[Car_Overhaul] Laser Green 205 1.6 Gti

[Alan77 78 1 Cars]

Great work! I love these rebuilds from scratch...

[Daviewonder 533 3 Cars]

Tom, any idea what that hole is for in the metal strip that goes between the caliper sliders and the bolts?

[Tom Fenton 1,542]

Tom, any idea what that hole is for in the metal strip that goes between the caliper sliders and the bolts?

No, it doesn't seem to be used for anything on the 205. Perhaps it's a parts bin special originally used on something else where that hole has a purpose in life?!

[Slo 283 1 Cars]

Love threads like this superb detail Tom, hardcore 205 porn is rare these days (who wants to see pictures of someone changing a wheel/headlight if you know what I mean).

 

I think that hole is to hold the brake pad wear sensor wires originally with a fastener?

[eddie bullit 37]

Looks really amazing Tom. I can't wait to see it finished. A real inspiration to get mine started.

[Tom Fenton 1,542]

Only one picture today, the front subframe built up with new wishbones, rebuilt steering rack, rebushed fork, anti roll bar etc

 

Untitled by Tom Fenton, on Flickr

[allanallen 528 2 Cars]

Looks nice gaffer! Thought you were outing PAS on?

[Tom Fenton 1,542]

Not on this one mate, I'm keeping this as it was. PAS stuff is for the blue one when it goes back to 1900 8v.

[hoodygoodwood 70 3 Cars]

Great job , you will be scared to drive it by the time its finished .These cars deserve a bit of TLC .

[Tom Fenton 1,542]

So update today.

Rear end is as far as I can get for now, so turned my attention to the front.

First off removed the front legs and front subframe/steering rack/shafts

Next on the agenda removed the master cylinder, it was working ok but looked crusty, and I've heard enough horror stories of 205's hitting things due to failed master cylinders!

Untitled by Tom Fenton, on Flickr

 

Now i thought I'd finished with scraping underseal but oh no some more awaits. Grot grotty grot.

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In progress

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Ready for final prep and paint

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[dcc 855]

Tom please can you stop posting photos, it really bugs me.

 

What I mean is mine will never ever look that good, in fact I actually doubt it looked anywhere near as good as that when it came new from the factory, so if you don't mind.

 

Or at least just use black and white photos from now on. Cheers.

 

In other news, seriously sweet looking motor

[Alastairh 47]

Looks great Tom, nice work.

[Tom Fenton 1,542]

I wasn't in the mood for underseal scraping tonight so instead set about repairing the gear linkage rod heatshield.

 

It had the usual corrosion damage around one of the mounting studs, I'd taken it to work and wafted it over in the shotblaster, I didn't want to go too mad as it's only ally and the blaster could make holes in it.

 

Untitled by Tom Fenton, on Flickr

 

So I made a repair piece then welded it into place

 

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Then I painted it, made a replacement for the small bracket at the back, and riveted it on. Pleased with how it's turned out really.

 

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When I was under the car I noticed the rear mount bush was looking a bit soft and soggy so I dug a better one in a housing out of stock, sandblasted the casing to clean it up then went over with some lacquer to stop it furring up again.

 

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Finally decided to test fit up my driving lamps. They are my plated and powdercoated frames, Denji glasses, into OE backing shells, with a pair of the PSCUK protectors.

 

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[mrfirepro 127 1 Cars]

Nice work Tom

 

Given me some good ideas as well, keep them coming.

 

Was the paint anything special you used on the heat shields, I just know I'm gonna have to copy that , they look good.

[allanallen 528 2 Cars]

Nice effort on the heat shield buddy! That's some thin ally!

[Tom Fenton 1,542]

On the heat shields I acid etch primed and then painted them with zinc cold galv spray. Will see how they last.

 

Welding the piece in was really s*it or bust, as you say mega thin! It went OK though, I'm pleased with the result given that no one will ever see it anyhow!

[deathbringer929 49 1 Cars]

ive seen him weld one of my red bull tins i split. very nice thomas

[Tom Fenton 1,542]

A bit more cleaning and scraping last night and this morning.

 

As usual got bored of that so found something else to do, which was to fit an airbox support bracket. Fitted perfectly and what a nice thing it is too even if I do say so myself!!

 

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[Tom Fenton 1,542]

This afternoon got the OSF arch in stonechip then paint. NSF is also nearly there. Have to say I'll be glad to see the end of the cleaning scraping and painting phase for now! Engine bay clean up and engine and gearbox renovation I plan to do another time.

 

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I also decided to break out some more goodies from the stainless reproduction shelf so fitted a stainless driving lamp bracket whilst I was there.

 

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[dcc 855]

can see this being at pug fest at this rate!

[Tom Fenton 1,542]

That is the goal Dan. Hoping to have it ready for MOT before the end of this month with a view to taxing it from the start of July.

Once I have finished the NSF arch I have everything else barring refinishing a set of wheels ready for it.

[Tom Fenton 1,542]

First off today bulkhead heat shield blasted and painted.

 

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Next onto some real work, NSF wheelarch. Got it finished and masked up

 

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Then into paint (wahoo)

 

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So thankfully (as I've had enough of the mess now) that's all the painting done for now. Tomorrow once it's all hardened off I can start getting the subframe and suspension back onto the car.

[Tom Fenton 1,542]

No pictures just now, but subframe is on, legs are on, steering rack connected, brake pipes 90% done, new master cylinder fitted, gear linkages in progress.

MOT time is now looming!

 

To do list at present is;

Finish brake pipes

Bleed brakes

Driveshaft seals, driveshafts fit

Gearbox drain plug new washer

Gearbox oil

New sump plug new washer

Engine oil and filter

Refit mud flaps

Spanner check all round

Wheels to paint

Tyres have fitted

Rear valance to fit

Rear fog reverse lights to fit

Bulbs for driving lights

Tracking

Plugs dizzy cap rotor arm

[Tom Fenton 1,542]

So a few pics

 

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Untitled by Tom Fenton, on Flickr

 

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It is also now crunch time- on my way home today I passed the MOT place I used, and in a fit of keenness booked a test for 4:30pm tomorrow... I think the phrase is again "s*it or bust"?!

[Tom Fenton 1,542]

Fast forward to now (forum down about 12hrs!) and she is ready for her MOT.

 

Last night was a long night sorting out odds and ends. One thing that tripped me up was one of my rebuild front calipers had a leak from the flexi hose to caliper joint that I just couldn't arrest. So I ended up doing a quick rebuild of one of the old calipers that came off the car. A shame as the one that leaked had been sandblasted etc and looked like new, this one has had to make do with a quick wire brush and a strip and check of the seals. I'll have to revisit this another time.

Other than that, I painted a rough rear valance with a bit of green I had kicking about, just to put it through the test. The actual one for the car is away with Paul who is sorting getting it painted properly.

Bleeding the brakes was a bit of a faff but got there in the end, the brakes are still pretty mediocre at the moment but given everything is brand new I'm sure with a bit of bedding in they will improve.

The only thing left to do is get the proper wheels for it powdercoated or painted and have the new tyres fitted. However the old stuff is good enough for MOT so will do for today.

 

So a few pics

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Suspension and brakes complete

 

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Driving lights fitted

 

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Temporary rear valance fitted

 

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First time out in daylight as a complete car for a long time!

 

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Quick wash ready for MOT!