[car_restoration] Matts Standard 1.9 Lazer

[m@ttc 30]

ok so i thought id get round and start a topic since i have done quite a bit on the car now and i cannot see me finishing soon. what started as a quick overall to get the car back on the road has seen the car off the road for the past 2 years, in that time i have done :-

 

complete rear beam refurbish new bearings, seals, trailing arms etc painted to look pretty

ditch the 16 inch alloys and refurb some original 1.9 alloys (rattle can's in shed) which have come up really good

4 new tyres, falken ziex ze912, (seem to get good fedback on the furum)

head gasket changed for an oe one, cam belt changed and water pump, valve tappets shimmed, headbolts new, new seal on cam cover came in kit with headgasket also in kit inlet manifold gaskets, exhaust manifold gasket, and valve stem seals

valves re-ground to the cylinder head

big bore zorst put in bin and a new back box from the stealers (imported from france for me) new exhaust rubers

new engine mounts from auto five

new dizzy, leads, ignition amp, vacume advance, spark plugs

coil and tacy relay changed for known good ones

exhaust manifold weldeld in usual spot the surface ground back the sittng face level

new oil n water/ ecu temp sensors

dash lights changed blown bulbs

alternator belt

original clarion stereo off ebay wired in

injectors refurbed by mad professor

exhaust gasket between maifold and down pipe new spings and bolts fitted

new gear selecter rods from stealers and lever ball on subframe

sad tested working fine

changed fuse board

 

theres probably a lot more but thats all i can think of for now

 

so now im at a stage where i had a problem with the starter not engaging properly with the fly wheel after checking all the common problems that normal occur with this and getting nowhere, i decided to drop the box to see what was going on which has seemed to escalade into another mountain of jobs to get through, see i seem to think whilst its off i might as well:-

 

refresh the front suspention

drive shafts

crank shaft seals

fix broken stud in gear box housing for the oil filter mounting

get a new oil filter housing thingy (thanks marksorrento205)

fix the brocken stud in the block for the gearbox mounting (only held on with 3 bolts)

refurb brake calipers with new piping etc

 

then ithink to myself whist it stripped this much i might as well get the engine out and sort out some of the rust issues in the bay ive had a decent shell in the shed for a while, just a base model from the scrap yard

 

so the engine bays al stripped and ive started to do something with the rust whilst doing every thing else at the same time so ill stop rambling heres some random pics

 

http://i1034.photobu...ct/P1010392.jpg

http://i1034.photobu...ct/P1010012.jpg

http://i1034.photobu...ct/P1010432.jpg

http://i1034.photobu...ct/P1010512.jpg

http://i1034.photobu...ct/P1010407.jpg

http://i1034.photobu...ct/P1010406.jpg

http://i1034.photobu...ct/P1000414.jpg

http://i1034.photobu...ct/P1020043.jpg

http://i1034.photobu...ct/P1000969.jpg

http://i1034.photobu...ct/P1000965.jpg

 

there's loads more but there on the laptop and its got a virus ill sort em later if you like or put em in an album and post the link

 

ok so this is what ive been upto today

 

here she is

http://i1034.photobucket.com/albums/a429/mattc205/205%20project/P1020093.jpg

drivers headlight panel removed no need to have gone poking with a screw driver on this one, funny thing is the part number stickers on the back how does paper last longer than steel?

http://i1034.photobucket.com/albums/a429/mattc205/205%20project/P1020113.jpg

http://i1034.photobucket.com/albums/a429/mattc205/205%20project/P1020118.jpg

think ive gotta remove a bit more still

http://i1034.photobucket.com/albums/a429/mattc205/205%20project/P1020114.jpg

drilled off back mud guard panel

http://i1034.photobucket.com/albums/a429/mattc205/205%20project/P1020117.jpg

drilled off good panel from doner

http://i1034.photobucket.com/albums/a429/mattc205/205%20project/P1020119.jpg

removed seam sealer from this area dunno why just had a gut fealing too, glad i did found this

http://i1034.photobucket.com/albums/a429/mattc205/205%20project/P1020116.jpg

 

ok first question can any body tell me exactly what the different layers of material are in this image in order i want to try and recreate it when i come to it

http://i1034.photobucket.com/albums/a429/mattc205/205%20project/P1020120.jpg

the first coat on the bare metal seams to be two differnt colors here

http://i1034.photobucket.com/albums/a429/mattc205/205%20project/P1020121.jpg

Edited September 9, 2012 by m@ttc

[vtifan 26]

looks a good base mate,love the colour,if you are going to do it do it right,looks like you are doing a proper job on her

[m@ttc 30]

little update. been cutting out some rust in the bay, im gonna do the right hand side first then tackle the left heres the pics.

http://i1034.photobucket.com/albums/a429/mattc205/205%20project/P1020131.jpg

had to remove the engine mount to get this bit out

http://i1034.photobucket.com/albums/a429/mattc205/205%20project/P1020128.jpg

little rust between the panels on the engine mount wouldn't have known it was there, if i hadn't of taken it off.

http://i1034.photobucket.com/albums/a429/mattc205/205%20project/P1020124.jpg

http://i1034.photobucket.com/albums/a429/mattc205/205%20project/P1020125.jpg

ive been using a draper type dremmel thing to get to hard to reach places/precision grinding

http://i1034.photobucket.com/albums/a429/mattc205/205%20project/P1020122.jpg

thing is the cutting disks are really weak gone through 10 on 2 inch of grinding, need to see if i can get stronger disk's from some where.

the red paint in the pictures is some holts top coat, i dunno if this is ok to use? just wanted to protect the bare metal until i get back to it.

also need to do something with this but not sure what yet

http://i1034.photobucket.com/albums/a429/mattc205/205%20project/P1020129.jpg

dont know wether to cut it out and put a better strut piece in? seems a bit advanced for me dont want the front wheels out or anything, probably just grind it back and paint.

 

thats pretty much it so far although ive done some welding on the gear box ,i dont get chance to play in the bay in the week. So in the week this week i plan on tarting up the brake servo so hope fully that will be nice and shiney next week, i only plan on removing the rust and hammerite it, hope it looks ok when im done.

Edited September 16, 2012 by m@ttc

[m@ttc 30]

ok little update, managed to get some reinforced cutting disks for the dremmel something like 2.50 for 20 disks there great for awkward areas dont get much cutting out of little disks thou. 1 disk does this much

also got some mini steel wheels for it great for removing rust in between panels

also managed to paint the brake servo

decided against black and try to match its original colour, i went for ral 6003 olive green

 

well the engine bay looks the same as last time, the welder i had planed to use i brought off ebay, just isn't up to the job so iv'e ordered a new one, so im waiting for that to arrive at the moment

in the meantime ive been cutting metal of the bits in the shed

shell from scrap yard

rusty bits and not so rusty bits

also been shopping and brought this

 

thats it for the body so far, as the cars outside and the nights are drawing in this may have to wait a bit or be a little slower progressing as id have liked. There's lots of other things to be getting on with on this car so ill still be busy over winter months

 

got my oil filter housing off marksorronto welded, then with the gearbox the mounting hole was fubard so i drilled and tapped in some ally althread and welded it in place. then had the suface's machined level

checking flatness with eng blue

all i need now are the 7mm pins that mount it to the gearbox

 

thats it for now, i need to get a new window wiper mech and suspention mounts bearings and rubbers mine look like this

wiper mech (a little worn out)

and these bits hopefully they all come in the kit

[Tom Fenton 1,541]

The suspension top mount kit usually comes only with the rubber donut and the bearing. You have to re use all the other bits. I have blasted mine and then had them plated to make them look nice rather than the usual crusty finish.

[m@ttc 30]

The suspension top mount kit usually comes only with the rubber donut and the bearing. You have to re use all the other bits. I have blasted mine and then had them plated to make them look nice rather than the usual crusty finish.

I've thought I may have to take this route. What finish did y

ou have them plated Tom?

[cybernck 402 1 Cars]

Is that a genuine headlights panel?

[m@ttc 30]

Is that a genuine headlights panel?

no its not i brought it from imperial automotive, hoping it'll be an hadriens panel but turned out to be rhibo??

each individual pressed panel look great but the assembly of them isn't looks like it might need a little tweeking to fit properly but we'll see

[cybernck 402 1 Cars]

Oh well. How much was it and do they have inner wing panels too? Sorry for the slight off topic .

[GLPoomobile 958]

The suspension top mount kit usually comes only with the rubber donut and the bearing. You have to re use all the other bits.

 

Peugeot used to do a complete kit with everything. Dunno if they still do as I've not been on Servicebox for about 2 years. Probably NFP by now

[Tom Fenton 1,541]

Certainly worth looking to see if the Peugeot kit is still. Available, I must admit I didn't look at that option.

I had my bits done in yellow passivate as I think it looks smart, one thing I struggled to find was info on what finish the visible strut top bits would have been from new? Certainly looking at the concours and show and shine cars at Pugfest there were some in silver plating, some painted silver some painted black.

 

Here's a pic of my bits, with the other stuff I had done at the same time. I still need to have some spring top pans done.

[m@ttc 30]

Oh well. How much was it and do they have inner wing panels too? Sorry for the slight off topic .

it was £107.81, it dont look like they have inner wing panels but they have front wing panels £70.49 heres the link

http://www.crashrepairparts.com/parts/markid/579/peugeot_205_hatchback_1991_1996_facelift/body-repair-parts-and-panels?_ts=1870

[m@ttc 30]

the kits are still available from peugeot, the large kit includes a spring but they show NFP for the spring seperate, but does come with the bearings which i need. The smaller kit dont come with the bearings and it dont show you if you can buy the bearings seperatly . Im gonna give them a ring next week and see what i can get. Spring top pans dont come in any kit and they dont appear to have an part number, but im gonna see if i can get the place next door to my works to hot dip galv them for me

[Tom Fenton 1,541]

You can buy a decent SKF kit which comes with the bearing and the rubber donut.

[m@ttc 30]

You can buy a decent SKF kit which comes with the bearing and the rubber donut.

cool where can i get this magical item??

[Tom Fenton 1,541]

Truth be told I got mine second hand/unused from Craig on here, I am sure he can advise where to source.

[m@ttc 30]

ok , update time ive been shopping at peugeot brought two new top mount kits

 

doesn't come with a spring but does come with a galvenised top pan, so no need to get my old one done now

 

also brought new wiper mech kit

 

ive started to refresh the sub frame some pics

this took ages to get this clean, high pressure steam cleaner, hot jet wash, sand blasted, rust treated and wire wheel'd until i was happy with it.

 

etch primed

 

and painted, I decided to use hammerite smooth out the tin, i used a paint roller and put two too three coats on, and a last coat of the same paint out of a spray can and im quite happy with the result.

 

some blasted parts

 

some gold parts again hammerite gold smooth spray can paint

dunno if i should have done the heat sheild in that paint? But its done now i wonder if a coat of clear VHT on top might help?

 

ive stripped the rack down to change the internal bush, but since doing this i have learnt the bush is different in pas racks and are not available to buy seperately

heres the bush

ive decided to make one myself, i got the plain bearing for 92p and gonna turn a new housing on a lathe at work, also ive made a tool so i can press the ends over after to keep the bush in place, thats the plan anyway

 

Edited December 16, 2012 by m@ttc

[m@ttc 30]

update continued.....

 

ive been tarting up the gear box

 

 

its had a new

clutch housing plug (pt no 212143)

gear box breather (forgot pt no)

primary shaft seal and guide bush (210535)

yellow bushes (217514 + 217622)

 

ive removed and painted the end cover there was a little surface rust inside which is now gone so im glad i done that, reasealed the diff housing with rtv silicon as that had a little leak on it. And a little bit of welding to one of the mounting holes as it had split the casing. and a bloody good clean as it was filthy

 

i think thats all i can do without stripping it, it was fine before so im not going to bother.

 

ive changed the lower engine mount bush too

this is the best method to remove i find a lot less toxic and quicker than burning it out.

 

new bush fitted (pt no 180904)

 

this is the only eng mount not availble from auto five so i got it from pug

 

have auto five stopped trading??? i wanted loads more stuff from them so its a shame if they have.

 

 

[cybernck 402 1 Cars]

Yes, it seems they have.

[dcc 855]

I just hammer the bush out - a firm tap does the trick.

[m@ttc 30]

ok, time for a long over due update. Been a while ive mainly been sorting out spares and refubing a few things.

subframe is now looking like this. Nice new track rods and rubbers, made a new bush fits like a treat lot less movement now. I brought new plastic bushes and pin for the L bracket also and a new ally cap for the top of the pin.

 

http://i1034.photobucket.com/albums/a429/mattc205/SAM_0726_zps14f4629e.jpg

 

think it looks ok, as ive painted it in hammerite, should be good to do any repaires if its stone chipped.

 

got me some original half decent green gti mats.

 

http://i1034.photobucket.com/albums/a429/mattc205/SAM_0727_zps34094df9.jpg

 

black gti signs coming off a bit, i would like to know what this is made of and how to go about touching the worn areas up a bit, its like a furry kind of felt or something??

 

refurbed my old gti mudflaps as there going for stupid money on ebay and was not prepared to pay that much for them. The steel was rotted beyond repaire so ive made new ones out of stainless steel.

 

http://i1034.photobucket.com/albums/a429/mattc205/SAM_0728_zps3888e209.jpg

http://i1034.photobucket.com/albums/a429/mattc205/SAM_0729_zpscde5119f.jpg

 

i did buy the badges new thou, there not as good a quality as the originals but there in new condition so ive used them. The originals are more rubbery and these are more plastic.

 

 

I'll update again soon, its stoped raining now, im back off under the bonet

Edited July 28, 2013 by m@ttc

[m@ttc 30]

ok imback its started to rain again

 

since december, realising its not easy to do this job on the front drive, i decided to make this. Something to work under, stop people stoping and asking me if im gonna scrap it, and kids looking at the tools and hanging around etc.

http://i1034.photobucket.com/albums/a429/mattc205/580_zpsadc0d796.jpg

http://i1034.photobucket.com/albums/a429/mattc205/586_zps0fd5769f.jpg

http://i1034.photobucket.com/albums/a429/mattc205/587_zpsea0b1b9a.jpg

it's quite heavy too so it shouldn't blow away

 

also made this sand blast pot and cabinet to help remove rust

http://i1034.photobucket.com/albums/a429/mattc205/588_zpsf54b38bf.jpg

http://i1034.photobucket.com/albums/a429/mattc205/589_zps971c6408.jpg

works a treat on the works compressor but not so well on my home compessor.

[m@ttc 30]

Here's a pic of the bush i made for the power steering ram.

http://i1034.photobucket.com/albums/a429/mattc205/205%20project/440_zpsb4954fcb.jpg

Edited August 26, 2013 by m@ttc

[m@ttc 30]

got some welding done on the car today,

 

before

http://i1034.photobucket.com/albums/a429/mattc205/205%20project/SAM_0523_zps856ee8c9.jpg

 

during

http://i1034.photobucket.com/albums/a429/mattc205/SAM_0946_zpsb080eac5.jpg

http://i1034.photobucket.com/albums/a429/mattc205/SAM_0945_zpsea2a0696.jpg

http://i1034.photobucket.com/albums/a429/mattc205/SAM_0944_zps6c394dc2.jpg

 

after

http://i1034.photobucket.com/albums/a429/mattc205/SAM_0943_zpsc4e5f6b5.jpg

http://i1034.photobucket.com/albums/a429/mattc205/SAM_0942_zps6addf497.jpg

 

the spot welds for the wheel arch panel were coroded, think it may well have been the reason i was getting water in the foot well, so cut them out and pet a new piece in.

http://i1034.photobucket.com/albums/a429/mattc205/205%20project/SAM_0869_zpsc2ebf7fb.jpg

http://i1034.photobucket.com/albums/a429/mattc205/205%20project/SAM_0874_zps43c4968f.jpg

http://i1034.photobucket.com/albums/a429/mattc205/205%20project/SAM_0875_zpsa7f52cd0.jpg

 

also some unwanted holes left by an alarm installation

http://i1034.photobucket.com/albums/a429/mattc205/205%20project/SAM_0880_zps295dd051.jpg

http://i1034.photobucket.com/albums/a429/mattc205/205%20project/SAM_0881_zps9fe353f7.jpg

 

there was also another hole about the size of a penny from the alarm installation which is no more but forgot to take a photo, dunno why they have to cut a hole when theres plenty of holes that could have been used.

Edited August 26, 2013 by m@ttc

[m@ttc 30]

well it seems if you go looking your gonna find rust

just gone inside to put some primer on the in side of some patches and found this.

 

 

seems ok on the out side, the seamsealers very brittle and has started to fall of and start rusting. Also the paint in the area, if you touch it, it comes off in flakes You can see daylight through the joint of the floorpan and bulkhead where the exhaust sits as if they were never fitted properly when the car was built.

 

access is tight here and im not sure if to take the dash out to do a proper job or not? but never really wanted to do this. Always thought if i did this id have a proper shell respray but that would have been in the future when/if i ever get a garage to play in.

 

as you might tell im not happy with the speed i work the cars gonna rot faster that i can repaire it

job list seems to get longer and longer i'll be to old to drive by the time it's finished.