[car_overhaul] Reshell, Restore And Rebuild

[pugpete1108 62 1 Cars]

after ballsing up my sunroof and being fed up with driving a matte black car i decided to reshell all my bits onto this very lovely (if not a little rusty) graphite shell courtesy of James_pug.

 

 

the doors are a little ripply but i have a nice set of straight doors here ready to paint, i cant decide if to keep the std arches are refit my rallye ones (bearing in mind the std are painted body colour and a bit flaky and one is missing)

 

it need a new drivers wing which i have 2 good ones of and couple of small patches cleaning up.

 

and after last weekend i am now probally looking for a new vts/gti6 engine too as mine is a little poorly

 

anyway here is where i started with the 205, door first:

 

 

both doors done, and my son not helping very much :

 

 

i have now stripped all the rear end electric and bumper/glass and have most of the dash and the spaggheti wiring loom. i'll add more pics tomorrow when i should be well on the way to having the engine out.

Edited May 17, 2011 by pugpete1108

[Daviewonder 533 3 Cars]

Nice seats. What they out of?

[pugpete1108 62 1 Cars]

Nice seats. What they out of?

 

 

405 mix4 ones. there are up for sale and in near mint condition (apart from some small weld burns i made which you can barely see)

[GLPoomobile 958]

For god's sake get your priorities right! Stop pissing about with doors and such like, and get the dam ugly pin stripes pulled off of the graphite.

 

Can you guess I'm not a fan of them? Wrong side of the retro/tacky line for me I'm afraid.

[Leet205 48]

new shell looks lovely and shiney. i love the pinstripe - very retro

[pugpete1108 62 1 Cars]

Glp I agree with you mate. I hate em and yes they will be coming off.

 

They are std though I do believe

[Arahan 4]

What don't you like about the matt black mate?

[pugpete1108 62 1 Cars]

What don't you like about the matt black mate?

 

Pita to keep clean to be honest. It looks good for about a week after it was sprayed.

 

And I miss spending a Sunday afternoon polishing a car

[Tom Fenton 1,542]

What is happening to the old shell? Is it a non sunroof?

[pugpete1108 62 1 Cars]

What is happening to the old shell? Is it a non sunroof?

 

being scrapped mate, its pretty solid though so would be a shame but i got a new one coming next week so it got to go.

 

and with regards to the sunroof; it was a sunroof, i plated it over but in the process i managed to warp the roof somewhat. i filled it but it still looks warped and the filler is now cracking.

 

this was another reason for reshelling tbh.

 

you want it? its free if it goes within the next week.

[pugpete1108 62 1 Cars]

right, been round this morning to empty the fluids.

 

this was what came out of the radiator:

 

 

no wonder it overheated.

 

interior nearly done:

 

 

engine out today hopefully:

 

[pugpete1108 62 1 Cars]

well i am now nearly ready to drop the engine out, takes bloody ages to remove all the little bits

 

it was also like a scene from a bad porno; there was white gunk pouring out of every hole and i now have little puddles of mayo all over the garage floor.

 

 

just got to figure out how i am going to get all these wires through that tiny little hole.

 

 

and i now know why i couldn't get the idle below 1500 even with the butterfly fully closed and no idle valve.

 

blown the whole side of the resonating box open:

 

[Masekwm 2]

Why do you use Megasquirt instead of the standard ECU?

[pugpete1108 62 1 Cars]

Why do you use Megasquirt instead of the standard ECU?

 

i was running bike bodies but had a lot of trouble balancing them so went back to std inlet.

 

plus it gives me the oppourtunity to upgrade to turbo/supercharger or bodies again in the future.

 

on top of that when i bought the engine it didnt come with any loom or ecu

[Stolton 0]

petes new shell looks pretty solid & clean in the flesh & i def know that it willl look mint when done, if you need any help pete just give me a call. get some more pics up

[damien 22 1 Cars]

how bloody quick do you work !!!!!!

 

what did you use to spray your block?

[pugpete1108 62 1 Cars]

cheers martin

 

and damien, im in a bit of a rush as the shell is coming next weekend. once this one has gone and the new one is here work will slow down considerably.

 

im sure i just used engine paint for the block? tbh its started to shown through as you can just make out on the bottom of the engine. i'll prob do it again when its out.

 

how you getting on with the engine? dont sell your old one just yet as i may need it if mine is buggered.

[pugpete1108 62 1 Cars]

right well the engine is out on my home made trolley (que wincing as im moving it incase the wheels collapse)

 

 

yum mayo:

 

 

so its nearly all done now, just the brakes and running gear to do but thats easy really.

[james_pug 26 1 Cars]

Good work so far Pete when do you think it'll be completely stripped by? I'll try and get your new shell ready to go this weekend, what day next weekend do you want it?

[pugpete1108 62 1 Cars]

Good work so far Pete when do you think it'll be completely stripped by? I'll try and get your new shell ready to go this weekend, what day next weekend do you want it?

 

there's not much left to go mate, but im back to work tomorrow so wont get alot done until next thursday.

 

just got to finish the wiring and then drop the front subframe complete and the rear beam complete and the fuel tank + lines etc. god that sounds alot

 

im thinking sunday would be best provided i can get rid of this one. i might be able to get the bloke to take mine after he has dropped the new one off. just gotta drag it out of the garage with no wheels on i wonder if my little engine trolley will be up to the job?

[james_pug 26 1 Cars]

All the engine bay wiring pulls into the cabin easy enough and the boot wiring Is still in the grey shell

 

Does he have a winch that'll pull your shell out easy enough no were will be open on a Sunday to take it away though? Can you ask the bloke how much to pick mine up from warhorne and take it to mine?

[pugpete1108 62 1 Cars]

All the engine bay wiring pulls into the cabin easy enough and the boot wiring Is still in the grey shell

 

Does he have a winch that'll pull your shell out easy enough no were will be open on a Sunday to take it away though? Can you ask the bloke how much to pick mine up from warhorne and take it to mine?

 

2 problems there mate.

 

i have all the engine managment loom on the bay side and the wiring aint going through that hole (but seeing as the shell is being scrapped i'll just cut the hole big enough)

 

and my garage is i a block that has another block opposite and there aint enough room to get the truch straight on to it if you see what i mean?

 

he'll keep it on the truck until tuesday i should imagine? have a word with him when we come to yours mate, im sure it wont be much?

Edited May 19, 2011 by pugpete1108

[damien 22 1 Cars]

cheers martin

 

and damien, im in a bit of a rush as the shell is coming next weekend. once this one has gone and the new one is here work will slow down considerably.

 

im sure i just used engine paint for the block? tbh its started to shown through as you can just make out on the bottom of the engine. i'll prob do it again when its out.

 

how you getting on with the engine? dont sell your old one just yet as i may need it if mine is buggered.

 

 

im picking up the engine on sunday but im still unsure if im keeping the bodies, im in no rush as im not planning on getting her back on the road this summer

[pugpete1108 62 1 Cars]

im picking up the engine on sunday but im still unsure if im keeping the bodies, im in no rush as im not planning on getting her back on the road this summer

 

yeah me neither mate. i dont plan on having it done until after xmas at least. just dont go getting rid until you've spoken to me cheers

 

is your new engine complet with manifolds etc?

[Stolton 0]

if you need someone to take your shell away pete let me know as i know someone that will pick it up for you. like i said if you need a hand doing anything just give me a buzz. cant wait till its all done tho