Phase 2 1.9 Restoration

[Andy_C 50]

I've owned this car for a few years but it's sat unloved in my garage since the end of 2012.

 

I previously poured a lot of money into a pretty tidy P1.5 Mi16 and selling it was a mistake.

 

This car has some forum history as it was owned recently by Anthony, Feb before that and another member previously. It was at one point a full SBC GTi-S specification car, not to mention very tidy indeed.

 

Plans? Well for starters I'm going to build it the way I want it to look and feel. I'm also not going to fret if it gets dirty - my anal car cleaning days are (almost...) behind me.

 

What it needs;

1. Repainting - body, door & boot shuts and engine bay; sticking with Sorrento.

2. Front seats to be retrimmed and I've had quotes from £350 a seat upwards so far.

3. Engine (will be removed for paintwork) to be initially serviced, cambelt and water pump replaced and cleaning/painting.

4. Replacement of any damaged trim or fittings and all visible bolts, scews etc. are being plated or replaced - can't stand fresh paint with crappy old screws.

5. Some hoses replaced with braided stainless because I like pretty stuff.

6. Wheel refurb - straight silver.

 

Rear beam was done by Anthony before I bought the car - I will no doubt try andf persuade him to give it a once over as the car hasn't moved for over 2 years!

Where are we at?

 

As at last night the front end is stripped, rear bumper bolts soaking in WD40(!) and interior gutted. Sunroof removed, mirrors removed and door seals off.

 

Day 1 (last weekend) was initial stripdown.

 

 

 

Edited September 19, 2014 by Andy_C

[Andy_C 50]

Yesterday we gutted the interior and I'm still bloody chuffed that the internal floor is as photographed - like new. A couple of minor surface patches which will be sanded and primed.

 

The car lived in a hot and dry climate for some time which, coupled with careful previous ownership, has certainly paid off now.

 

 

 

 

I should add that neither me or my partner in this project are mechanics; I can do a basic oil change but that's it. I have a reasonable Halford Pro tool kit but again that's it. We're using Haynes and some knowledge slowly creeping back from when I did work on my last one a few years back. This will be a fun and steep learning curve I reckon.

Edited September 19, 2014 by Andy_C

[Andy_C 50]

There is also a FB page for more regular updates.

 

Search for "Pug Restoration Project".

 

I'll summarise on here rather than photos of every part falling off or being hit with a hammer etc.

[Anthony 1,003]

Rear beam was done by Anthony before I bought the car - I will no doubt try andf persuade him to give it a once over as the car hasn't moved for over 2 years!

No worries, sure we can work something out when the time comes Andy, especially as presumably you're going to want the ride height changed at the same time to match whatever springs you decide to go for on the front

[Andy_C 50]

Thanks. Beam will be removed at some point for inspection and whatever's needs to the underbody so that's probably a sensible time. Will holler as and when.

[Andy_C 50]

Latest updates.

 

Interior now pretty much stripped completely and any surface corrosion treated and primed.

 

Back bumper fought me all the way but separated from valance.

 

I've started stripping out the engine bay and found what I hope is the only serious corrosion; luckily we know a good welder! Behind the passenger side headlight; luckily it doesnt appear to have gone any further back into the inner wing or chassis leg but once the battery is out we'll have a proper poke around.

 

We've also decided that if the budget permits we're going to find and fit some SL434's

 

 

 

 

Edited September 29, 2014 by Andy_C

[Andy_C 50]

We now have the radiator and fan cowling out.

 

New rad added to the shopping list too!

 

Some nice shiny bits have arrived courtesy of Mr Fenton and a replacement gearlever gaitor from the bay.

 

Up on axle stands next week for exhaust and beam removal and heading towards "engine oot" point.

 

 

 

 

 

 

[Andy_C 50]

Overdue update.

I've built up a large pile of new / NOS parts to be refitted once the car's painted but in the meantime yesterday saw a major part of the dismantling process.

Rob (2-pugs) came over and we removed the engine & gearbox. Working with Rob is an absolute pleasure as he enjoys immersing himself in removing parts carefully; his knowledge of 205's is a big bonus too.

For my part I got to use some big hammers so I'm happy.

The borrowed lift proved brilliant as we did this without using a crane and used the car's weight to tilt it back & forth.

The engine is now on a stand awaiting further stripping and detailing and the gearbox needs only a lick of paint.

The only damage is to the PAS pump bracket which will need replacing - it was broken before removal as is the bracket holding on the PAS pulley.

Here's where we got to;

 

 

 

[Andy_C 50]

 

 

Next up is further stripdown of the engine bay, removing all hoses, brake lines, M/C and servo, expansion tank so the bay can be cleaned and rubbed down,

The driveshafts and hubs will be stripped and painted; all new front suspension is coming so the car will roll on the old stuff for now.

Exhaust to be removed and repainted and fuel tank to be dropped for cleaning, new fuel lines and check for any corrosion above it (usual rot spot on these).

Busy winter ahead...

[mrfirepro 127 1 Cars]

Nice work, keep the updates coming,

 

I've got a spare PAS bracket that's been plated if you want one (PM me your address)

[Andy_C 50]

Thank you mate. Will PM you - I'll cover postage at least!

[Andy_C 50]

Managed to get some more hours in on this and had a visit from the painter (more on that further down).

 

I also went to the NEC on Friday and picked up some Kunifer piping for the brake pipes as they're all being replaced. Stopped by the PSCUK stand, renewed my membership and drew some inspiration from the handful of very nice 205's displayed on the stand.

 

I've started to do some stuff which I'm good at - painting, polishing and general detailing work.

 

Firstly the fuel regulator was removed from the fuel rail. The injectors will be cleaned separately and the rail repainted or plated.

Lots of polish, wire wool and elbow grease later and quite a transformation!

 

 

 

I then set about the inlet manifold - several coats of VHT later and good as new.

 

 

The driveshafts need checking for any small tears in the boots as there's a lot of oil on the O/S wishbone, hub and caliper. They'll then be rubbed down and painted VHT black.

 

I removed and polished the front heatshield - still some small marks but I'm not throwing away perfectly good cheap thin French tin lol.

 

 

 

[Andy_C 50]

And further progress on the bay - coolant tank removed with last hoses and loom removal started. Battery tray has joined a growing pile of parts to be sent for blasting and coating and the rust beneath is thankfully superficial.

 

 

And painting; Craig came to see me Thursday night and we agreed on a price to include all welding and repair work needed (specifically the O/S/F wing and roof) with me priming the bay and arches. I will flat & polish to help with costs; very happy with the price - just a lot of work between now and it going to him!

 

Next is removal of calipers for stripping down before adding to blasting pile and work starting on the hubs and wishbones. Master cylinder and servo also need to come out, as does fuel filter (which is being relocated to O/S inner wing behind headlight).

[King Pug 0]

Nice work mate looks good so far! keep it up!

[Andy_C 50]

Sorry chaps, neglected this thread and rather a lot of progress.

 

The car's now fully stripped, engine bay primed and only a few more bits to do before she's off to the painter, from where she'll emerge wearing a coat of laser green paint.

 

In the meantime, I've cleaned, primed and painted the subframe and rack and reassembled (waiting for ARB clamps to dry before reattaching that). Old struts will then be put back, allowing car to roll.

 

Beam dropped and a free replacement will be attached to allow the car to move.

 

Loads of new/NOS parts piled up for refitting when the car's painted.

 

While the car's away I'll be cleaning up the engine & box and giving it a proper service, cambelt and water pump etc.

 

Beam will be checked and painted.

 

Few pictures of progress to date.

 

 

 

 

 

 

[Andy_C 50]

And a few more.

 

 

 

[johnboy1984 5 1 Cars]

Love the progress on this... This is exactly how I intend to go with mine... Full engine bay and underside spruce up and then repaint the whole car... I too have limited mechanical knowledge and I'm a bit concerned about taking on such a big task, but I'll photograph everything before removal so that I know which way it has to go back... Awesome stuff mate

[Andy_C 50]

Rather a big hit on this as my partner's had to pull out for very good reasons (not for him sadly) so at something of a crossroads as I need to find an un-budgeted £2k to paint it. Bit of a bugger but I'll persevere. Painter will halve the cost if I do all the prep and priming and to be fair he's offered as much help and advice as I need.

 

Another new skill to try and master!!

Edited March 18, 2015 by Andy_C