[Car_Upgrade] 1.9 Gti Rust Repairs And Bodywork

[johniban 59 1 Cars]

im just buying all the bits that are old and knakard like wishbones and driveshafts need to get it off the axle stands and rolling so i can spray it

[Juttie205 123 2 Cars]

Looks like your making good progress keep it up.

[johniban 59 1 Cars]

thanks juttie, im trying to get it all done before the next bhp show, so i can hopefully take it instead of the 106 or the rallye

[johniban 59 1 Cars]

Had a long old day today, fitted the engine again, and then found out the the 'gti6 205 exhaust' i bought is actually for an mi16 engine in a 205.

 

 

so that will be up for sale now, silly me to think it would fit...

 

anyway, engine back in, original gti6 manifold on and reangled/welded up.

and got on with finiishing the fuel system

 

i originally wanted the fuel regulator on the passenger side in the engine bay but i would have to route the fuel line from the drivers side to the passenger side, that would look messy so i have mounted it on the drivers side also made a start on the brake lines..

 

[johniban 59 1 Cars]

 

link pipes made up to join carbs to regulator, and regulator mounted,

 

front bumper on and finally looking like a car again

 

[johniban 59 1 Cars]

This turned up today, along with some extra parts like new wishbones and aux belt and tensioner

 

 

looks really good, not the lightest thing in the world considering it suposed to be a lightweight racing battery but still

[johniban 59 1 Cars]

also got a set of these from pug racing, recommend to anyone, not set up yet but that fit easily and feel nice and strong

 

[jamie_1992 66 1 Cars]

If you have done the linkages I would recommend changing the bushes for the bronze ones BBM do I did and there is no play what so ever

[johniban 59 1 Cars]

thank you for the advise i shall probably do this

[johniban 59 1 Cars]

started making up the exhaust today, got some 2.5 inch stainless tube and started making it up, relised i have probably angled the manifold to far so the exhaustt down pipe has a bigger angle than it should have, but it will work, i may have to get a pro to tig me up a decent down pipe but this will do for now.

 

even though i am running carbs i have added a lambda port and bung just incase i need it for setting up fueling, i then relised i had welded it on the wrong side doh! so i cant leave a lambda sensor in there as it will foul on the gearlinkages,

 

wish i had some stainless wire as it probly end up having to paint it as it will rust

 

[johniban 59 1 Cars]

battery mounted in boot, have mounted a hidden cut of switch in arms length for security and possibly safety and to not make the interior look like its got aftermarket items fitted

 

[johniban 59 1 Cars]

really happy now i have power and lights, and engine turns over, strange earthing issues as rear washer pump activates with right hand indicator but ill sort that out

[johniban 59 1 Cars]

coilovers fitted, not my choice but its what i have for now, new wishbones, track rod ends, drop links brake lines and hel braided brake lines

 

[johniban 59 1 Cars]

not sure if i have the brake flexi the right way around but it looks ok, just need some spring clips to hold the hose in place.

 

[welshpug 1,661]

no, that is very wrong.

 

 

wrong way up in the bracket, and wrong side of the strut, the unused bracket of the strut should have been a MASSIVE hint...

Edited January 5, 2014 by welshpug

[Tom Fenton 1,542]

That big kink in the downpipe will not help flow. If it has to be like that you would be better to use a swept bend in there rather than a sharp pipe join.

 

Here is one I made for my turbo car.

 

[johniban 59 1 Cars]

i do need to have a redesign on the down pipe, but i want to get the car up and running at the moment, them perfect everything afterwards

[cybernck 402 1 Cars]

Just a quick comment on recent injection reliability issues etc topic.

 

I often say that it's a shame most of 205 GTI's in the UK ran Jetronic engine management and many of you haven't experienced an 8v engine equipped with Motronic 1.3. They simply start up every time and under any conditions, idle perfectly, never stall and always rev-up without any hesitation of jerkiness. Until one of the electrical components fail, ofcourse, which again doesn't happen often.

 

Not much to do with the actual theme of this build, just my 2p worth in general .

 

 

Anyway, back to the main topic and keep up the good work!

[johniban 59 1 Cars]

Got a new home for the gti last week witch is good, just spending time fitting it out, tools, lights ect,

 

 

decided now i have a proper place with room, im going to strip the 205 down to a shell, redo the repairs id done previously and get it painted up.

 

plenty of room in here

front end strip down

 

[johniban 59 1 Cars]

Windscreen out, mirrors off,

couldnt get the door off as the bolts are seized

 

All trim off and boot off, really heavy when trying to remove yourself!

 

Really unhappy with the boot repair i had done previously but im unsure what todo about it

 

[johniban 59 1 Cars]

The seam sealer had cracked so i think im going to sand it down and seal it again

 

Then i removed the engine with everything attached to it, much easier this way!

 

[johniban 59 1 Cars]

All going to be stripped back down, powercoated or painted where possible and built back up, ready for some nice throttle bodies

[johniban 59 1 Cars]

Couldnt resist buying some shiny parts for it these were very expensive yet seem to be cheaper to buy brand new than second hand?

 

 

really happy with them, and they just bolt straight on with no fuss

[johniban 59 1 Cars]

strut tops strengthened

 

 

seam sealed, filled and smoothed out arch

 

 

DIY spray booth

[johniban 59 1 Cars]

Engine fitted, started on brake lines,

 

 

this tool is amazing and cheap!!

 

Battery wiring sorted with a junction box