[Car_Restoration] My 1989 205 1.9 Gti Restoration Project

[mrfirepro 127 1 Cars]

Pics to follow, but just completed the front struts and fitted them to the car.

 

Now I'm in a position to test the brakes and check for leaks, the whole system is virtually new (reconditioned calipers) and a new master cylinder.

 

What is the best Brake fluid to use (make and type please) (standard road use, no track use)?

 

I will have a read of the Haynes manual but is it as simple as...

 

fill resevoir

open bleed nippple

pump brake pedal until fluid runs out clear

 

then repeat for each caliper?

 

Is this all possible without the engine running?

 

thanks

[jackherer 543]

Yes that's pretty much what the haynes says and it gives you the order to bleed the calipers in too. I'd get a pressure bleeder like a gunsons ez bleed though, it makes it much easier and it's kinder on the master cylinder (although that isn't much of an issue for you as yours is new.)

 

And you don't need the engine running for any method of brake bleeding but sometimes you wont notice a spongy pedal until the servo is working so it might need another bleed when you get it running.

[mrfirepro 127 1 Cars]

Thanks,

 

Been reading lots about brake fluid, and am more confused than when I started(Dot4,5,5.1 ...wet & dry boiling points...Silicone based etc etc...)

 

I guess standard DOT4, good well known brand....Y/N? (perhaps Motul?)

 

I have also read that some of the colored fluids stain the reservoir, any experience of this as I have a new reservoir and dont want it stained.

Edited June 23, 2014 by mrfirepro

[jackherer 543]

Yes, standard DOT 4 will be fine. I've never heard of coloured fluids staining reservoirs but it wouldn't surprise me.

 

It can be useful to alternate between coloured and clear fluids each time you change it, then you know you've fully bled a line when the fluid changes colour.

[mrfirepro 127 1 Cars]

All the pictures from this update are here

 

http://s1238.photobucket.com/user/mrfirepro/library/205%20projects/23%20June%2014

 

Been a mixed couple of weeks with some decent progress and some massive backward steps.

 

The good news is that the new engine fired up first time and ran for about 20 seconds before I switched it off (as no cooling installed yet)

 

However the euphoria was short lived as when I tried to start it again the next day it was stuck solid, finally decided to take the sump off to find some sand in the oil...... I instantly remembered I had sand blasted the oil pipes between the oil inlet and the cooler and never cleaned then out, hence the sand. I feel highly embarrassed and stupid and decided I would not mention it here, however when it come down to the story of my build it wouldn't have been accurate to leave out this part.

 

Anyway on a positive note, engine now rebuilt and spotlessly clean, liners, rings and pistons were unmarked, new shells, crank, oil seals, stripped oil pump, full head strip and usual gaskets etc etc....

 

 

Found a new electroplating company, and hopefully this will be the last batch.

 

 

this is the company, very pleased with, quality, price and timescale

 

 

Finally had all the parts to rebuild the front struts and install calipers

 

 

and here they are installed on the car

 

 

 

You know sometime your really chuffed with the smallest detail well here's mine

 

 

enough of my indulgance..

 

also got the wheels back from the powder coater and noticed there are 3 speed line and 2 SMR (are there any difference between them?)

 

 

and the spare wheel cage

 

 

and finally to end this update, is this just me or are others this tidy......

 

 

 

Thanks for all the support and kind word so far, unfortunately it won't see Pugfest this year.

[unariciflocos 49 1 Cars]

SMRs are quite a bit heavier, almost 1 kg from what I can recall.

 

I wouldn't dare put that thing on the road once it's finished. Don't think it looked as good when it was new.

[mrfirepro 127 1 Cars]

God No...I wont be driving it, it may get dirty... :lol:

[mrfirepro 127 1 Cars]

All the pictures from this update are here

 

http://s1238.photobucket.com/user/mrfirepro/slideshow/205%20projects/8%20july%2014

 

The last couple of weeks have been a bit of a mixed bag finally decided to renew any parts of the engine that have been subjected to the sand so this is on going. So have been getting on with some other items whilst I source and prepare a new engine.

 

Farmer managed to find me some Brand New OE sunroof trim, unfortunately they were in white

 

 

Peugeot do a special grey plastic trim paint

 

 

 

It remains to be seen if they can survive typical UK weather, but quite pleased with the finish (Others have used this to make black bumpers grey)

 

 

Also bought the OEM BBM rubber water hoses and my first impression is that they are really good and are very close to the OE finish.

 

 

Have fitted rear bumper

 

 

Exhaust

 

 

Front Lights

 

 

Also been experimenting with this stuff

 

 

Quite pleased with the results for the bonnet panel and radiator housing/cover

 

 

 

also decided to recondition the original jack and finally assemble the front driving lamps

 

 

and finally late one night, in the garage I was joined by a little helper.....

 

 

Didn't half frighten the SH1T out of me as it hit me square on in the back of the neck (it's over an inch across)

[Juttie205 123 2 Cars]

the plating company you used is close to me what was the price for all the plating you had done.

[mrfirepro 127 1 Cars]

Timoth123 gave me the heads up on this company, I think he had a bit more done than me and it was about £30

[mrfirepro 127 1 Cars]

All pictures from this update are here.

 

http://s1238.photobucket.com/user/mrfirepro/slideshow/205%20projects/20%20july%2014

 

started trying to get the sunroof finished, Farmer came up trumps again and managed to find me some OE tape for the sunroof

 

 

considering the age of the tape it was in excellent condition and went on a breeze

 

 

Finally got to use some more shiney shiney bits..

 

 

 

 

Unfortunately euphoria was short lived when I realised I didn't have any of the seven bolts that go across and behind the sunroof

 

 

Got on the Farmer hot line, and as by magic some will be with me next week

 

Also fitted new window rubber runners in both doors...what a pig of a job, if anyone else has to do this job, put the rubbers in the runners first, fit runners, then fit the rubbers to the door, if only I'd done this to start with

 

 

 

fitted my rebuilt wiper assembly

 

 

 

and finally fitted a few bits and bobs from Pug

 

Spoiler fixings

 

 

 

Jack fixings

 

 

 

Tailgate board fixings

 

 

 

and bodywork grommets..

 

 

Scuttle fitted

 

 

Hopefully should have the block and head back from being vapour blasted this week and can go about getting the engine rebuilt....

[Juttie205 123 2 Cars]

Got any sunroof tape left you want to sell?

[GLPoomobile 958]

When you fitted the wiper assembly back on, did you remember to get the spindles on the correct sides? As in they are subtley different lengths so that the passenger arm sweeps a wider arc.

[mrfirepro 127 1 Cars]

When you fitted the wiper assembly back on, did you remember to get the spindles on the correct sides? As in they are subtley different lengths so that the passenger arm sweeps a wider arc.

your a star ..didn't notice that. Bit of a problem though, had about six of these and selected the best two for plating, what are the chances I've plated two of the right ones

 

So there will be a longer one and a shorter one, the longer one is the passenger side?

 

Going to measure them now...

[mrfirepro 127 1 Cars]

what are the chances of that, drivers side 80mm, passengers side 85mm (passenger side has a hole on the middle, I guess for identification), think I'm going to play the lottery this week......

 

not only plated the right two out of six (5 actually as I broke 1 ) then got them the right way round, what are the odds of that....answers on a post card..

Edited July 20, 2014 by mrfirepro

[Juttie205 123 2 Cars]

The sunroof bolts you have used did you put in with the fibre washer on or did you leave off only ask as would get mine plated but would have to destroy fibre washers.

[timoth123 37 1 Cars]

Awesome work as ever paul, looking very good!

 

 

 

Juttie, You should use new fiber washers, when you use them first they compress, used again and you might not get as good a seal as the first time. A leaky sunroof after all this work is the last thing you want. I just ordered some M4 fiber washers from eBay. Job done.

[Juttie205 123 2 Cars]

Thats great thats all I needed to hear thanks

[jackherer 543]

Don't buy over priced ones that say 205 GTI in the listing, they should only be a few pence.

[Juttie205 123 2 Cars]

No worries have found some for pence really making a start on stockpiling parts ready for day car goes back together.

[mrfirepro 127 1 Cars]

Back to the wiper arms, been thinking about this and I thought the longer one (with the hole in) should be on the passenger side, but a shorter arm would provide a wider arc......

 

could someone have a look at their car and tell me which side the spindle with the hole is on. (expect it to be drivers side, the opposite way to the way I have fitted them)

 

thanks

[mrfirepro 127 1 Cars]

Time for another update,

 

All the photos in this update are here..

 

http://s1238.photobucket.com/user/mrfirepro/slideshow/205%20projects/4%20Aug%2014

 

Finally managed to find a block without any corrosion, I dont know how this has survived but it looks like brand new internally,

 

 

strangely there is more than the usual amount of corrosion on the outside!!!!

 

 

Had the block, head, and gearbox casings vapor blaster by TSR in Sevenoaks, which I then painted with Hycote engine enamel before a 2 hour bake at 250 degress

 

 

 

Refurbed the car jack, Tom Fenton kindly made a replacement pin (Thanks Tom) as the original has to be destroyed to disassemble the jack, am pleased with the results.

 

 

More plating, I hope this is the last batch (Electroplate (UK) have been brilliant)

 

 

Quite pleased with this mod, used OEM connectors with new speakers

 

 

Finally got around to using the soundproofing/insulation that I bought from Cloverdale...this stuff

 

http://www.ebay.co.uk/itm/Car-underfelt-soundproofing-sound-deadening-underlay-LB-/180579062315?pt=UK_CarsParts_Vehicles_CarParts_SM&hash=item2a0b59d22b

 

As it is about half the thickness of the original I decided to use two layers that I was going to glue together, finally decided not to glue them as the glue may go hard and brittle after a few years.

 

took original for both front and back, going to do the same with the boot at some stage in the future.

 

 

Marked outline

 

 

cut out

 

 

did this twice, this is the end result

 

 

Both front and back

 

 

And finally a bit of help..

 

After dismantling my gear box I found this and have no idea where it came from, I have assembled the box and all seems fine, am hoping that someone can put my mind at rest as I'm not 100% sure it's from the gear box. (it's very solid and impossible to bend, some sort of hardened or sprung steel)

 

 

I hope to have all my engine components back from the machine shop by the end of next week, so the engine can be put back in. Also hope to complete the sunroof install this week. (just waiting for some sunroof bolts from Farmer, who performed miracles to find them for me)

 

that's all for now, thanks for dropping by...

Edited August 4, 2014 by mrfirepro

[welshpug 1,658]

looks like an outer CV retaining clip.

[james_pug 26 1 Cars]

How many meters of the carpet underlay did you use? The cars looking amazing!

[mrfirepro 127 1 Cars]

James,

 

Thanks

 

I ordered 3m originally but that only did the two rear ones and one front, I ordered another 3m to do the other front one and some spare to do the boot insulation, but I cant find the boot insulation at the moment so was guessing a bit.

 

If you want to do them all at double thickness I think you will need 6m, there is a bit of waste as the front mat is wider than 1.37m so has to be cut length ways.

 

Also in hindsight I should have held out and got a really sharp pair of scissors, as the edges could have looked a lot neater and the radiuses (if that a word) a lot sharper

Edited August 10, 2014 by mrfirepro