[Car Upgrade] 205 Gti6 Supercharged Rollcaged Maxi Project

[dam205 2]

Hi All,

 

I have had my 205 for 15 Years now, its undergone many modifications in that that time and been SORN for the last 8 Years. About a year ago I sold my TVR Cerbera after 7 glorious years and decided to hold off replacing it for a while to give me enough time to do to my 205 what I have always wanted to do!

 

 

To started about a year ago by stripping it all out. I will try and post as many pictures as I can as I go along as I have hundreds!

 

At the start I didnt trust my welding as I hadnt done it for years so I got the rollcage welded in by a Garage that came recommended.

 

 

 

 

 

 

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[MiniGibbo 142]

Awesome project, love cars with history like this..!

[dam205 2]

Thanks for the comments. I will try and put some more pictures on today. The car has been dismantled and partly back together partly a few times so far as I have had to move it from a a few places but most of the work has been done in my garage which unfortunately is only a single one. I have had to do things in a funny order because of this and have uncovered a lot more work than I thought I had as I have found loads of rust and had to replace the drivers side sill!

 

The engine block is all built so I will try and get those pictures on as well.

[dam205 2]

This is the start of the work on the engine bay and front wheel arches, found plenty of rust here!!

 

 

 

 

 

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[dam205 2]

Got my welding perfected though after a 16 year absence! Seam welded every where I could, painted over with Primer.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

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[Vili 18]

I hate to say this because there is lot of effort put into this and the project is just great, but the welds don't look very good. Welds look like they are done with either too low current/voltage or lacking shield gas. What do you use for welding? How did you prep the seams before welding?

Have you seam welded inside the shell already? It would be better you stitch weld instead of continuous weld. That way you won't warp the shell so easily.

[dam205 2]

To take a break from all this body work, which I am not a fan of, I built the engine block and head. Its a Gti6 Block, Bored out to 86.5mm Cylinder diameters using Wossner 86.5 mm low compression pistons, with PEC con rods and ARP Bolts. The crank is standard with lead based bearing shells and a rebuilt oil pump. Below are the pictures of the Block and assembly, Head photos to follow.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

[calvinhorse 870]

More more more! Looks good, what compression are you going for?

[dam205 2]

Looking for about 8.5 to 1. Using this bad boy, and some parts mostly from Lynxpowerengineering based on the high boost kit. Im using the basics from the kit and adding a bit of my own invention, using a charge cooler not an intercooler, 4-2-1 Exaust Manifold and some more interesting bits.

 

 

 

[dam205 2]

Here are the pictures for the cylinder head build. I had a bent valve so ive totally rebuilt the head, nothing special like oversize valves as im using a supercharger and I dont think I will get many gains!

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Edited August 26, 2013 by dam205

[dam205 2]

And the finished head and block, painted, on the engine stand, under plastic and away at the back of the garage until I finish the shell!

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

[Paul_13 212 1 Cars]

Has that head been skimmed before you put it back on?

[stef205 92 1 Cars]

That's no supercharger! That's a no lag turbo only kidding great work!

[dam205 2]

Had the head checked and tested at the same time I had the block bored and washed and it didnt need it. Was cleaned and smoothed on the surface after the photo was taken and before it was fitted.

[dam205 2]

Well back to the shell, and some more pictures of rust fixing! Interior this time.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

[dam205 2]

Then I attacked the knackered sill........

 

 

 

 

 

 

 

 

 

 

 

[2052NV 24]

I commend your determination on repairing all the rust, that is a tonne of work! were bloody lucky down here in New Zealand.... we have hardly any rust problems

[dam205 2]

Took some time off rust treatment to paint some parts.

 

 

 

 

 

 

 

 

 

 

[dam205 2]

Needed to turn the 205 around in the garage so had to put it on its wheels, gave me a chance to trial fit the suspension.

 

 

 

 

 

 

 

 

 

[dam205 2]

Now its turned round in the garage Plenty more rust found!!

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

[dam205 2]

Managed to find some time to do some more work on the 205.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

[dam205 2]

Stripping of under seal practically finished, started to paint areas with primer.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

[Rams_gti6 12 1 Cars]

Love my dial up connection!

[dam205 2]

Right got some more Primer on the underside and ive attacked the arches and removed the lip on the edges in preparation for fitting the maxi rear panels.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

[cybernck 403 1 Cars]

Any more progress with this? Are you building a trackday car or a road car?