205 Sport Van - Supercharged Gti6

[allye 530 3 Cars]

I’ve got a thread running on 306OC (mainly to get more posts so I buy stuff and send PM’s!) As its a 205 it’s about time I got a thread up here. I purchased the van last year for the pricely sum of £250 from Maxi205 (205maxi? Can’t remember his name) Hired a trailer and went and got it.

 

The idea of the build is a little Sport Van with good MPG, such as Astra van's, quick Vito's etc.

 

 

The van is on 165,000 and is in very good nic, turns out to be a ex fire service car with the service reg/number still in the engine bay which I may get re made when I paint the bay for a bit of history. The bonnet is also a bit ruined from the stickers they had on there.

 

 

I then parked it in a hedge and left it for the summer. Autum last last year I was keeping an eye out for a Bosch injected 306, pref a very early one. I found a very very early 1.9TD non EGR Bosch car down the road for £250, ripped the engine out and got to work on it. Turns out it had been reconditioned at some point as it had blue paint on loads of bolts and the head was shimmed perfectly to tolerance.

I had never fully rebuilt a bottom end or complete head so was a nice little exercise.

 

 

Head is fully rebuilt, all de coked and cleaned, new camshaft seals, stem seals etc etc, gave the valves a quick lap too.

 

[allye 530 3 Cars]

After rebuilding the engine (with HDI rods too) I decided I didnt want a smokey old XUD in it and am now going for a 2.0 HDI, stage 1 remap (don't you hate that term? Stage...) no intercooler to keep the bay simple and the factory radiator setup. I picked up this 306 just a couple days ago for £200 on 175k, high millage but it pulls really strong and as I was about to tow it away the lady explains she bought it new! Sold with a noisy 3rd but just the release bearing is super noisy.

 

 

Last year I also picked up a complete phase 1.5 GTI interior for £40!

 

 

And a few weeks ago I picked up some sofa like 405 seats that will find there way in at some point

 

 

Starting the work on the van on Monday

 

 

Only a couple small areas of rust to attend to and 1 cracked seat rail.

 

 

Salvaged a couple of bits the sand blast, paint and re use, the rest of the suspension will be rebuilt, standard spec GTI set up, HDI front brakes.

 

 

And this is what makes it a 205 van. I need to modify this so the seats can further back though.

 

[allye 530 3 Cars]

Unfortunatly underneath the carpet was soaking wet

 

 

.........but the floor is perfect, so need to find the source of the leak.

 

 

And this is how its left, underside completely stripped ready for underseal. Complete with army of big f***ing spiders that fell on me when I removed the tank.

 

 

Up to date! Will get all the rust proofing and under seal done before november, then it will be no progress until March unfortunatly.

[Wes 86 1 Cars]

cool. i've just found one for sale near me. thinking of getting it as my run around/dog car and getting rid of my mondeo estate.

[Paul_13 212 1 Cars]

If you do the same mods to that engine as I have done with mine you'll be bloody impressed, 306's weight let's it down.

 

And yes I do hate the old stage... talk, does my nut

[allye 530 3 Cars]

sticking to a mild non intercooler map first thing, keep things simple with good MPG. Even so it will have 1.9GTI BHP, twice as much torque and 60mpg!

[Paul_13 212 1 Cars]

Power corrupts

 

 

You know this well having a v6

[Leet205 48]

Following this with interest! would love to get a UK van and do similar mods but have the ¨fourgonnette¨ back end on it like that - http://images.forum-auto.com/mesimages/364113/205service.jpg

[allye 530 3 Cars]

I'd love one of those! Actually useful space rather mine which is just the same as having the seats down....

[S@m 156]

I too am very interested in this, i've got a 1.8D and i've been toying with the idea of putting a Xantia XUD9TE in it.

 

Can i ask why you intend to go for the DW10 in the end instead?

 

Either way i'll be watching with interest as i have with your previous projects.

[Paul_13 212 1 Cars]

Something different at a guess and doesn't overheat when you've been ragging the hell out of it

[allye 530 3 Cars]

XUD are basically 30 year old engines. Smokey, but decent power. DW's are far more modern, refined compared to a XUD but not other common rail diesels to be fair.

 

The deciding factor for me was better MPG and less smoke, ease of tuning is a added bonus. Less prone to chucking rods too!

[S@m 156]

I'm waiting for someone to somehow shoehorn the 2.7/3.0 v6 HDI into a 205 (which i imagine would be near enough impossible), i've driven a few and they go very well indeed. The twin turbo DW12 is pretty damn good aswell.

 

I thought the DW's were only less smokey than the XUD due to their particle filters and additive fluids but i'm very new to diesel tuning, there's no doubt that its a more refined, modern engine but they seem more problematic in my experience, aside from the conrods!

 

Can't argue with the MPG though; will be a fast, cheap works van.

[welshpug 1,657]

a healthy standard xud won't really smoke much, the efficiency of the hdi comes from much higher injection pressures, more than one injection moment per stroke, and direct injection.

 

other than that the block and crank are identical on many other than bore diameter and machining, 16v heads are crossflow where 8v are laid out much like the xud, they do have hydraulic tappets rather than the solid tappets (which share the same shims as the 8v xu)

 

the additives are to combat the NoX gases (those ones vw are cheating on...)

[Paul_13 212 1 Cars]

[Paul_13 212 1 Cars]

Just got that out of a full tank.

 

Hdi, front mounted, remapped with a r70 pump and 1800 bar rail sensor

[Paul_13 212 1 Cars]

Running at a guess 160bhp, haven't had it dyno'd yet to see roughly what it is. Goes bloody well though.

[allye 530 3 Cars]

16v maybe something for the future.

 

I'll be sticking to a mild tune a fairly OE turbos and fuel pumps etc. reliability and MPG!

[allye 530 3 Cars]

Had three days at the garage so got a bit done to the van, inbetween a transit clutch, susuki clutch, astra radiator and other bits I had some time to get the arches and engine bay sorted and readish for paint and underseal, only a couple small bits of rust to sort. Pretty decent for a 21 year old I reckon!

 

Normal rust spots.

Removed the loom all labelled up ready to mate to the HDI loom.

Finally managed to get this out in one go, anyone ever got the foam out in one piece though!?

[allye 530 3 Cars]

Got the bulk of the body work done! Was my aim before leaving for winter so it wouldn't rot any further. First think was to get it inside, bolted the beam on with 2 bolts and placed the front on a towing dolly, one person pushing around.

 

 

The drivers seat mount had split, I know common on 205's but the first time I'd come across it. Got that welded back up.

 

 

Let my friend weld that as it's slightly important! I did all the rest though.

 

 

Couple of the patches made up, half seam welded and some plug welds.

 

 

Primed behind the front panel patches to try and stop it rotting any further.

 

[allye 530 3 Cars]

Then the utterly horrible job of cleaning up the underside, a day of wire wheeling destroys your arms! I'm not going back to bare metal just a thorough clean up, protect where needed and paint. I've undersealed using the gun, when I'm back I'm going to brush on some epoxy mastic to finish it off. Used Jenolite rust eater all over too, much prefer it to kurust.

 

It's in very condition under the 20years of self rust protection and grime. What I started with.

 

 

Wire wheeled, I used a fairly mild wire wheel and a knotted one on more stubborn/rusty areas.

 

 

Zinc primed bare metal areas, then under sealed.

 

 

As said I will go over with white epoxy mastic in the spring. Thats how its left, bolted the beam back on and wheeled it outside once it was dry and wont be touched until March! Then I have all of March and April to finish it.

[blacksmoke2.0 0]

nice to see another hdi project on the go. im on doing a one in my gti shell atm. give me a shout if you want any advice on the conversion because it has a few little issues n mods to do mounting the engine n box in.

[allye 530 3 Cars]

Cheers brad I'll drop you a pm now.

[allye 530 3 Cars]

It's getting close to van building time! I've started collecting a lot of bits for it and after realising the original fan cowling is not going to fit which I wanted to do for the OE look, I've decided to slip a intercooler in as well! That way with the help of a boost controller I can have a safe and reliable 150bhp and 250ft/lb which will be fun.

[lybker 26 2 Cars]

Good project, I can maybe also assist you if issues should arise, as I have built both a 2L hdi and 2,2 16v hdi into a 205 shell :-)

 

Feel free to ask