[Misc_Work] Project Pug 205 Gt

[Arwing 3 1 Cars]

Had my Peugeot 205 GT a few years now. Has been off the road the last year due to me putting my Jap import back on the road and not being able to afford to run 2 cars. Backpacking again in May 2014 indefinitely, so sadly have to sell the Mitsubishi. Buying myself a cheap run about for work and going to do the Pug up as a project. Will be keeping it at family or friends once i go away. I predict the 205 will be worth a lot in years to come, much like the Mk II escorts are now (though probable not quite as much).

 

 

So it's a 205 GT on H registration (first of the phase 2's). 1.4 engine (TU3?). The GT came standard with GTi bumpers and a different set of steel wheels than the norm. GT sounds posh but as i'm sure you all know, with the exception of GTi, G=4 door and X= 3 door, but still, love saying i have a GT but it's basically a 4 door XS.

 

 

Lacquer has peeled (common on older pugs) on bonnet and roof and paint faded to white where this has happened but personally i think it's part of the charm of having an older car. No rust, which is the main thing.

 

 

While engine has never let me down, it's burning oil which i'm pretty sure is because of the valve stem seals (common on the 205 once it hits a certain age). A little oil is leaking from head gasket too.The head gasket is "compromised" but not gone. Fan won't engage and if idle for a long time, heaters do need to be put on. But as long as she's moving, all is fine. Been on 300mile trips and temperature stays on 1/4.

 

 

Entire back end has gone. Brake plates, rear cylinders, etc. Also have a sag in the axle (which apparently isn't the axle itself but some bushes??). Anyway, i have a new axle from a N reg 205 to be fitted complete with hubs. Shocks are good but need new springs and top mounts on the front. Might put new discs and pads on front while i'm at it, but otherwise she's good for an MOT.

 

 

As extras i have a genuine 205 GTi spoiler to add as well as a set of 4 Grayston mud flaps. I'm also trying to source a set of 1.6 GTi alloys which i'll spray white. Would like to change my front and back bumper valance from the grey, with chrome strip to a GTi black, with red strip. I think it'll give the car a nice rally look (even though it's 4 door). Engine wise... this is the dilemma, i can get the head skimed and valve stem seals replaced for about £60 and do the head gasket myself (and remember to use new stretch bolts this time ). Or i can put another engine in. I did have access to a Nissan Pulsar engine but it would be too much power through the front wheels. Having researched the 4 wheel drive conversion and adapting of the drive shafts etc, it's too big a project and have scrapped that idea. Might chuck a Toyota Starlet GT engine in though. 1.3 turbo.

 

 

Will be doing pretty much all the work myself with help from my brother (he's had a few GTi's in his time and has done lots of work on them including an engine change). Only things i won't be doing is fitting the mud flaps. Probably won't be able to do rear axle either. Me and my brother got it off the one at the scrap yard but i think really you need a pit or ramp to do it properly and safely. Hope to have this done by xmas at the latest. Will keep this post updated with progress and appreciate any tips/feedback/suggestions.

[omega 82]

if you can change the engine to a Toyota you can fit a rear beam!

theres a guide on here that shows you how.

will watch with intrest

[Liquid_106 97 1 Cars]

If your bumpers and chrome strips are in good condition, probably best to plasticare them using the black version to darken the bumpers down and then spray / wrap your chrome strips as good condition red replacements are silly prices now.

 

Liking the idea of the white 1.6 alloys - what would the GT steeliness look like in white?

[Arwing 3 1 Cars]

if you can change the engine to a Toyota you can fit a rear beam!

 

We took the rear beam off the other 205 easy enough, but that was on top of another car at the scrappy. The issue is gaining access to the underside of my car safely. If i go ahead with the engine conversion it'll be done at a garage. My brother put a 1.9 in a 1.6 once but obviously with a Toyota engine would need to change loom and everything which is out of my skill range.

 

If your bumpers and chrome strips are in good condition, probably best to plasticare them using the black version to darken the bumpers down and then spray / wrap your chrome strips as good condition red replacements are silly prices now.

 

Liking the idea of the white 1.6 alloys - what would the GT steeliness look like in white?

 

Might try the plasticare (or black shoe polish) on the bumper trim. Might keep the strip chrome, see what it looks like, as like you said, the red gti ones go for stupid money. Have toyed with the idea of spraying the steels white as they look alright, but while the back one (shown in side view picture) is good condition, the others will need sandblasting down as have a bit of surface rust beginning on them. So might be cheaper just to buy some 1.6 alloys or if i can find them, a set of white compomotive 14" TH or TH2. Most are in ford fitment though so while the studs fit, need spacers and longer bolts. Most are 7inch width too which i think'll be too wide for my 205.

Edited August 18, 2013 by Arwing

[calvinhorse 870]

Looks a good project

 

Few things-

 

Gti bumpers are wider so won't fit properly, so like said keep yours and repaint/plasticare

 

Your top engine mount is the old style one so won't take and gti/Xu engines (just a pointer!)

 

And the rear beam can easily be swapped with 2 axle stands and a trolley jack.

 

Oh, and rear lower spoiler on gts isn't a gti version it's a colour coded base model version.

The gti one looks loads better

[jonXS 30 1 Cars]

I second the rear beam change. Did one myself at the beginning of the month on my XS, its the same year and colour as yours is including the faded paint lol. oh and a second pair of hands helps massively.

 

one question is, what strut brace is that you got fitted there? I'm struggling to find one that fits over the carb and filter

 

best of luck to you, it looks like a good base to start with.

[Arwing 3 1 Cars]

And the rear beam can easily be swapped with 2 axle stands and a trolley jack.

 

 

I second the rear beam change. Did one myself at the beginning of the month on my XS, its the same year and colour as yours is including the faded paint lol. oh and a second pair of hands helps massively.

 

one question is, what strut brace is that you got fitted there? I'm struggling to find one that fits over the carb and filter

 

Will try to borrow some axle stands and give it a go with my brother then. The strut brace (spoiler and red stitch gear gaiter ) came off a donor GTi of my brothers. It did have an OMP sticker on it, though weather that was because it is OMP, or just stuck on for show, i have no idea. There is barely enough room to slide a rizler paper though, it's a tight fit. But even on slow cars, they make a difference around the corners. I'm a big fan of strut braces myself.

[Arwing 3 1 Cars]

Damn! Can't believe it's been almost 2 months since i started this thread (and my project). I'm a little behind my original predicted timeline. Though i have been pre-occupied selling my Mitsubishi and buying my hunk of junk Citroen in-between car. Anyway, here's an update on progress...

 

My 1994 Mitsubihi has now (sadly) been sold.

 

And here is my 1996 Citroen ZX. Hunk of junk with no body panel un-dented but reliable and a bargain at only £150 with 6months MOT.

 

So, back to the 205. I started by cleaning and treating the engine bay. Gave it a good scrub and polish before treating any surface rust with KRUST and then a few layers of Hammerite paint. Here are the results.

 

Treated with KRUST

 

Painted with Hammerite.

 

Next came changing the shocks. My top mounts were very bad and my springs not too good. Worked out cheaper in the end to buy a set of second hand shocks as opposed to new mounts and springs. They're off an XS which is a 3 door version of my GT. What a bitch of a job this was. All the bolts and nuts came off lovely. However, getting the hub carrier to release the shock was a nightmare. And equally as difficult getting it back in again with the new ones. Enlisted the assistance of a local garage to fit the new shocks on as i wanted all the bushes replaced anyway.

 

Old and new. Again, KRUST and Hammerite treated the top mounts.

 

Hub carrier was also Hammerite treated after the KUST application (no picture). I also cleaned all unter the arch as well as in and around the shock well, Hammerite treating a small area where the paint had been scratched.

 

Thanks to forum member "205wrc" i now have my set of 1.6 alloys. Rubbed down the first alloy and primed it today using an etch primer. Will give it 5 - 7 layers next weekend of competition white paint before adding the laquer a few days after. Only doing the 4 wheels. Will keep the spare silver.

 

Here are the wheels i bought from 205wrc

 

First one sanded down and primed ready for the top coats.

 

Next update i will have the wheels finished and will hopefully have swapped the rear beam over.

 

 

[GLPoomobile 958]

Couple of tips for the future....

 

I don't know if your hub carriers are similar/same but on the GTI the gap where the bolt clamps up the shock is the perfect size to slide in a square ended sump plug tool. So to remove and refit the shocks a good method is to first spray a penetrating fluid (Plusgas) around it, then after undoing the clamp bolt, insert the end of the sump plug tool in to the gap and twist it 45 degrees, which will spread the hub open slightly. With the gap opened, spray in more penetrating fluid. Keep doing this and eventually you'll free it up enough that you can work the hub carrier free of the shock.

 

Secondly, Kurust is alright for basic rust tackling duties and probably suits you fine for what you're doing here (preventative maintenance rather than concours prep), but I'd recommend Bilt Hamber Deox C or Deox gel. Great results with minimum effort.

[Arwing 3 1 Cars]

It's finally beginning to take shape now. What you perceive in your mind as 2 or 3 short jobs turn out in reality to be 6 or 7 long winded jobs. I'm enjoying and hating this project in equal measure at the minute. But there is light at the end of he tunnel at last.

 

Here are the 1.6 GTi wheels halfway through thir spraying process.

 

Here is the first wheel finished. Primed, sprayed and lacquered in competition white.

 

 

Chrome strip removed and heat gun used to darken bumper valance. Prior to application of plastic dye.

 

First layer of plasticare dye applied - will need 2 - 3 coats in total for a good, even finish. I applied 2 layers with a sponge using a brushing technique. Then added a third layer dabbing the sponge. This is some amazing s*it. Easy to apply with outstanding results.

 

 

Coloured adhesive stripes for cars, boats and other vehicles attached to the chrome strips in order to make them red. This was 15mm wide and fitted perfectly over the chrome strip.

 

 

 

 

Up on axle stands i'm borrowing from a friend to finish fitment of new shocks. Also changed the oil and oil filter and fitted new spark plugs. Only did the air filter last year prior to car coming off road so that didn't need replacing.

 

 

 

 

 

 

 

Strut brace was looking a bit tired so have frinded it back, treated it and primed it ready. Not sure on final colour yet but am leaning towards white.

 

 

 

 

SIEM driving/fog lights removed. Cleaned up and metal surrounds treated. Also one needs bonding together again prior to refitting. One of he wires had broken too so only one light worked. Checked my Ciroen and it had the exact same wire so stole it from that and have now fitted it to the Pug and all works fine.

 

 

 

 

Starting to take shape now. Work and service of entire front end and engine completed. Off axle stands and wheels refitted. Still waiting for tires for the alloys. They'll be fitted as soon as they arrive in stock.

 

 

Now the car drives again. I'm putting it in my garage to finish it off as the weather is less than friendly at the moment. I have the new rear beam ready for fitment. I'm removing the dampers and putting my old ones on as they're in much better condition. I'm taking the beam to a garage to strip the shoes etc (there are so many clips and springs i don't know where to begin). I'll then grind back, treat and paint the hubs, arms, torsion bars and beam. Then i'll take the beam back to the garage to reassemble shoes.

 

 

Once the beam is done and changed. It's just fit the alloys, attach mud flaps and rear spoiler and she's done and ready for the MOT.

[Arwing 3 1 Cars]

Project FINALLY finished! (still have mud flaps to fit though)

 

Garage had it over a month for the MOT as they were back logged over xmas. It went in only needing rear brake lines fitted. Now has an MOT, Tax and has been on the road the last week... though not before the alternator decided to die. Thanks to a 106 at the scappy, she's running again now.

 

Here's the rear beam just before i refitted it. Everything grinded back and hammerited.

 

Tried to take the same angled pics as when it was standard for comparison reasons.

 

 

 

 

 

Engine Bay

 

 

It's been a really good project. Really happy with the end result. Learnt a lot about the car through good times and moments of pure frustration. Really pleased with the wheels and fog light covers i bought off members from this forum. Thanks to all who gave advise during this project too.

 

Just the mud flaps to fit now

Edited February 8, 2014 by Arwing

[jonXS 30 1 Cars]

That's looking great mate, what you done makes a massive difference. Well done

 

looks kinda like mine just i got less doors haha. One question hows you fit the spoiler on, just tiger sealed??

[Arwing 3 1 Cars]

That's looking great mate, what you done makes a massive difference. Well done

 

looks kinda like mine just i got less doors haha. One question hows you fit the spoiler on, just tiger sealed??

 

Got some mastic tape from where my cousin works (industrial). They had a chart with different tapes sticking different materials (rubber, metal, glass) together. I used the rubber to metal on the top against the boot lid, and the rubber to glass on the bottom of the spoiler to the rear window. It's not budging. Frost proof etc too.