[Body_Work] Rust Rust And More Rust!

[Telf 230 2 Cars]

The bottle is to be honest rubbish. The sensor wouldn't fit , seems the molding inside is incorrect. Anyway I pushed it so hard I actually broke the tube ... so I cut it down and made my own float stop. Whilst at it I stripped the middle bit out and found the reed switch burnt out so replaced that.

 

It's all pressure tight but just I dunno a bit crap.

 

Anyway it's up for sale so of anyone wants a 205 let me know  

[Telf 230 2 Cars]

2 hours ago, Anthony said:

OK to me - shade is probably a little off and would have the concours lot tutting

Cheers Anthony.

 

I give zero fuxks about the concourse crowd. Most of the so called experts weren't even born when I was bombing around in my first 1.6. They can feck off.

 

Makes me laugh I had a 1.6 in 93 , it was a pig of a car even then on a G plate. Rusty wings, it leaked water into the footwells but boy could it shift! 

[Telf 230 2 Cars]

1 hour ago, Leslie green said:

plastic doesn't age that well as anyone who has taken a 205 part knows only too well 

Mines carnage mate , my dash is laughable with only afew screws in it. Strangely it no longer creaks and everything sits lovely and level. So much easier taking it to bits when I need to. 

[Telf 230 2 Cars]

6 minutes ago, Telf said:

. Rusty wings, it leaked water into the footwells but boy could it shift! 

That's without mentioning the falling to bits seats, absolutely trashed rear beam and a manifold that had more cracks than you could wave a stick at. I think it had 68 k on it . My missus finally killed it 5 years later when a BMW thought it could outrun a Pug and was proven wrong along with the who can brake faster test.  God I loved that car and have absolutely no pictures of it. No one gave a f*** what they looked like then just how quick they went.

[Telf 230 2 Cars]

well Spring is almost here!

 

I think the 205 is going to have some money spent on it (again) the list is long

 

>New seats- not sure the best way to go with this - does anybody have any good experiences with seat retrimmers? I'd prefer to get them all done at once. 

>Exhaust- looking to replace the entire system and thinking that a stainless manifold and full system may be the best way to go.

>New tyres, its been a few years since I built the car- still have the same 4 tyres on - they need to go.. at least an easy one to acheive.

>Engine build. Yep I'm going to finally drag my slumbering engine out of storage, strip and build it if the seat liners are ok. Its actually the original engine and has been stored ever since I took the car to bits in 2015. 

> Gearbox replacement. I've also had a 1.9 gearbox waiting to be fitted for about a year now.

 

The never ending journey continues, I'd sell it but nobody wants it, apparently its 'too high mileage' 

 

[Leslie green 126]

Few jobs to keep you going this year Paul.

[Telf 230 2 Cars]

Yep. I did a bit today. An oil and filter change.. it's only done 3000 miles since the last one but that was a year ago.

 

Also managed to find time to inspect the front wheels, brakes, and associated suspension. All looks good , showing its age after what 5 years since I built it. 

 

 

 

[Telf 230 2 Cars]

My next bit of work will be an exhaust change, I've opted for replacing the original with a stainless manifold and complete system.

 

Initially I'm just going to fit the manifold and mate it to the remainder of the exhaust, nothing to do with performance, I suspect it wont improve over the original design. Its more a case of fitting a stainless system and forgetting about it.

 

I have a cracked manifold and cannot be bothered trying to source another original one.

 

[SRDT 195]

Don't use the manifold gasket on this picture, manifolds of this kind are usually fine but the gaskests are just crap.

[welshpug 1,676]

You'll need a firm lower engine mount too.

[Telf 230 2 Cars]

12 hours ago, welshpug said:

You'll need a firm lower engine mount too.

Ah ok I didn't know that, the standard one wont suffice?

 

[Telf 230 2 Cars]

14 hours ago, SRDT said:

Don't use the manifold gasket on this picture, manifolds of this kind are usually fine but the gaskests are just crap.

i was planning on using the standard gaskets I'd normally use?

 

[Leslie green 126]

The way the original lower mount was fitted there is far too much movement I find   , I saw spooks recommended to turn it through 90 degrees to have the rubber facing the engine rather than the void in the rubber to stiffen it up for gti6 applications and I wish I saw that before I fitted mine  and the solid ones are going to transmit a lot of vibration but will soften a bit over time.

Stainless is prone to cracking anyway , the stainless systen on my xr2 lasted no  time at all till it cracked tight through at the back box at a hanger.

Edited March 11 by Leslie green

[SRDT 195]

9 hours ago, Telf said:

i was planning on using the standard gaskets I'd normally use?

 

I have no experience with 8v gaskets. It looks like the XU10J2TE one with integrated heat shield could fit but I don't know if it's necessary.

 

What I have seen up close is this kind of gasket simply cut from a sheet with no crimped metal rings, there is one thrown into the box when you buy a 309 GTI16 stock-like manifold. I didn't use it but someone else got 110 miles out of his before it started to leak.

[Telf 230 2 Cars]

On 12/8/2019 at 10:56 PM, Telf said:

 

 

 

Is this for real? £4.5k for a brake kit. Can someone explain this to me please?

[Leslie green 126]

Paul it's 1500 for a single wheel of them  the prices are next level !

[Tom Fenton 1,561]

All approximate, calipers £1500 the pair, discs £500 pair, bells £300 pair, pads £200, hoses £100, OK still a good mark up, but we are not talking about a set of corroded 25 year old Brembos off a 406 here. I've got a set of 4 pot AP racing calipers with 295mm discs under the standard 1900 wheel, they are fantastic.

[welshpug 1,676]

i'll show that to Godspeed, they do an AP kit for £1750!

[barneys66 125 1 Cars]

12 hours ago, Tom Fenton said:

All approximate, calipers £1500 the pair, discs £500 pair, bells £300 pair, pads £200, hoses £100, OK still a good mark up, but we are not talking about a set of corroded 25 year old Brembos off a 406 here. I've got a set of 4 pot AP racing calipers with 295mm discs under the standard 1900 wheel, they are fantastic.

Wishbones too by the look of it:

 

To facilitate the fitment of the kit, it includes our proprietary adjustable lower wishbone with spherical bearing and poly bushes. 

[Telf 230 2 Cars]

Well the manifold arrived, it seems to have an imperfection, think I may send it back!

[Tom Fenton 1,561]

Not really, it will only be welded on the outside of the flange.

[welshpug 1,676]

I dont see any issue in the photo?

[Telf 230 2 Cars]

Alright thanks, I was hoping some of you would respond and say its OK. Thanks.

[welshpug 1,676]

On 3/11/2025 at 10:58 AM, Telf said:

Ah ok I didn't know that, the standard one wont suffice?

 

Unfortunately as the flexible joint is moved a long way down the tubes the movement of the engine on a standard bush allows the manifold to sit on the subframe and buzz/clunk away,    back in the day the Magnex manifolds would come with an uprated lower mounting bush.

[Telf 230 2 Cars]

Collecting the parts to change the manifold continues,  £38 from Spoox for some genuine manifold gaskets. This has to be the most I've  ever paid for them.