My 1991 Peugeot 205 Gti Long Term Project

[Rostle1984 2 1 Cars]

Well after searching for quite a substantial time I came across this nearly a year ago, Whilst she look pretty clean (to be fair it is for 23 years old) it does need some TLC. But I'am the right guy for this.

so this will be an on going project not to be done asap just as and when as I plan never to sell it like the previous one I let go 4 years ago.

This car will make the odd appearance at shows, but more importantly I hope it turns some heads.

so here goes.

The Cars history from Day one, Owned by 7 people in its life, seems a few but each and every one has documented every part of its life Now to me this means everything, Infact to complete the history I bought the original Sales brochure for £17 :shock:

I have every MOT certificate, I have every tax disc but 1992. and every single receipt for work and services etc and some history a previous owner had documented. More importantly I have the orginal Book Pack that came with the car fully stamped & the original Lion AA Guide.
The gti by Rostle84, on Flickr

The car has covered a Genuine 95k Approx since new & is backed up by the national Mileage register and HPI
The gti by Rostle84, on Flickr

The interior of the car is completely standard And this is how it left the factory apart from the radio has been changed to a pioneer unit, The Mats never came with this car However these are Genuine GTI mats from Peugeot which came with the limited edition 1.9's back in the day., Kindly Given to me on long term loan from My Mother a previous gti owner in 1990.
The gti by Rostle84, on Flickr

The gti by Rostle84, on Flickr

The Paint work is finished In Sorrento Green and complimented with the Original Speedline alloys, this will be getting re painted at some point due to age its suffered a fe knocks in its time plus some bubling in the paint means it needs doing
The gti by Rostle84, on Flickr

The engine on the car is completely standard Apart from a couple of blue hoses which wont be staying on the car. 130bhp XU series engine with everything as it left the factory, Missing at present is the Jack.
The gti by Rostle84, on Flickr

Still has the original speedline alloy spare with Michelin tyre fitted to it, bumper needs new Irons fitted to secure it further & the tail gate badges need refreshed
The gti by Rostle84, on Flickr
The gti by Rostle84, on Flickr

The Iconic 1.9 badges speak volumes
The gti by Rostle84, on Flickr
The gti by Rostle84, on Flickr

General Body condition overall isn't too bad, some corrosion to deal with but that's easy sorted
The gti by Rostle84, on Flickr

The gti by Rostle84, on Flickr

Meets the rest of the fleet of vehicles. Looks well at home
The gti by Rostle84, on Flickr

The gti by Rostle84, on Flickr
The gti by Rostle84, on Flickr
The gti by Rostle84, on Flickr

[Rostle1984 2 1 Cars]

Time to go play in the garage.

This is what I had presented to me once I'd removed the front end of the car. 23 years of use has taken its told or its had a minor bump at some point and a crap repair.

Cutting out the tin worm on project gti by Rostle84, on Flickr

Passenger side headlamp surround pretty much the same.

Cutting out the tin worm on project gti by Rostle84, on Flickr

So with both front wings removed and the top section of the headlamp surrounds removed this is what was hiding behind it
Cutting out the tin worm on project gti by Rostle84, on Flickr

So I took the plunge and ordered some new panels last week, I had to go down the route of pattern parts for it. I'm pleased I got two new front wings as this is what was lurking under the passenger one

Cutting out the tin worm on project gti by Rostle84, on Flickr

The inner wings on both sides were remarkably spotless which was a huge relief

Cutting out the tin worm on project gti by Rostle84, on Flickr

As to can see easily on the drivers inner section where the jack sits its literally holed its that rotted through, But never fear that's nothing major and I will crack on with the next bit.

Cutting out the tin worm on project gti by Rostle84, on Flickr

Washer bottle and battery removed from the passenger side, Looks better than the drivers but I always say the only way to deal with rust is to cut it out back to good metal and replace.

Cutting out the tin worm on project gti by Rostle84, on Flickr

First piece on that side cut out, the bottom section I wasn't happy with so cut that out later too.

Cutting out the tin worm on project gti by Rostle84, on Flickr

As above but the corner piece was cut out too as It was starting to rot. the rest is minor surface rust which will mop off with a wire wheel attachment and sort out later.

Cutting out the tin worm on project gti by Rostle84, on Flickr

as per the otherside, the only way was to cut the whole lot back to good metal

Cutting out the tin worm on project gti by Rostle84, on Flickr

as you'll agree, they sections removed are pretty much buggered, These will be used to make up copys on new zinc coated metal.

Cutting out the tin worm on project gti by Rostle84, on Flickr

Both sides cut out, photo taken before the section removed on the passenger inner section

Cutting out the tin worm on project gti by Rostle84, on Flickr

Well heres the old section ready for the scrap vs the new galavnised front section.

Cutting out the tin worm on project gti by Rostle84, on Flickr

Quick offer up of the new panel, with it being a pattern part and not an original I thought it may be a bit out in places, But its pretty sweet.

Cutting out the tin worm on project gti by Rostle84, on Flickr

[Rostle1984 2 1 Cars]

So I bought a brand new Mig Welder and Big Hobbyweld Tri mix cylinder, no messing around with disposable ones.

So armed with new sheets of steel My dewalt Grinder and a box of grinding and cutting discs and a few Panel beating tools Kindly Loaned from martin (Cheers Mate) I set too with the repairs to the boot floor section.

Heres what I'm talking about. Rotton and holed, Most common areas, Plus two holes in the center.

20140915_183609 by Rostle84, on Flickr

Only a small Hole but the rust where it joins the rear arch was going to come through at some point so that was cut out too.
20140915_183619 by Rostle84, on Flickr

First piece in the middle of the floor removed and a plate made up, Weld magnets are ace for this no more trying to juggle metal.

20141108_151503 by Rostle84, on Flickr

20141108_151511 by Rostle84, on Flickr

20141108_155658 by Rostle84, on Flickr

First section ground back and primed with Acid etch

20141108_181643 by Rostle84, on Flickr

Second section ground back and primed

20141108_182612 by Rostle84, on Flickr

Corner piece all cut back to solid metal and a dummy plate cut but needing trimmed is offered up
20141108_153128 by Rostle84, on Flickr

Welded in and drilled down to the chassis and welded through to give rigidity

20141108_155651 by Rostle84, on Flickr

Not bad, slight overlap no huge lumps uniform in size, I think that will suffice.

20141108_161015 by Rostle84, on Flickr

all ground back and wire brushed, Bit shiney really.

20141108_185000 by Rostle84, on Flickr

Now etch primed up

20141108_185333 by Rostle84, on Flickr

That's one side down, One to go

20141108_185438 by Rostle84, on Flickr

The other side cut out plated ground and primed.

20141108_185450 by Rostle84, on Flickr

20141108_183633 by Rostle84, on Flickr

That's all for today, Next instalment is Inner wing repair to outter wing plates and bumper mounts.

[Rostle1984 2 1 Cars]

Front panel fitted and clamped into place ready to be welded on Bonnet fitted and catch setup to front panel. Both front wings fitted. Osf needed manipulated into place to sit right as the forming wasn't quite right plus had been bent a little at some point compared to the nsf. Doesn't look much of an update but I can assure you it took a while to achieve.

10614330_10155361569285157_6796788906958143391_n by Rob Ostle, on Flickr

10410251_10155361568930157_5900792382189939412_n by Rob Ostle, on Flickr

10408763_10155361569880157_4417649481004714394_n by Rob Ostle, on Flickr

11009199_10155361569045157_2012998812337184129_n by Rob Ostle, on Flickr

11054329_10155361570150157_3889296478109985702_n by Rob Ostle, on Flickr

Small progress report today on Project GTI. The fiddly bits that everyone hates doing. Inner wing sections were the sunroof drains run we're literally rotted away to nothing. This means the rear bumper has no corner support (bumper supports to make at a later date). Anyhow cut the inner arches away to good metal with the plasma cutter and the took the shape to a new sheet of steel and cut to the exact shape enabling me to butt weld in the new steel making it sit flush. These bits will never be seen but I like things done right. After welding those in there was the little task of making a new rear tow eye. This was literally hanging on by a wing and a prayer. So cut that off and the supposed support brackets to the rear body. I then set about fabricating a new tow eye using the original pressed loop. Easy enough but took a while to shape etc. once done offered it to the car were it became apparent I needed to add a support for extra strength. I then welded a small section over the top then cut down and welded. 90 Deb section so it would weld onto the chassis rail. Easy enough. Job done. Etch primed and painted. Next update coming soon.

11870728_10156049758745157_6664872463790803824_n by Rob Ostle, on Flickr

11222586_10156049760750157_8025187924315525632_n by Rob Ostle, on Flickr

11811400_10156049759050157_1695018312504654539_n by Rob Ostle, on Flickr

11846700_10156049761300157_4194844679160571718_n by Rob Ostle, on Flickr

11825724_10156049761615157_2955714174761792284_n by Rob Ostle, on Flickr

11218924_10156049762075157_6102272465625057003_n by Rob Ostle, on Flickr

11825230_10156049763175157_8591319009955633347_n by Rob Ostle, on Flickr

[arbor 2]

Some nice work there, keep the updates coming.

[welshpug 1,657]

indeed, very good, surprising what lurks under a nice looking car too!

 

What's the subaru?

[Rostle1984 2 1 Cars]

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indeed, very good, surprising what lurks under a nice looking car too!

 

What's the subaru?

 

Your quite right about what lurks under the car.

Fuel tank is ready to drop out after a bit of persistence with the long bolts at the rear of the tank. Couple of holes under the rear seats which need seen too Plus looking from under the car in front of the tank it looks quite nasty under there. I spotted a few threads before I was able to register where you had kindly commented about taking the fuel tank out etc

 

Also the front outriggers had to be cut off as I'd guess its been jacked up in the wrong place and crushed the metal leading to the tin worm setting in.

 

Enjoying the challenge that's for sure.

 

 

The Subaru was my old daily driver, Built the engine and tinkered with it a touch, 460bhp 500ft/lbs it could certainly shift on. Sadly been replaced as I'd had enough of it.

 

Heres a couple of pictures of them both

 

 

 

 

[Telf 224 2 Cars]

Top Work.

 

After picking up my second Pug Ive realized I need to buy a welder - so I have! Its posts like this that have made me think I can do that too!

 

Keep the updates coming

 

Nice Subaru - I prefer old school tin though

[Rostle1984 2 1 Cars]

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Top Work.

 

After picking up my second Pug Ive realized I need to buy a welder - so I have! Its posts like this that have made me think I can do that too!

 

Keep the updates coming

 

Nice Subaru - I prefer old school tin though

 

I was lucky with my previous 1.6 GTI as the body was pretty good, Shame I sold it really.

I don't mind a bit of welding, least once its done I'll know the shell is rust free & the satisfaction of knowing I repaired it.

 

Your quite right as nice as my new cars are I still prefer old school cars better. I work on the new stuff day in day out and its boring and can be quite complex, So it's good to get back to simpler things with the GTI

I bought this one as a 30th birthday gift for myself quite fitting really as the GTI was also celebrating 30 years too. This one wont be getting sold once its rebuilt that's for sure

 

Quite a wealth of knowledge on this forum which is brilliant.

[JamPug 22]

This looks really great ! It's motivating me to get on with my problems as they are literally the exact same aha.

[Rostle1984 2 1 Cars]

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This looks really great ! It's motivating me to get on with my problems as they are literally the exact same aha.

 

haha, I'm glad I'm not the only one that's for sure, after reading a few threads it seems to be the norm with a few of them. Good luck with yours.

[Hobbyweld 1]

Hi Rob,

 

I'd love to feature your 205 welding work on the Hobbyweld website - drop us a line when you get a moment - info@hobbyweld.co.uk - we'll hook you up with a free fill of gas in exchange for your story Look forward to hearing from you!

[Rostle1984 2 1 Cars]

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Hi Rob,

 

I'd love to feature your 205 welding work on the Hobbyweld website - drop us a line when you get a moment - info@hobbyweld.co.uk - we'll hook you up with a free fill of gas in exchange for your story Look forward to hearing from you!

 

That would be absolutely fantastic, I'll be sure to drop you an email with my story on for your website. Thanks again that's a truly brilliant offer

[Rostle1984 2 1 Cars]

Small Update for tonight, I bought some new tools for the Job at hand. I need to make new sections for the front inner wings as basically they have seen better days so I cut them out back to good metal with no rust on.

New vice and a clarke Metal folder and some panel beating hammers& dollies.

 

Excuse the state of My garage there are tools lying everywere at the moment.

 

Untitled by Rob Ostle, on Flickr

 

Started with cutting the basic shape with the Plasma Cutter and popping it into the folder to get the nice smooth folded edge to weld back onto the wing section, Old one on the right as you can see has seen better days

 

Untitled by Rob Ostle, on Flickr

 

The next bit was to figure out how to get the curve in the center to match up to that of the front panel.

 

Untitled by Rob Ostle, on Flickr

 

Easy enough once I got my head around it. Slight cut in the center with the Plasma cutter then with the use of the Hammers and dollies made the basic shape needed to match the front panel Then welded the center up and edge piece & flattened back

 

Untitled by Rob Ostle, on Flickr

 

Untitled by Rob Ostle, on Flickr

 

Job done for tonight, Coated with Galvanised Zinc primer, Ready to weld in.

 

Untitled by Rob Ostle, on Flickr

[iPlod999 143 1 Cars]

DA in the background of the last picture?

[Rostle1984 2 1 Cars]

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DA in the background of the last picture?

 

Yes indeed, I do the odd bit of paint correction now and again.

[Rostle1984 2 1 Cars]

Something has been annoying me for a while and now I saw the ideal chance to do something about it.
You can tell that in the 1990's folk really couldn't be bothered with there jobs. Alarm and immobiliser to be removed
Removing the faulty alarm & immobiliser by Rob Ostle, on Flickr

I don't think they should be on a classic car unless its factory fitted.

[Rostle1984 2 1 Cars]

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Went to fire up the GTI today. A complete no go-er.
Engine would crank but refused to start, didn't even hint to want to start.
Few checks of the Tachometric relay indicated no power from the ECU to the relay.
Enough is Enough, Not knowing the brand of alarm or engine immobiliser the only option was to rip it all out and re-wire the fuse board.

With all the crap pulled out and re-wired, first flick of the key we had engine starter signal & fuel pump relay clicking and energising, Quick check at the fuel pump end we have power this is good but no noise & power returning down the earth line.

Quick check at the distribution block at the rear lights became apparent that I'd not bolted it back to the body. Bolted it on and hey presto she lives
Untitled by Rob Ostle, on Flickr

Untitled by Rob Ostle, on Flickr

[jackherer 543]

 

I don't think they should be on a classic car unless its factory fitted.

 

 

Insurance companies used to insist on at least an aftermarket immobiliser before they'd cover a 205 GTI unfortunately.

[Rostle1984 2 1 Cars]

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Insurance companies used to insist on at least an aftermarket immobiliser before they'd cover a 205 GTI unfortunately.

 

Yes your right there, My previous 1.6 gti the insurance company insisted it had one fitted and required proof of fitting.

My current insurer has never asked for such proof and neither have I declared one as I don't know what the make or model was. I couldn't even start it with it fitted it cut the starter and fuel pump circuits.

If there comes a point they ask I'll buy something like a Cobra 8510 and try to discreetly fit it some were allot neater than the previous install

[Rostle1984 2 1 Cars]

After playing around with the Immobiliser and getting inside of the brain I found the cause of the issues I was having. One of the wires onto the main board had come adrift. Also found out its a genuine Peugeot 96721t unit so I happily repaired the unit and refitted it to the cars electronics. The alarm remains in the bin. Cheap fix all in all.

Anyhow Garage door shut, tunes on, Heating on I decided to start making the offside front inner wing section.

First off when I removed the sections from the car I still don't know why I cut them into two pieces but nevermind.
I offered the two sections onto the sheet steel and drew around them to get the basic shape I needed with the additions of two pieces that needed folds applied so I can affix them to the front panel and wing sections.
Offside front inner wing fabrication by Rob Ostle, on Flickr

Cut out the basic shape with the added on sections which needed folded.
Offside front inner wing fabrication by Rob Ostle, on Flickr

Section applied into the folder and folded to shape.
Offside front inner wing fabrication by Rob Ostle, on Flickr

Nice and tidy Fold, quite like that machine.
Offside front inner wing fabrication by Rob Ostle, on Flickr

The front edge however after the main fold couldn't be fitted in the folder so, Out with the Hammers and dollies, I had to run a cutter up the center as it needed to fold a bit further in the middle.
Offside front inner wing fabrication by Rob Ostle, on Flickr

After a little alterations and dressing with the grinder I offered it into place on the car & pleased with the fit its very snug
Offside front inner wing fabrication by Rob Ostle, on Flickr

Offside front inner wing fabrication by Rob Ostle, on Flickr

[Rostle1984 2 1 Cars]

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Bit more tinkering. With yesterday's panel. I realised I hadn't fitted the jack mount on it. DOH. Hole cut with plasma and smoothed off with the grinder. Cut the old insert out of the old panel and welded it in place. Just need a jack now since it didn't come with one haha. Primed up in zinc ready to weld the pair in now. also refilled the cooling system with corrosion inhibitor & antifreeze for winter

Untitled by Rob Ostle, on Flickr

Untitled by Rob Ostle, on Flickr

Untitled by Rob Ostle, on Flickr

Untitled by Rob Ostle, on Flickr

[arbor 2]

Great work and some nice tools for the job. Cracking stuff.