[car_restoration] 1989 205 Gl

[GTIJIM 10]

just reading through my usual forums and spotted what looks to be your Pug?

looks like it as just before it got painted

Edited January 8, 2012 by GTIJIM

[ktm_kate 11]

just reading through my usual forums and spotted what looks to be your Pug?

looks like it as just before it got painted

 

Yep, that's mine Well spotted!

[ktm_kate 11]

After a bit a slow patch I have some updates:

 

All the door glass and lock mechs are in

 

 

Sunroof too

 

After finding new headlights more difficult to source then expected I decided to refirb a pair of lamps I had already. They are a matching pair of Valeo/Marchal lamps but the seal was black and mouldy and letting in water. After cutting out the old sealant and a good cleaning all over I puttied them back together and I'm quite happy with the results. I decided to use Tiger seal as I thought that would be longer lasting then silicon or bathroom sealant.. only time will tell.

 

 

 

 

More updates soon.

[Richie 32]

Attention to detail is great, hope to see her at Pugfest! If you feel like re-trimming another phase 1 wheel let me know :b

[sensualt101 31 1 Cars]

what a stunning rebuild and nice to see a non gti getting a full restoration! am loving your trimming skills and attention to detail i hope to see a full update of the finished car and i am sure she really will be a "pretty polly"

[Lowercase 56]

just read the whole thing, well done kate, what a trooper. glad you are keeping this ol' girl on the road for future generations to appreciiate.

[BenC 6]

Really enjoyed reading through this, it's the first 5 door restoration I've read. I think your work on the re-trimming is fantastic, can't wait to see it finished!

[ktm_kate 11]

Thanks for all the positive words.

 

This weekend I finally got an exhaust and the rest of the intake fitted and had a go at starting the engine for the first time. She started really well but wouldn't idle.. which I traced to the rouge spare vacuum spigot (yellow circle below) on the manifold. I don't remember what attached to there but have a feeling it might be for the sun roof (donor car had a factory fitted unit), Anyone know for sure what it is?

 

 

 

For completeness here's a shot of the engine bay with air box on.

 

[ktm_kate 11]

On second thoughts... I haven't connected up the brake servo vacuum yet. I'm betting that is what its for! Time to have a look at some old pictures..

[Lowercase 56]

any updates?

[ktm_kate 11]

Small updates..

 

I've been working on the second front seat, its slow and frustrating work and I'll be glad when its finished! The two part bolster design looks lovely, but its a right pain to upholster. I'll be doing the Cavalier next and its seats look like a piece of pie compared to the 205 ones.

 

I've also fitted the windscreen, adjusted the central locking actuators and adjusted the doors and tailgate. These are not very photogenic jobs hence no updates lately.

 

I have had even more exhaust issues. I ordered a sportex pipe and it didn't fit at all. It fouled on the handbrake cables and the rear pipe hung way too low. So I've sent it back and I'm splashing out on a custom stainless steel one.

The other issue is that the manifold is an iffy fit to the head and so the and top right (as you look from the front) exhaust nut just hits the pipe on the peaks and ever so slightly flexes the stud as you turn it and I obviously can't get a ring spanner or socket on it. Because of this I'm scared to tighten it up enough to seal against the head so I've ordered some 12mm nuts in the hope that they will at least stop the clash even if I still can't get a socket over it.

 

If I was doing this project again I would have either gone for a full custom stainless system from the start or just kept the standard manifold and pipes and put a GTi silencer on.

 

I'll be fitting the seats and new wheels any time now so I should have some nice photo updates soon.

[S@m 156]

Great work, very much enjoying this thread! As everyone says, nice to see something a bit different (but still 205!) getting some love for a change.

[samthornton1990 23]

Not a big fan of 5 doors..... this one though beauty!

[Tom Fenton 1,542]

The other issue is that the manifold is an iffy fit to the head and so the and top right (as you look from the front) exhaust nut just hits the pipe on the peaks and ever so slightly flexes the stud as you turn it and I obviously can't get a ring spanner or socket on it. Because of this I'm scared to tighten it up enough to seal against the head

 

Get yourself some M8 "K-NUTS". These have a lot smaller multihex head, you will hopefully find this solves your problem.

[ktm_kate 11]

Thanks for the info, not seen those K-Nuts before. I've ordered some to try out, I'm not 100% sure if the flange will clear the pipe but if it does then they will be perfect.

 

Also, I know have the Snickers advert in my head: "get yourself some k'nuts"

Edited March 2, 2012 by ktm_kate

[ktm_kate 11]

Sewing jobs are all done at last. All the seats are done, and I even had enough fabric and enthusiasm to trim the sun visors to match.

 

 

 

Before and after

 

 

 

Happy days!

[Tesstuff 222]

Fabulous work Kate!!

 

You could have work coming out your ears if you chose to do that full time

[DaveW 6]

Wow the steering wheel is impressive, does the car run ok now? after you put the servo hose back on

[Will Eastman 6]

Seats look amazing!!! how hard were they to do?? What material did you use?

[ktm_kate 11]

Seats look amazing!!! how hard were they to do?? What material did you use?

 

Thanks.

The new fabric for the bolsters is Alcantara. The centres are the original GT/XS items, I had two full sets of seats to pick the best fabric from.

 

Yes, they were quite hard to do. I am quite competent with my sewing machine and I used the old fabric as patterns for cutting the new fabric, but it was still a total pain to get the stitching right around the dip in the front seat bolsters. The rear ones weren't too bad tho.

 

If you can sew then I'd recommend having a go, especially if you have a spare set of seats in case it all goes wrong

[Will Eastman 6]

Sounds pretty good, might have to have a go of it. What sewing machine did you use, or was it done by hand, just guessing it was quite hard to sew through?? Also what kind of price was the material???

 

Cheers, keep up the good work!!

[ktm_kate 11]

Sounds pretty good, might have to have a go of it. What sewing machine did you use, or was it done by hand, just guessing it was quite hard to sew through?? Also what kind of price was the material???

 

Cheers, keep up the good work!!

 

I use a Brother NV950, but any normal modern sewing machine will cope with the Alcantara, its about as heavy to sew as thick denim. I use an old heavy duty machine for leather.

You'll also need bonded nylon thread and leather machine needles to take the thicker thread, and I'd recommend using hog rings and hog ring pliers for re-attaching the covers.

 

Alcantra is anything from £25 - £75 per meter and I used 3m to do the seats.

[ktm_kate 11]

Big day today. The car moved under its own steam for the first time, hooray! The epic journey took her 2 miles down the road to Retropower where she's having a nice new exhaust made up this weekend.

 

Latest pictures:

 

 

 

 

 

 

The eagle eyed among you will have noticed I've also fitted the 206 wheels...

 

What does everyone think?

 

 

Cast your votes now

Edited March 16, 2012 by ktm_kate

[sensualt101 31 1 Cars]

they really suit the car kate so now you have 2 sets of wheels you can have 1 set for summer tyres and 1 for winter tyres!

 

and the car looks amazing! really well restored and reflects your skill and determination to finish and use polly! well done hun!

[allye 530 3 Cars]

206 wheels for sure.