[Trackday_Prep] 205 8V Turbo Track Toy

[eddy_gti6 3]

Hi all i have been meaning to start a thread for a few weeks now just not had the time.

So i bought my 1st 205 gti at the end of September as a little winter project... Well i was hoping a little project at a budget but that went straight out the window within the 1st week haha.

 

The car had been sat for 4-5years unloved I bought the car from a mate who had it around 2 years and he bought it off an old bloke whos son owned it who unfortunately went away to Afghanistan and never came back. RIP!

The lad had fitted a 2.0l 8v turbo engine from a Peugeot 605. All he had done tho was fit the engine onto the mounts and that was it, no wiring, exhaust, shafts or anything else.

 

 

When i got the car home i cracked on pulling the front end off ready to lift the engine out and at 1st glance it looked in pretty mint condition with a small hole in the O/S chassis leg and a bit of rust build up under the paint on the N/S chassis leg. Got the wire brush on the grinder and went at it to get rid of all i could, things were coming out quite well.

 

 

Next up was time to pull the engine out and make a start sanding back the rest of the engine bay ready for a coat of primer. Pulled the engine out, took out the master cylinder and dropped the sub frame so i was down to a bare engine bay. Also pulled both front wings off, One of what was siliconed on very well so that was damaged when i removed it.

 

 

Next job was to tidy up the subframe, paint it and replace most parts and bushes. Superpoly race ARB bushes and wishbone bushes with Group A fork bush, New tie rods and track rods fitted

 

 

List of parts bought so far

8v turbo engine

205 GTi inlet manifold

205 GTi 1.9 cam

BakerBM engine mounts

309 wishbones

SuperPoly Race ARB & wishbone bushes

Group A fork bush

TD04 turbo

38mm external wastgate

Bailey Blow off valve

Hydraulic handbrake with AP Racing bias valve

Full braided brake lines

Superblue racing brake fluid

Turbosmart Boost gauge

AEM wideband lambda and gauge

4 padle clutch

Saxo Dash

Thats all i can think of at the minute

Next job was the engine. With it sitting for so long i was just hoping it would turn over, got a spanner on the crank and i turned over quite easy what i was very leased with. Thought i would get away with a quick build. All gaskets and belts replaced with fresh oil. Pulled to head off to find water had found its way into one of the ports further inspection i found water had found its way through one of the injector seals into the head and through an open valve.

From there i stripped the bottom end, pulled the pistons ect out and took everything down to may mates to have the engine honed and new rings and bearings fitted along with water pump and oil pump cleaned. Also my clutch plate was sized to the flywheel so going to have the fly sent off the be lightened and balanced.

 

Weekend just gone i finally gave the engine bay a paint and started getting bits put back on. Made a start stripping all the crap from inside the car too. Here is how the car is for the time being

 

[TT205 42]

Busy boy!

 

Keep it up

[Davy 18 1 Cars]

Flip! No hanging about here! Well done and keep it up!

[welshpug 1,661]

have you got an intact upper steering column shroud there going spare or are you keeping that?

 

 

did you drag that bottom end from the north sea?

[eddy_gti6 3]

Thanks lads. Hopefully getting my engine back at the weekend so I can gti it built back up.

 

Can you see a column shroud there? If so it will be in my pile of plastic bits ready for the tip so if you want it mei let me know and you can have it for postage cost.

[welshpug 1,661]

I can see the lower bit!

[eddy_gti6 3]

I will have a dig through and see what i can find? Nood good to me anyway with me running a saxo dash

[eddy_gti6 3]

Picked my nice fresh bottom end up today along with a rebuilt head that has only done around 200miles. Hopefully get the head on and all timed up tomorrow if i get a chance. Will get some pics up tomorrow when i can get a few more pics together.

[eddy_gti6 3]

Had a couple hours here and there to work on the engine. Swapped the cam over for the 1.9 GTi cam, made a start on reshaping the inlet ports and get the head on so i now have a complete engine

[A1AXX 26 2 Cars]

Mmm

Edited November 4, 2013 by A1AXX

[dcc 855]

That head does not look like it will seal on that bottom end very well. personally I would find a new head as the corrosion on that seems to go under the headgasket seal on the bore, either that or use a bottom end which has a smaller bore to move the seal away from the corrosion.

[allye 530 3 Cars]

That head does not look like it will seal on that bottom end very well.

 

I have to say I completely disagree, how can you say that looking at photos over the interwebs!

[dcc 855]

Hopefully your sight is just slightly impaired while you're down under, as it is pretty obvious as to what I mean...

 

but just for you I have outlined the clear area (using high tech mspaint) to illustrate the corrosion which covers half of the sealing surface on the cylinder head.

 

​

taking into account of the increase cylinder air pressure (due to the forced induction) - that in my eyes is a ticking time bomb

[eddy_gti6 3]

Head came off a perfectley good running engine what had only done 200mile since the head was rebuilt when someone went into the back of the lad and wrote the car off. Reason for my getting the head. Need to get it all checked and maybe reshimmed to suit the 1.9gti cam

[eddy_gti6 3]

Head came off a perfectley good running engine what had only done 200mile since the head was rebuilt when someone went into the back of the lad and wrote the car off. Reason for my getting the head. Need to get it all checked and maybe reshimmed to suit the 1.9gti cam

[welshpug 1,661]

It will certainly need re-shimming, not difficult, just time consuming.

 

Will be pretty easy if you still have the engine out, pop the plugs out to make it easy to turn over and measure away.

[eddy_gti6 3]

Engine will get getting re-shimmed towards the end of the week or early next week. I would rather just leave it for someone why nows what they are doing then i know its not my fault if it breaks haha.

Got a few more bits and bobs sorted yesterday after work. Missed a parcel too so will have to wait till Wednesday to collect it. Can only be my 440cc injectors or my U/J for the rack, if its that then means i can crack on and get the subframe back on one night. Going to try get the wishbone bushes out tonight and ball joints, thats going to be a ball ache!

Yesterday i started modifying the 205 gti inlet to suit the head, little more work needs to be done its getting there. Clutch fitted, oil filter on. getting there slowly.

[eddy_gti6 3]

Bosch 440cc injectors turned up today with a nice helmet net for inside. Got polybushs fitted into the wishbones today as well, will be dropping them in with Jim over the weekend for him to modify the ball joints into rose joints.

Sat and wrote out a little spec list so i can keep track of whats what. Think i have put down everything so far.

Fully rebuilt Peugeot 605 2.0 8v turbo Engine,

*Bores honed

*Piston Rings

*Main & Big end bearings

*Head rebuilt

*Head gasket

*Water pump

*Timing belt kit

*Head bolts

TD04 Turbo relocated above the gearbox,

205 1,9 GTi cam,

205 GTi inlet manifold,

306 S16 throttle body,

Bosch 440cc injectors,

38mm External wastgate,

Bailey Dump valve,

BakerBM Group N mounts,

Group A fork bush,

Large Front mount intercooler,

4 paddle Clutch,

13 row Mocal Oil cooler,

Full Braided brake lines,

206 Cup race car Hydraulic handbrake,

AP Racing leaver bias valve,

Superblue Racing brake fluid,

GTi180 brakes,

SuperPoly Race wishbone & ARB bushs,

Pro race 1.2s

Fully stripped interior,

Sunroof removed,

Flocked Saxo dash.

Think thats it for the time being.

[eddy_gti6 3]

These early nights are no good! Need to get some lighting sorted out so i can still work on the car when i get in from work. Got the subframe on and made a start fitting the front brake lines. Next thing i know its pitch black and i cant see a thing!

[Liquid_106 97 1 Cars]

Nice project, but one question: why have you chosen to fit a hydraulic handbrake?

[eddy_gti6 3]

Was cheap and it had the AP racing bias on it so thought I would Just fit the full lot, also can still run the cable as well so ok for mot and road use

[dcc 855]

erm those brake lines are going to be right next to your hair dryer. Also did you get the head sorted?

[eddy_gti6 3]

Head is fine. Had it checked by by JBM. My turbo is being relocated to above my gearbox and manifold pipe will be heat wrapped too. Brake lines are not fitted properly yet so I can move them around once I get the engine in and find whats going where.

[eddy_gti6 3]

Dropped my wishbones off tonight to have the ball joints replaced by rose joints, also while i was down at jims i had him steam clean my gearbox while i rounded off the ports on my inlet. Got the box home and give it a lick of paint so its now nice and clean to match my engine Also picked up a 205 GTi fuel rail, painted that and got it fitted with my Bosch 440cc injectors.

Picking up a new thrust bearing in the morning, fitting the box to the engine and then thats the engine ready to go back in Things are moving quite well at the minute.

[eddy_gti6 3]

Cleared out all the crap inside the car and pulled the rest of the trim out so i could trail fit the saxo dash today. Its not too far out, a little trimming in the corners by the windscreen and it should go in nicely, Bulkhead mounting points are about 10mm too wide what shoudnt take much to modify them to fit through the holes. Once i get the engine back in on its mounts i will pull the windscreen out to allow my to access the dash from the outside so i know what needs cutting ect...