[Car_Restoration] 205 Gti Fore16Ver

[cybernck 402 1 Cars]

205 GTI Fore16ver

A daydream coming true

 

 

On a sunny February day in 2012, I accidentally stumbled upon this 1993 Miami Blue 205 GTI 1.9 for sale.

It was no stranger to me, as I'd known the car and its history since it was imported more than 10 years ago.

 

 

I've always lusted for a late Miami Blue 205 GTI, so a deal was struck for the car without its wheels. It was

in a really bad condition but rather cheap and perfect for what I initially wanted it for - a Ph2 parts donor

for my old Ph1.5 Silver 205 GTI.

 

 

Sadly, the original late DKZ 122 bhp CAT engine had been replaced by a DFZ 102 bhp unit in the past.

Also, the head was clapping and it was overfueling due to still using the original (now incorrect) engine

management. Not that it had mattered much to me as I was not interested in its engine anyway.

 

 

It had also been fitted by a crude BRC LPG system that I've had no interest in whatsoever and just

wanted it off of the car.

 

 

As this late model 205 GTI was assembled in Spain, it's got some odd parts, such as Ph2 cloth seats

(hiding under those seat covers) - pretty knackered of course. And the worst condition steering wheel

I've ever seen!

 

 

The horror doesn't stop there - the ventilation knobs are all broken, as is the center console, while the main

dash part was molested too :-(. And for a complete experience - how about a third of a gear knob? Interior

door handles and some other parts have been deformed too.

 

 

 

To be continued...

 

 

Full size photos: http://photos.cybern...205gtifore16ver

[MiniGibbo 142]

Christ you're up against it with that..

 

What happened to the gear knob then

[cybernck 402 1 Cars]

Yes and you've not even seen it all yet...

 

However, I plan to save its life!

[Slo 283 1 Cars]

Thats got to be the best looking err worn gear stick ive ever seen lol

[cRaig 273 1 Cars]

What a starting point! Looking forward to seeing the progress very much

[Kezzer30 40 1 Cars]

Hahhaha normally its a case of saying thats a nice decent starting point for u there , but im going to have to say u have some considerable amount to sort but im sure it will be top once its done pal good look

[pugdamo 111 2 Cars]

Good luck,im sure you will make it a minter once again

[cybernck 402 1 Cars]

Like I said, it's even worse than it looks .

 

But I'm going to explain it all soon .

[cRaig 273 1 Cars]

I hope making all the decisions about what to do werent too painful, I know you were busy debating it all last time we spoke!

[cybernck 402 1 Cars]

Episode 2: ...and it gets worse!

 

 

As the car's registration had been running out that day, I put my wheels on it, given it a quick wash

and took it for a technical test, to see what else is wrong with it, while I still could. Needless to say,

wishbones, engine mounts and track rod ends were all dead.

 

 

Brakes were all worn out, but surprisingly completely functional and well balanced, while the rear beam

seemed fine, save for dead shock absorbers. It may look much better now than before the wash, but make

no mistake - the bodywork is in the same bad condition as the interior and mechanics.

 

 

An ugly-looking ripple, caused by a recent bump, starting to rust where the paintwork had peeled off.

Also, some weird unexpected rust on the nearby passenger door.

 

 

Problems with lacquer, as on many late model 205 GTI's. However, holes in the tailgate, where an aftermarket

spoiler used to sit many years ago, posed a much bigger problem, as the water was going through them and

soaking the boot liner underlay, trapped under this gigantic gas bottle, which lead to boot floor being

infected by rot.

 

 

Other than that and the usual rusty patches under the rear seats, the floor and sills seemed fine. At least

on first sight. But if you thought this was all, then I'll have to disappoint you! Driver's side front end of

the car is completely rotten, as a result of a front end impact that the car suffered many years ago.

I was aware of it though, so I was prepared to find something like this.

 

 

 

To be continued...

 

 

Full size photos: http://photos.cybernck.com/205gtifore16ver

[Kezzer30 40 1 Cars]

Welk good luck pal hahha

[cybernck 402 1 Cars]

Episode 3: The decision

 

 

Three 205's (with four engines :-)) but unfortunately one too many. Since I was just about to start

restoring my full stock Ph1.5 Silver 205 GTI 1.9 (aka 205 GTI 999), it was a very difficult choice,

made even harder as Ph2 Miami Blue with 16v engine was a receipt for my "dream spec" 205.

 

 

Helped by the fact that I would end up with a free Miami Blue rolling shell by selling the parts

I don't need off of it and also already having most of the parts I will need for the build just

laying around doing nothing for a number of years - I decided the only sensible option would be

to sell the Silver one and build the Miami just as I want it.

 

Hopefully this explains why am I going to put up rebuilding a car in such bad condition to start with.

Furthermore, as a bonus, the Silver 205 is in good hands, so the future is looking bright for it as well.

 

 

Since I decided I was going to keep the Miami Blue 205, it was bugging me that the car had original

remote central locking but the key with the remote had been long lost. Then I remembered I've had

this pair of RCL module with the matching remote sitting in my parts stash.

 

 

The replacement RCL module fitted straight in the place of the original one, so I crossed that

off the list (one job down - 465 left to do). It made me feel better about my decision as well.

 

 

Full size photos: http://photos.cybernck.com/205gtifore16ver?page=2

[cybernck 402 1 Cars]

Episode 4: Shock and horror - continued

 

 

Just as I was going to start the work on the car, I stumbled across a XU10J4RS engine for sale.

It wasn't really looking nice to begin with but since this type of engine is extremely rare where I live,

I just had to buy it. A plan of a modern-engined 205 with ABS and A/C was quickly formed :-).

 

 

Since I had to inspect and refresh the engine prior to using it, I started taking it apart. Wiring had

all been cut and injector plugs all broken and glued on (!), so it wasn't looking good, but I was

hoping the internals would be fine at least.

 

 

No such luck though - someone had been "playing" with it, crudely enlarging the valve pocket cut-outs

in the pistons. At this point I thought I would still be able to make a good engine out of it, by replacing

the pistons and giving it a full rebuild.

 

 

However, the head has had a similar kind of "mods" done to it and even one of the spark plug threads stripped.

At this point I decided not only to scrap this engine but also the whole idea of a "modernised 205" and just

"keep it simple".

 

 

 

Full size photos: http://photos.cybernck.com/205gtifore16ver?page=2

[Slo 283 1 Cars]

Looks more like over enfusiastic cleaning to me rather than "mods" but the stripped plug thread is unfortunate although repairable

[cybernck 402 1 Cars]

No, the valves had also seen some angle-grinder action (not really visible in the photos),

as if someone was trying to advance the inlet cam quite a bit or perhaps didn't really know

how to time the engine correctly. Also, I don't really like the deformations and deep scratches

in the combustion chambers.

 

By the time I got the engine fully rebuilt and sourced the pistons, wiring loom, ECU and PAS pump,

the cost will have risen way too high. And it still wouldn't really inspire me with confidence.

[dcc 855]

Looks like a lucky break that you stripped it tbh.

[pug_ham 244 3 Cars]

That's unfortunate, its started out looking quite bad but really has gone from bad to worse.

 

I've got a set of used standard GTI-6 pistons I don't need if you're interested in them?

 

g

[welshpug 1,661]

I would say that's a poorly repaired snapper unfortunately, the parts you need really aren't that expensive though.

[cybernck 402 1 Cars]

Well... I would need complete wiring, unlocked ECU, PAS pump, pistons and postage for the lot.

 

And then extensive head work and basically full rebuild, ASSUMING the crank and block are perfect.

 

Therefore quite a bit all in .

[DamirGTI 342]

Shame for the engine , i know how rare are they over here ... though , an used XU10J4RS engine can be found it scrapyards in Italy but they're quite pricey !

 

1.9 8v engine is really simple reliable and easy to maintain , and can be a lot of fun with a few mods

 

Damir

[cybernck 402 1 Cars]

Hehe, that's true. However, this Pug is going to end up with a 16v engine, in any case .

[DamirGTI 342]

I see .. then , if this one is beyond your budget to repair S16 engines are also good (leave some bits from the GTI-6 and sell some so you can fit on a S16 or Mi16 )...

 

Or even a 1.8 16v , engine with bad head ports shape from factory which makes it kinda gutless , but with that fixed it'll go like stink especially on SA management ... it's an complete aluminium light weight engine , head and block as well like the old Mi16 version .

 

Damir

[cybernck 402 1 Cars]

Another requirement is that it's a stock engine with stock engine management .

[DamirGTI 342]

stock engine with stock engine management .

 

.. what's the matter Nick , is it the age factor or something else ?

 

Damir

[cybernck 402 1 Cars]

Hahaha, not really. This car is bound to be a well-sorted fully-restored daily-driver, done on a limited budget too, not a project car.

 

Therefore either a standard XU9J4 or XU10J4RS.