[car_restoration] 405 T16 Restoration

[B1ack_Mi16 67]

Also needed to repair some broken mounting studs on the dashboard. Hard to remove a 405 dash without these breaking, at least when doing it alone.

 

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Shortened the plastic stud by around 3-4mm and used a circular plate which I threaded. Then used a threaded rod and drilled holes in the dash so I could preload the stud with the rod and threaded circular plate. Added glue and tightened the plate with pliers.

 

It seem to be strong now.

 

[B1ack_Mi16 67]

Lately I've mounted the gearbox and transferbox to the engine

 

 

 

 

And just started to make copies of the hand brake cable brackets mounted on the trailing arms

 

[welshpug 1,661]

that gearbox looks a hefty old thing!

[B1ack_Mi16 67]

Indeed the ME5 box is quite a bit stronger than the BE ones. Input shaft has the gears machined on so it's not possible to change around with ratios though, well apart from 5'th gear.

[imaS 0]

Where did you manage to get transferbox input shaft seal? If I remember correctly, this was with odd dimensions.

[B1ack_Mi16 67]

It seemed like the existing one was in good condition, and when I put new shaft in place (ATD axles) then there no wear lip either, so I hope it is ok.

 

That said I managed to get some seals also there, but they were a bit too thick. But I think they can be slightly modified (I think problem is one of the plastic gears might touch it) and used without problems. But I did save it for later as the existing seal looked so good.

 

I think the seals I found were to some sort of motorcycle. Might look at the dimensions if I remember when I go to the garage.

[estland 3]

Excellent work

[DrSarty 90 1 Cars]

Yep. All still lovely.

 

And me and my boy ARE coming to Scandanavia 31 May to 8 Jun: Denmark > Sweden > Norway; so it'd be silly not to meet up. Nordic roads and my 205 GTI6 on bodies!

Edited May 6, 2014 by DrSarty

[B1ack_Mi16 67]

For sure. However Norway is a looong coountry, so where in Norway are you staying?

[B1ack_Mi16 67]

Today I actually had some more progress.

 

Have used a long time to find motivation to change the dash loom, which I actually did tonight

So now I suppose it's ready for mounting it in the car.

 

 

Also managed to paint the doors with white 2 pac paint. Now I can see if there's still some small dents in it that needs to be filled in (probably a few).

 

Edited May 6, 2014 by B1ack_Mi16

[calvinhorse 870]

This car and your work is incredible, absolutely amazing!

[B1ack_Mi16 67]

Put the engine in this weekend... now I just hope it will prove possible to get that Holset turbo fitted without too much hassle.

It's a bit big so downpipe might turn into a problem.

 

 

[Lowercase 56]

drool. top work on this. how long do you think you have left on this build?

[B1ack_Mi16 67]

Thanks.

 

I'm not really speculating on any finishing date, as I've tried before and it always seem to be about 2-3 years more than initially thought

 

I don't think this one will be driving anywhere until next spring maybe.

[JeffR 51]

Fantastic project! Great to see another 405 re-born.

[shalmaneser 26]

Wow, just read this whole thing through, what an incredible job you've done!

 

That rust was insane! Good luck for the rest of your project!

 

[caballino 11]

WOOOOOOW awesome project!!!!! :D :D this is amazing!

[B1ack_Mi16 67]

Haven't had much progress lately.

 

But I did spot weld up an adapter for the turbo.

 

 

Also painted the doors red and mounted them onto car

 

 

 

This week I took engine out again and started on making turbo downpipe, very little clearance with 3" pipe.

 

 

 

[wicked 103 3 Cars]

Are you sure you want to mount a heavy turbo that way?

The T16 manifold cracks easily, so extending the manifold like that (weight*length), trying to pump double power/heat through it, will make it crack for sure... imho...

 

Love the project and effort you put into it..

[welshpug 1,661]

thats where the original turbo was...

[B1ack_Mi16 67]

Well it probably was a bit further back, guess that's what he referred to.

 

I'll make some supporting braces at the front to carry the load of the turbo, bolting it to the gearbox housing, it should stabilize it and reduce dynamic loads.

 

As far as I've heard the T16 manifolds often crack quite easily yes, but once drilled and welded they apparently don't necessarily crack any further, so might be something that occurs in a "fresh" manifold?

[wicked 103 3 Cars]

Indeed that's what I was refering to; the turbo is now placed aprox 30cm more to the front and bigger. That's a lot for the manifold without supporting braces.

iirc the original turbo should have supporting brace on the box as well.

 

Keep up the good work!

[B1ack_Mi16 67]

Some more progress.

 

Have testfitted the propshaft now, upgraded it with a ATD Performance tripod, as the orginal tripods for the first models are weak and tend to crack.

 

Made a bracket for the wastegate actuator as the orginal position will not work as the turbo is re-clocked.

 

 

Shining up the front driveshafts slightly:

 

[B1ack_Mi16 67]

Also recieved some more parts, 3" cat and wideband kit and 95A alternator.

 

 

And started building the exhaust system.

 

 

 

[B1ack_Mi16 67]

Finished up the exhaust now. Very tight fit, but clearance all over in the end. Bought two sets of 205 gti polyurethane hangers also so now it won't fall off due to cheap rubber hangers

 

 

Intermediate (longest) and rear pipe

 

 

Simple looking outlet