back in and running soon!

[Tom Fenton 1,542]

If you are using the 6 speed box and sump you will need to check clearance to the radiator bracket. You may need to relieve the casings to get it clear.

[EdCherry 34 1 Cars]

Who did your powder coating I know a great guy over in Sells Green. Looking like its coming together well, although sure its thin enough to be engine oil?