[car_upgrade] My Graphite Grey 1.6 > Gti6 Rebuild Project

[matty_gti 20]

I was trying to put doing the underneath of the car off for as long as possile but I knew I couldn't put a nice and shiny beam on when it's dirty and rusty. My weapons of choice...

 

 

First thing was just a general going over.

 

 

 

I then invested in some 'Deox' products being the gel and the rust converter. Well worth the money I say . The gel really works well, the only bit I was not happy about was then spraying it all of with a hose but it really did work!.

 

 

I went over with the gel about 3 times and then moved onto the rust converter.

 

 

 

Edited April 2, 2012 by matty_gti

[matty_gti 20]

After that and I was happy with the results I could then move onto the primer. I used Upol and Halfords etch primer for this using Upol first.

 

 

 

 

 

 

The most amount of rust and dirt build up was around the full tank but was all sorted with only surface rust.

 

 

Next up, black stone chips, two cans of!.

 

 

 

 

Much better

Edited April 2, 2012 by matty_gti

[matty_gti 20]

After leaving that to dry for a few days I emptied all the old fuel from the full tank...

 

 

 

A very odd colour!.

 

Next up, clean the full tank from dust and grime and refit...

 

 

The rusty fuel lines that came off the car were chucked and I bought some new fuel 'lines' from Peugeot. In actual fact It's one long line that you need to cut in two and bend to shape. Not the easiest job but keeping the old ones for this you just match them up, bend and match up again, then bend some more!. In the end you get these.

 

 

[Zara 41 1 Cars]

i started reading this and was thinking where the hell is this going then i saw one little white car and thought i know whos that is!!!! then i finished reading!

Looks really good though! cant believe youve got rid of Jelly now!

[matty_gti 20]

I thought I would write up the story of the 205's I've owned and how I caught the bug!.

 

I didn't get rid . First she got hit up the rear by a young (actually probably the same age as me at the time!) dive of a driver in his chaved up corsa. When it came to sorting the insurance his insurance company said it was beyond repair and that they were going to pay out and then it wen't silent. A bit of advice, do not go with Admiral as they are the cheapest for a reason, they are rubbish!. Not one bit of help what so ever.

 

To add to the blow, while I got no where with the insurance company I actually wrote her off. Was going a bit to fast and lost the back end on a slightly damp road. She went from this...

 

 

To this...

 

 

 

Was so gutted.

 

Edited April 2, 2012 by matty_gti

[Zara 41 1 Cars]

oh nooooooooooooooooooooooooooooooooooo!!! such a shame! haha i remember that weekend! was funny!

[matty_gti 20]

I know.

 

Look what I just found...

 

 

 

[Zara 41 1 Cars]

hahahaha omg!!! anyways ive probs sent you a bit off topic so back on topic Mr!

[matty_gti 20]

Next up, taking apart the rear beam...which I will update next time!.

[matty_gti 20]

It's beam refurbing time!

 

The plan, strip the old 1.6 beam down and inspect the parts - Once apart only one of the trailing arm shafts were good so this was pressed out and kept. Once this was done I had the beam tube and TB's blasted and powder coated. Not wanting to have drums I bought some 306 GTI6 rear trailing arms so I can run discs on the rear and have the slight negative camber. These again were all wire brushed, rust treated then primed and painted black. I've bought all new seals and bearings from peugeot as I want this to last!. I also bought some uprated beam mounting bushes from BBM and the biggest job here was removing the old bushes!

 

 

 

 

 

Finally knocked the old bearings out...

 

 

 

It took a blow torch and a hack saw to get the old bushes out...

 

 

Parts ready for the powder coaters...

 

[matty_gti 20]

Onto the arms...

 

 

 

 

 

 

And then some new bits!.

 

 

 

[samthornton1990 23]

Looking good this bud.

[cybernck 402 1 Cars]

Don't forget you'll need 306 rear discs now .

[matty_gti 20]

Thanks for the comments. I did um and ar about that until I did a search I've searched a lot to make sure I do things right!.

[matty_gti 20]

After fittng the fuel tank i decided to go over the underside again with some black stone chip along with waxol in all the nooks and crannies...then re-fitted the tank.

 

Got the bits back from the coaters and all my nuts and bolts from the platers

 

I started first by fitting the BBM bushes and new bearings. I best thing to use to get the inner bearings in the right place was the spare trailing arm I had!.

 

 

Having a look at the beam height settings

 

 

 

Edited April 8, 2012 by matty_gti

[matty_gti 20]

Fitted the 306 trailing arms and Bilstein shocks...

 

 

One 'good as new' beam

 

 

[allye 530 3 Cars]

Why do you keep teasing us with dribs and drabs!

[matty_gti 20]

It'll be worth it in the end!.

[matty_gti 20]

Ok Allye here's some more...

 

These wheels came on the TT I had, the tyres were past it so they were removed. The wheels themselves were ok just were really dirty.

 

 

 

 

 

These were all scrubbed and cleaned with some alloy wheel cleaner.

 

 

These then came up pretty well I thought...

 

 

The coloured lip on these are different to the normal style of lip. I prefer these. I then needed some rubber so I bought these of a chap off here for IIRC £50~ delivered and they have loads of tread which was a bonus.

 

 

Took these down to a mate that works for Merityre who then fitted them for me

[matty_gti 20]

Well it's update time!.

 

This is how she sat for a long time.

 

 

Old engine and new engine.

 

 

The engine I bought from Ed on here who built the lovely sorrento. He called me one day and asked if he could borrow the engine crane again, I asked why and then a few days later he dropped the engine off with all the bits for the conversion!. it was only at that point I knew I would put a 6 engine in the car as I had no idea what route to go down.

 

Before putting the engine in I wanted to modify that big lump of iron that holds the PAS pump and alt etc, just to save a bit of weight.

 

Before...

 

 

During...

 

 

After, much better.

 

 

More to come.

 

 

 

 

 

[matty_gti 20]

Just added some more pictures to photo bucket...

 

After cutting the alt/pas bracket down it was time to fit the engine so out came the trusty engine crane.

 

 

 

 

 

After getting the engine in I just needed to add a spacer or two to the mounts to get it sitting level. The manifolds are all standard with the engine tilted around 10mm. Rather tham the standard soft item I fitted a 'smaller in height' top engine mount so the engine sits around half an inch lower than standard so I didn't get the usual clearance issues.

 

Next on the list was getting on with some wiring. I wanted to have the battery in the boot for a) for weight distribution and to have more room in the engine bay. All this stuff was bought from Vehicle wiring products onlne. I also made my own battery tray out of a piece of metal I cut out of an old washing machine.

 

 

 

 

And with the engine in fitted with the inlet manifold and a few other bits slowly getting ready for it to run.

 

[dcc 855]

SNOW?!

[matty_gti 20]

I then started to sort out the two brown multi plugs after doing a bit of research on here.

 

 

A few other pics...

 

 

 

I made up some brackets for the rad to sit lower than standard to miss the engine. I needed to cut away the lip in the front bar to do this so out came the angle grinder.

 

 

 

I then started to sort out the height for the rad and location of the ECU. I basically cut right down a standard box and made it fit infront of the expansion bottle.

 

 

[matty_gti 20]

SNOW?!

 

I put the engine in December last year, it was bloody cold!.

[matty_gti 20]

Some more pics!

 

 

And then came fitting the 309 shafts. You can see the radiator mounts along with the radiator cowling that I later changed as the fan was not good enough/in a lower position so was replaced with two slim line fans.

 

 

 

Right the next thing was the interior. I really did not like the grey dash and plastics so spent along time dying these with plasticare which actually worked a treat!. I also spent a looonnng time washing the carpet. Every time I washed it with carpet cleaner dirty water just kept coming off it!. After 3 days of washing and a long time drying I got it back in the car. Only got a few pics of this.

 

Before:

 

 

 

During:

 

 

After:

 

 

 

 

More to come!.

Edited August 3, 2012 by matty_gti