[Car_Restoration] 1.9 Restoration

[Darrens205GTI 10]

Great thread Tim,

 

Between you and Paul you are giving me loads of inspiration to get mine out of the Body shop and work on it again. Fingers crossed our house move finally happens in the next 3 weeks then the car can come home

 

Darren

[Miles 331 1 Cars]

Soda blasting for the block works wonders, Not cheap thou

[andy-mac 4]

doing a great job here colour looks great

[calvinhorse 870]

Great project

[timoth123 37 1 Cars]

Thanks guys, appreciate it!!

[mrfirepro 127 1 Cars]

Tim,

 

If you get much more out that block you'll be able to build a sand castle

 

I bought another block (that was knackered as well) and stripped it down the liners are in good nick if you want them, just pay postage. Can send pics if interested. I also have a spare set of seal if you want.

[timoth123 37 1 Cars]

Tim,

 

If you get much more out that block you'll be able to build a sand castle

 

I bought another block (that was knackered as well) and stripped it down the liners are in good nick if you want them, just pay postage. Can send pics if interested. I also have a spare set of seal if you want.

Ha! Tell me about it mate. I was abit surprised to find that much in there.

 

I appreciate the offer mate, but I've got some brand new ones coming along with new seals. Thanks though!

 

Hows your engine coming on?

[timoth123 37 1 Cars]

Ok, progressed a little bit more over the last week.

 

Finally got all of the looms in and the main upper dash (no pics of this). Waiting for the screen fitters to turn up to put the front windscreen and tailgate glass in.

 

 

 

Got lots of nice powder coating back too, including the bits I got from Tom Fenton! Still waiting for the zinc players to get that stuff to me, been ages now!

 

 

Anyone have any idea what this bracket is? I've no clue!

 

Got the doors all finished with locks handles (plasticare makes a big difference)

 

 

This was the clutch cable fitted..

 

Obviously the wrong one has been fitted at some point,

I need one that will fit this pedal box

 

Also got the freshly powder coated front hubs sorted, new bearings and outer hubs fitted.

 

And the fuel pipes and new clips fitted ready for the tank to go on.

 

Also heard back today that the engine parts are on the way back to me, should get them tomorrow.

 

Any one got one of these crank seal brackets? Someone has butchered the one on mine!!

[welshpug 1,661]

That's the earlier BE1 pedal box with a bayonet type fitting, you can make the hole round to take the later ones if you need to.

[hoody_g 4]

Anyone have any idea what this bracket is? I've no clue!

 

 

It fits between the inlet manifold and the block. Don't have a pic to hand showing it in position.

[mrfirepro 127 1 Cars]

Tim,

 

I've got a crank seal bracket you can have.

 

Will be bringing my bumpers up so will drop it in.

 

Are you in any rush?

 

Paul

[timoth123 37 1 Cars]

Paul, you have a PM!

 

And thank you hoody_g, I never would remember that!

 

Merion, are the old type still available? (I've not forgot about those wings too)

[welshpug 1,661]

yup, usually off the shelf from any firstline dealers I know for certain, and Motaquip IIRC.

 

Depends which gearbox and clutch pedal you plan on using too, BE1 or 3 clutch arm, and pre or post 90 pedal.

[Tom Fenton 1,542]

I was looking at the pictures wondering if they were bits Ihad made, they look good in black especially the bumper corner bars, you would not know the difference from the originals.

 

Hubs wise, a bit late now but I would have pressed the bearings out completely before powdercoating, thats how I did my hubs.

[timoth123 37 1 Cars]

Ah brilliant, cheers Merion.

 

The powder coasters said the same Tom. But I didn't want the bearing faces touched. They came out easy enough though, circlip was a little tight but nothing a heavy duty set of circlip pliers couldn't handle. And yeh, your stuff came out lovely! I particularly like the air box bracket. They look factory! Good work on them!

[timoth123 37 1 Cars]

Quick pic of the hubs and fuel lines!!

 

Also got the front and rear glass fitted

 

Edited February 7, 2014 by timoth123

[timoth123 37 1 Cars]

Ok, little bit of an update.

 

Got the front end together so it can be moved around easier. Quite handy as I'm moving to a new workshop this week.

 

Looks like a bloody 4x4 now though

 

I noticed when fitting the rear wheels that the replacement wheel nuts I got hold of were the wrong type. The original ones were stripped beyond use, I need tapered ones, the replacements were flat. Anyone got a set?

 

Is it just speed lines that are tapered or is it an early late thing?

[welshpug 1,661]

that is the correct wheel bolt for that wheel.

[Slo 283 1 Cars]

Looks like some kind of washer is stuck in the recess from an old bolt. Tapered bolts are usually for steel wheels to locate them dead centre.

[welshpug 1,661]

just looks like its slightly disformed from having tapered bolts used on it in error.

[timoth123 37 1 Cars]

Ah, bugger!!

 

Well at least I've got the right wheel bolts.

There's no washer stuck in there. Like Merion says, they must be deformed.

Hopefully they'll be ok once they're refurbed.

[mrfirepro 127 1 Cars]

didn't know they did a 4x4 205 really should add some big bumpers to give it that complete 4x4 look

[pugsley 0]

Very nice, would love to bareshell mine one day!

 

Nice work!

[timoth123 37 1 Cars]

Ha! And maybe a set of bull bars and chunky tyres ey paul?!

[timoth123 37 1 Cars]

Minor update as this week as I've had to move into a different workshop.

 

Decided to tackle the engine now that I've got a replacement block. Mine had the same issue as mrfirepro's first block, liner seal seat was corroded. Bugger. Still, after abit of searching spoox come up trumps with a very good condition block and only charged me 50 quid. And to make things even better paul, aka mrfirepro was kind enough to pick it up and drop it to my door. Good man!

 

Ok, so I cleaned the engine completely of all dirt, grease and oil. Then got it in a make sift spray bay and spayed some hycote engine enamel on all the bits. Finish looked awesome......

 

But you have to bake it at at least 220degrees for 90 mins. I was a bit concerned about what the heat would do to the finish. Still better it happens now rather than on the car.

 

Enter this bad boy

The metal bashers on camp use it to heat treat various metals. Ideal for fitting everything in there in a oner.

 

So after 2 and half hours at 230 degrees. (I went for longer just incase) this is what I was met with on opening the oven door

 

The finish is fantastic, really very impressed. How it stands upto real life usage remains to be seen.

 

 

So on with the rebuild, got all the new main shells in and checked the running clearance with plastigauge, all good there. Fitted the new liners and checked protrusion, all good there too!! Just need to check the running clearance of the big ends and we'll have some pistons fitted too!

 

One question though, I'm using bother the Haines manual and a rebuild guide off the bay. I'm getting conflicting instructions when it comes to the large crank seal. Haines says drift it in to the same depth as the one you removed (how do you know the one fitted was right?), other manual says drift it in fully.

Anyone any idea what's best? Hopefully the pros will be along shortly.

 

 

Also been cleaning the carpeted bits. Center console and drivers foot well were absolutely hanging, but some interior cleaner and some soapy water it made a huge difference. The pics really don't show just how much cleaner and fresher they look now.

 

Dirty side

 

Clean side

 

Dirty carpet

 

Clean carpet

 

 

Anyway, hopefully have some more interior bits fitted this week! Just holding out to see if those repro rear quarter seals come to light. Damn I'd be happy if they did!!

Edited March 6, 2014 by timoth123