[Misc_Work] Peugeot 205 Rallye, Engine Done...now Suspension!

[Wallby 39]

Hi All,

 

I think its about time I started a project thread for my 205 Rallye. I have owned the car for just over 3 years now and it has changed quite a lot since then and will keep changing! The person who owned the car before me used it for a couple of hillclimbs so was fitted with bucket seats and harnesses. The engine was fairly standard apart from an Autosprint 280 cam and was quick enough for a while!

 

When I first got it home

 

 

I kept the buckets seats in for a few months but as this was my daily and only drive they soon did my head in! I was on the lookout for some rallye seats and came across a full rallye interior for £25! As I only wanted the seats, I sold the rest of it for £25 so it was a bit of a bargin! The seats were ripped like most so decided to get them and the rear bench refurbished. I took the seats to ‘A Touch of Class’ upholsters who did an excellent job! We decided to go for vinyl on the bolsters as it would be hard to get a perfect match for the rallye material and the vinyl would wear a lot better.

 

 

 

The car stayed pretty much like this for a year while I finished uni and found a job. The rallye then become a second car after the arrival of my 147 GTA and this is the point that I wanted more power! Initially I only planned on upgrading the carbs to some twin Webers, but that all changed when Adam ‘Trogboy’ told me that he was selling his TU24 head, carbs and TU3s bottom end. A deal was soon done and I was on my way to Bristol to collect my new engine. I have to say a big thanks to Adam as he spent most of the day with me helping to rebuild the engine!

 

It took me a few weeks to swap the engines over before it was booked in to get the carbs set up. Unfortunately the rollers broke the day before I was booked in so had to wait a few months for these to get fixed before I could drive it properly! After getting it setup it made just over 100bhp at the fly, which is around a standard TU24 power so I was quite happy. It still has a little flat spot when on part throttle but I hope to get that sorted soon!

The sound of the carbs at full throttle is really addictive! Just ordered a new synchrometer to balance the carbs again which should be here tomorrow!

 

 

And that’s where the car is at the minute. I have done a few trackdays in it this year at Llandow and Donnington which has highlighted the need for some suspension upgrades, there is quite a lot of body roll! I hope to get something sorted over the winter ready for the spring.

 

 

It does have some cheapo lowering springs on it, maybe spax dampers and bilstien rear shocks but think it is still on the original beam and front subframe.

 

What Im after is a nice fast road/track setup that doesn’t cost the world. Im going to upgrade to a 1.6 gti rear beam first, but need some advice on what to do for the front. Is it worth changing to a gti subframe? If anybody could give me some ideas that would be great!

 

Cheers,

 

Rhys

[allye 530 3 Cars]

I remember seeing these seats ages ago, they are rather nice! Exactly what I would do for a set of Rallye seats.

[cybernck 402 1 Cars]

Loving the seats!

[rallyeash 155]

looks good!

[aarontrophy 26]

Looks good mate

[MiniGibbo 142]

Awesome. i went for the easier/cheaper option of cloth gti seats but yours is perfect.!

[omega 82]

very nice

[N3VRAM 12 1 Cars]

very nice mate I love the seats!

[leemundo 3]

Just i wandered why your looking at putting a 1.6 rear beam in not 1.9 as im about to upgrade my rallye to a track car and was intending to use a 1.9 rear beam and subframe

[ORB 227 1 Cars]

I would go 1.6 beam. The brakes are better for a start....

 

 

[allye 530 3 Cars]

Just i wandered why your looking at putting a 1.6 rear beam in not 1.9 as im about to upgrade my rallye to a track car and was intending to use a 1.9 rear beam and subframe

 

Better brakes, better hand brake, hand brake doesn't fail!

[Wallby 39]

As they said above! Plus I like the idea of keeping drum brakes on the back.

[Wallby 39]

Small update.

 

I have decided to get the car on a rolling road again soon to get the cam timing set up properly and to also have another go at setting the carbs up. I want to try and get rid of a flatspot and generally get it running a bit better!

 

Im thinking of taking it to Mosleys in South Wales or if anyone knows of somewhere thats familiar with DCOM carbs please let me know!

[leemundo 3]

Cheers for that was looking at changing to disks though but will defiantly give the 1.6 a bit of thought then unless you would advise just being the drums?

[Wallby 39]

Engine back together now after taking the inlet off for a good clean and to check for any air leaks. Also fitted with all new gaskets so will hopefully be leak tight now!

 

While the carbs were off I tested the pump jets and noticed that they were out of balance. One side squirted earlier and for longer than the other which could explain why it was bogging down coming off the idle circuit.

 

Took it out for a quick spin last night and it did feel a lot better. Still got a bit of a flat spot coming off idle but much better than it was! A good balancing session should make it even better!

 

[Matt205 14]

There is loads of info on suspension options of you search. I have opted for the grp n Tarmac Billstien all round with Peter Lloyd 35mm springs and I'm delighted with the result. I have left the arb std but with new genuine bushes. I may consider changing the arb in due course.

 

I'd stick with drum rear brakes for the handbrake benefits alone :-)

[aarontrophy 26]

How much was it for the suspension mate?

[Wallby 39]

Engine is running great now after a little tune up, however there is a funny noise coming from the front passenger side!

 

Im thinking it could be the driveshaft, the noise is definitely speed related and gets worse/louder when turning the steering wheel.

Also, there is a bit of play in the nearside diveshaft when the car is in neutral, but when the car is in gear there is no play. Does this suggest the driveshaft could be at fault?

[Anthony 1,002]

Sure it's not a wheel bearing on the way out? That's normally a drone/rumble that changes with speed and gets worse turning one way (as you load it)

 

Driveshafts normally knock when turning under power (outer CV) or shake/vibrate under power (inner CV)

[Wallby 39]

Tbh it doesn't sound like a drone of a wheel bearing or a knocking of a driveshaft. It's more of a metallic rubbing sound, a very light one!

 

The fact that there was play in the driveshaft when in neutral led me to believe that this could be the fault. It's getting louder too and it's got the mot this month

[Wallby 39]

Just took it out and the sound is more of a squeak. It's coming from the front near side and only when turning left!

 

Think it will be coming apart for a look tomorrow!

[Wallby 39]

After doing a bit of reading on here/haynes manual and getting the car up in the air it seems to be the driveshaft intermediate bearing is at fault. Think I'll get a new 1 and fit it this weekend as I don't know how old the shaft is!

[Wallby 39]

Turns out it was the intermediate driveshaft bearing making the noise, although it did sound as if it was coming from the front left.

 

With that now sorted, a fresh mot and the weather getting better I can start getting the suspension upgraded. Front wise i'm thinking of B4s/Koni yellow dampers with Eibach springs then get the rear beam sorted when funds have built back up.

 

Hopefully this will be a nice little setup!

[Wallby 39]

Finished off lowering the seat last night, probably only lowered by just over an inch but feels good!

 

Looking forward to taking it out tonight and seeing the difference!

[Wallby 39]

Been doing a few cosmetic changes recently. Started off by painting the bumper inserts red and looks much better than the chrome/white that was on there before!

 

 

I also picked up a set of ph1 taillights for a bargin of £2, tried them on and I think they look pretty good...

 

Before...

 

 

After...

 

Have got a little problem now where my nearside headlight is dim. I have cleaned up all the earth points and even changed the connector but still no luck. It is only getting around 10.8V. Going to check the relay tonight after reading some stuff on here but if that doesn't work I'm stuck!

Edited July 15, 2013 by Wallby