[Car_Restoration] My 1989 205 1.9 Gti Restoration Project

[mrfirepro 127 1 Cars]

Got the crank and pistons check my a machine shop. found one of the big ends was gone, installed replacement conrod and problem sorted.

 

This time used OEM hockey stick seal and they went in easy as pie

 

Block 4 was rebuilt and all seemed fine until I got to stage one of head tightening and thread 10 pulled, this time I am going to helicoil it, M11 x 1.5 with 3d inserts ordered and should be with me next week, hopefully this will see the engine put back together.

[Anthony 1,003]

You've really not been having much luck with this build with what seems like one issue after another, but hopefully (touch wood) it's all going to go back together after this and won't give you any more issues

[mrfirepro 127 1 Cars]

I am on a steep learning curve and guess that some of this will be my inexperience, but I certainly was much quicker and more confident this time, at this rate I'll be able to build it with my eyes shut

 

Whilst I'm waiting for the helicoil I can finish the front subframe and rear beam.

[mrfirepro 127 1 Cars]

gear box pics here

 

Edited November 5, 2014 by mrfirepro

[mrfirepro 127 1 Cars]

I guess if you put it in reverse whilst still going forward this happens

 

 

new and old for comparison

 

 

I wonder where all those bits ended up

Edited November 5, 2014 by mrfirepro

[Juttie205 123 2 Cars]

If you dont mind me asking how much did it cist to get all that plating done?

[mrfirepro 127 1 Cars]

If I remember correctly it was around £120, but be prepared to wait as they do tend to take there time.

 

If you want an accurate figure would be happy to dig out the invoice, just let me know

[mrfirepro 127 1 Cars]

Just putting the engine back together and the thermostat seems a bit loose in its housing.

 

I am using OEM gasket (not really a gasket but a flattened O ring) and thermostat, when I install both into the housing the part that screws on the front does not seem to clamp the thermostat at all and it remains loose within the housing...is this correct or am I missing something??

 

Am also guessing I need to use some gasket sealant on the front part??

Edited February 28, 2014 by mrfirepro

[Anthony 1,003]

Do you have the older or newer style thermostat housing and takeoff? They use a different seal.

 

The older housing (which most 205's have) uses the flat O ring you mentioned actually needs two of them - one in front and one behind the 'stat. This is quite annoying as most thermostat kits only include one!

 

The newer housing is a slightly larger diameter and uses a seal which the 'stat sits inside.

 

In theory you don't need any sealant, but I always use a little RTV for good measure.

[mrfirepro 127 1 Cars]

Thanks Anthony,

 

I am guessing it's the older type as the stat sits quite snugly inside the housing.

 

That seems very logical, as service box only shows one seal, will order another one today.

 

At the risk of sounding stupid, whats RTV?

[Anthony 1,003]

The picture on Servicebox is misleading - it only shows one seal but if you look at the text detail it lists two as being required.

 

If the 'stat is a snug fit then does sound like you have the earlier housing - if it were the later one the 'stat would rattle around and be very loose without the seal fitted.

 

RTV is a silicon sealant

[mrfirepro 127 1 Cars]

Learned something new there, had totally missed the 2.

 

Will look out for that in future

[welshpug 1,658]

later ones used a single seal that wrapped around the thermostat.

[mrfirepro 127 1 Cars]

Thanks Guys,

 

Have found the old stat I took out and it is the old style, so will have to wait for another seal.

[mrfirepro 127 1 Cars]

New stat seal fitted and all is well.

 

On another issue, Have rebuilt the engine, fitted new head and fuel pump. I do remember turning the crank over manually a few times, there is no cambelt fitted yet. Could I have done any damage to any valves that may have been open? I dont remember there being any noises whilst I did this, I realise now it's a silly thing but didnt give it a second thought at the time.

[Anthony 1,003]

1.9 8v is an interference engine so if you've turned the crank with no cambelt then you could well have done damage - usually you'd feel/hear it though if the valves and pistons got intimate so if you didn't, you might well be fine.

 

(I've snapped a cambelt on one before at idle and didn't bend any valves - new belt fitted and all was fine with it again)

[mrfirepro 127 1 Cars]

Thanks Anthony, you seem to be my personal adviser on this build...keep up the good work

 

Am a little confused about the timing set up (as detailed in the haynes manual) but plan to put both pulleys in position (with dowels) and fit timing belt with the marks in the right place, which seems a little simplistic but I think thats the gist of the manual

[Anthony 1,003]

Ignore the marks on the belt as that just confuses matters IMO.

 

Just make sure that both the crank and cam pulleys are pinned with an appropriate dowel and it'll be fine.

 

Indeed, an 8v GTi is probably one of the easiest engine out there to do a cambelt on given that it's timed with dowels and has a spring loaded tensioner so that you can't easily fail to get the belt tension correct.

[mrfirepro 127 1 Cars]

Been quite busy on the project the last 4 or 5 days and have started to complete a few items

 

Front subframe now complete

 

 

Rear beam now finished

 

 

Engine coming on as well, the fifth block has now been repaired and is all fine.

 

 

For the eagle eyed, can you spot my deliberate mistake with regards the head??? (oh dear )

 

Some light porn here (thanks to Farmer)

 

 

The shell, should be finished and back with me the end of this month, the gear box this week and the remainder of the plating next week.

 

Have now started thinking about the wiring looms and am wondering what can be done with them to refurb, am open to any suggestions

 

By the end of next week I hope to have pictures of the engine complete with GB and all ancillaries.

Edited November 5, 2014 by mrfirepro

[timoth123 37 1 Cars]

Looking very bloody good mate! Keep up the good work.

You'll be over taking me in no time!!

[credowan 15 1 Cars]

Keep up the great work mate, looks like your making it into one very nice example

 

Gary

[mrfirepro 127 1 Cars]

Thanks for the kind words.

 

Tim, no chance at least you've got your shell back

[2052NV 24]

Porn all rite!

[mrfirepro 127 1 Cars]

Been a bit slow this week as haven't had much time.

 

Been looking at replacement beam plugs and found this item

 

 

The plug is a little too long so Tom Fenton is going to machine them down, they should be a fantastic replacement for the plastic item.

 

Finally put the front struts back together, decided to reuse the old parts that I have had plated rather than the new one that come with the strut kit from Pug.

 

Strut kit -

 

Finished struts -

 

 

Engine rebuild has been a bit slow as there are a lot of nuts and bolts away being plated,

 

Engine thus far, new PAS pump,alternator with refurbed dizzy from H&H

 

 

 

I hope to have my gearbox back from Spoox this week and all the plated parts from Avon, which should see me finish the engine and gearbox.

 

Started looking at my old hoses and there in not bad condition, does anyone have any method of restoring them?

 

 

Wanted the mileage to be set to zero, so thought I would have a go at this and it was amazingly easy

 

Edited November 5, 2014 by mrfirepro

[mrfirepro 127 1 Cars]

could do with some advice from you bodywork gurus on what to do with this collapsed/crushed floor pan

 

See this picture

 

Edited November 5, 2014 by mrfirepro