[Car_Restoration] 205 Gti Fore16Ver

[DamirGTI 342]

Understood

 

D

[cybernck 402 1 Cars]

Episode 5: The king... beheaded

 

 

After a failure with a GTI-6 engine idea, I continued the actual work on the car, by removing its

(non-)original engine. I've had a good idea of what I was doing (hint: a light bulb above my head) :-).

 

 

After some struggle with clumsy French engineering, the engine was beheaded. It turned out that

having had a swap for a DFZ 1.9 102 bhp engine in the past was a fortunate circumstance in this case,

as a friend was after such a head for an interesting project.

 

 

The next task was removing the engine internals (pistons with rods and then the crankshaft as well).

The pistons and rods have been sent away together with the head, while the crankshaft is hopefully

going to save a dead 205 GTI 1.9, sooner or later.

 

 

The last job for the day was to remove the front wings (easy, as they had been replaced in the past

and not resealed afterwards) and bumper (hard because all the bolts had been rusted up solid).

Removing the front wings has enabled me to get a clear view of a rotten inner wing, due to a known

incident from the past.

 

 

 

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

[JoeVTS 1]

my xu10j4rs cost me £100. I have no idea if it still works though.

 

or as damir says, the 1.8 has the lighter alloy block and bigger valves but smaller ports, so a 1.8 with RS manifolds, matched ports, cams and management ought to go like stink.

[cybernck 402 1 Cars]

I've scrapped the idea of using GTI-6 engine (and many other modern add-ons) and decided to keep it simple and stick to an Mi16 engine instead .

[welshpug 1,661]

What a strange comment just as much work using an mi16 as a gti6!

[cybernck 402 1 Cars]

Not when you've got a complete super low mileage Mi16 engine at your disposal, compared to a damaged GTI-6 engine

with molested loom and possibly locked ECU and most importantly no spares of any kind within a thousand km range .

[cybernck 402 1 Cars]

Episode 6: Winter sleep

 

 

With the weather turning for worse, the last thing I set out to do in 2012 was removing

the engine block and gearbox to have the engine bay ready for better inspection.

 

 

With the only help being provided by two small hydraulic jacks, fighting the lack of space,

adverse weather conditions and unpleasant neighbors, I manage to successfully pull it all out.

 

 

This is the point where the front crumpling zone ends (and how far back will the chassis have to be

cut off and replaced), with the rest of the impact having been absorbed by the roof and the floor.

 

 

Everything packed up tightly and ready for winter sleep.

 

 

Full size photos: http://photos.cybernck.com/205gtifore16ver?page=3

[Jolly Green Monster 51 1 Cars]

Nice project. Good luck.

Look forward to future episodes

[DamirGTI 342]

fighting the lack of space, adverse weather conditions and unpleasant neighbors

 

Same here , though i also sleep/live in my garage now ! made myself an small room which is connected with the garage directly , previously it was an additional garage working room (had my big working table , tools and spare parts lot inside before) .

 

Kinda used to the lack of space now after all this years , and the crappy metal garage doors which makes it a bit freezing inside during the winter time especially while it's windy outside (bad door insulation) ...

 

However - neighbors , i simply can't and never will used to that lot of grumbling evil old farts ... the older they are the more they're unbearable .. and i really do care about loudness in such way so that i do not torture any of them people living around my house with the noise levels , even tried to be diplomatic and sort out the issues by talking to them - no use , it doesn't make any difference at all i might as well start up and left one of my three 205's running without exhaust all day/night outside it'll still be the same (dunno why i even bother being quiet and cautious tbh !)

 

Also have bent chassis leg on my sorrento , the last project 205 which i bought (was really barging price) .. need to strip it down inspect and tackle with the bodywork stuff , more about that when i sort out funds for starting the project .

 

Don't let the bodywork issues scare you off Nick , you're brave and big fellow !

(i always had an soft spot for miami blue 205's looking forward to seeing it's rebirth)

 

D

Edited November 4, 2013 by DamirGTI

[cybernck 402 1 Cars]

Episode 7: Awakening

 

 

Most of the 2013 went by without having anything done on the car, purely because I couldn't find

anyone to take on the work of fixing the chassis and rust patches. However, near the end of the year,

it was time to continue the restoration work.

 

 

All the rear bumper bolts were rusted up solid, as expected.

 

 

Stripping off the remaining bits in the engine compartment and also the interior.

Only God knows how will I put it all back together!

 

 

To be continued...

 

 

Full size photos: http://photos.cybernck.com/205gtifore16ver?page=3

[jackherer 543]

Only God knows how will I put it all back together!

 

Is that a reference to your sig?

 

"205 haynes manual is my god"

[cybernck 402 1 Cars]

Episode 8: One Horse Power

 

 

During my hunt for parts, I managed to find just what I need - NOS replacement headlight panels!

I've also finally managed to acquire an "auto bonnet" - i.e. a bonnet off of a 205 Automatic.

It's not in the best shape, but it's crucial for my vision of this car :-).

 

 

Anyway, the second day of dismantling was mostly easy work. The front wings are reusable, but I'm

on a look-out for a pair of new ones - which are proving very difficult to get hold of now-days.

 

 

The front part of the floor pan would have been perfect, if it wasn't for a crack from the known crash,

while the culprit for the damage in the rear part were the holes in the tailgate and LPG installation.

There's just a small usual rusty patch under the rear seats.

 

 

Awaiting pickup, to be transferred to the bodyshop.

 

 

 

Full size photos: http://photos.cybernck.com/205gtifore16ver?page=3

[cybernck 402 1 Cars]

Episode 9: Cut

 

 

The car arrived at the body shop and it was time to finally start going in the direction of having a rust-free 205 shell.

 

 

The chassis had been pulled back to OEM specification, doors put back on using larger pins and body panel gaps set.

Then the crash-damaged rotten corner section was cut off.

 

 

Out with the cancer!

 

 

Next up, the replacement part I had sourced earlier had to be trimmed and a good inner wing panel fitted back on the car,

along with the brand new headlamp panels.

 

 

 

To be continued...

 

 

Full size photos: http://photos.cybernck.com/205gtifore16ver?page=4

[cybernck 402 1 Cars]

Episode 10: Paste

 

 

Ta-daa! Inner wheel arch welded on, as well as the new headlamp panels. Looks infinitely better

than the old mix of filler and rotten metal! Pretty seamless transition of the car's chassis and

the new part - it will look as new when it sees some paint.

 

 

The other side has seen some grinder action too. Another culprit and often overlooked area is

the bottom of the A-post.

 

 

The fuel tank has been dropped and the floor cleaned up with the boot floor section left to sort out.

 

 

Meanwhile, I decided to take a look at my very low mileage XU9J4Z 405 Mi16 engine I bought back in 2007,

that has been removed out of an 405 Mi16x4, crashed 10 years earlier, in 1997, with only 35 thousand

kilometers on the clock!

 

 

 

To be continued...

 

 

Full size photos: http://photos.cybernck.com/205gtifore16ver?page=4

[cybernck 402 1 Cars]

Episode 11: Solid foundation

 

 

Back at the panel beater's, the car has had most of the major body work done. Facial reconstruction

surgery complete. The red arrows are there to sway your attention towards removable lower section,

for ease of maneuvering the engine in at a later date.

 

 

The Automatic bonnet has seen better days, but I'm very happy to see it on the car none-the-less!

Some crude work has been done on the exterior too. The doors are rather rippled, but it will all be

sorted out, when the time comes. The hole in the floor patched, along with a few more in the front arches.

 

 

 

The car stayed at the bodyshop for some finishing touches while I was on a tour around Bosnia,

filling the car up with various 205 parts, including another (and hopefully better) Auto bonnet!

 

 

Also, I dug these wheels out, that I had purchased a while ago, with an intention of making

a transportation device for a bare 205 shell, heavy parts such as engines and apparently

cyclists too :-).

 

 

 

On the last day of 2013, I got the car back, fully rust-free and ready to go to the painters.

I've even had to rent out yet another garage, as the old one got filled with all sorts of parts

in the mean time!

 

 

 

Full size photos: http://photos.cybernck.com/205gtifore16ver?page=5

[cybernck 402 1 Cars]

Episode 12: 205. Un sacré numéro.

 

 

After a "Winter sleep", in May of 2014 I finally managed to find a bodyshop that has agreed

to do a bare-shell respray of the 205, so it was time to get it out of the garage and do

some more parts stripping and then finally make a move forwards, in every sense .

 

 

Only being satisfied with the best results, I decided (and managed) to get new replacement

front wings. Pattern parts, but the ones on the car were also not OE parts plus they have

been a bit rusty as well.

 

 

Meanwhile, in one of my other hobbies (cycling, if you are not already aware of it),

I randomly got my favourite number for a starting number in an international race .

 

 

 

Full size photos: http://photos.cybernck.com/205gtifore16ver?page=6

[cybernck 402 1 Cars]

Episode 13: Let there be paint!

 

 

Meanwhile, at the paintshop - the car finally sees some fresh Miami Blue paint! Yay!

 

 

The whole floorpan has been coated in stonechip and then resprayed in body colour.

Although I'm not really going to go off road with the car, it's nice to have some,

err, protection .

 

 

Also, not being satisfied with the two Automatic bonnets I've had previously acquired,

a friend has found me the best one yet! Sweet!

 

 

 

And here's the 4th engine presented in this story so far - rare and iconic XU10J4TE

a.k.a. 220 bhp 405 T16 engine. Although it would have been amazing to have this beast

fitted under the bonnet, it was missing a few things and would have made my project

even longer and more complicated, therefore I decided to let someone else enjoy it!

 

 

 

Full size photos: http://photos.cybernck.com/205gtifore16ver?page=6