Barn Find Laser Green 1.9 Gti.

[Leslie green 110]

Good idea Chris although mine has worn right through in a good few places due to vibration and oil contamination so for wire protection it needs replaced .Another job on the list !

[Tom Fenton 1,542]

The convoluted tube is really pretty cheap by the metre in a number of diameters. I buy it from Polevolt but there are plenty of places that sell it.

[Leslie green 110]

I was looking into it Tom and the Peugeot stuff on the museum site its rated to 175c whereas some on ebay was only around 100c some higher  .A lot of it isn't for car use .  It should in theory never get above a 100c coolant temp  and id need to sit down and see what I need as there appear to be 4 different diameters ,

Peugeot museum lists 9 , 19 and 26mm diameters (inner) which is 13, 24 and 32mm outer 

I measured 13 ( battery cable)  19 , 22 and 30mm but its not easy measured being split .

The museum stuff has a cool blue line in it which appeals to my ocd side but is more expensive and id only get it there if I was buying other bits as postage isn't cheap.

Edited October 24 by Leslie green

[Leslie green 110]

Bit of work on the exhaust the downpipe is not the right angle to join the manifold on the new system so I cut of the downpipe and fitted a genuine front pipe with the split inside I had ,It needed some repair but came out alright.As I didn't want to cut open the pipe I straightened the split then built it up with rows of weld  I joined it after reducer on the downpipe but with no straight pipe to align it it proved tricky , I had it on and off a few times tacking each time but it was worse each time so in the end I fitted it and used self tappers to hold it till I welded it. I expanded 20 mm of the end with a cheap expander tool so the downpipe fitted inside , this proved hard work and the largest one was about 1mm too big to fit inside the pipe at the start.

 

20241107_133228 by Leslie, on Flickr

 

20241107_145335 by Leslie, on Flickr

 

20241111_172117 by Leslie, on Flickr

[n0_b0dy_ce 1]

wow superb work

[Leslie green 110]

Thanks fitted today and shock back off to fit these new dust boots,still only one bas arrived, but can't decide what way they go again ,couldn't go either way and seem worse located than last ones .does the domed bit go up as there is no way to hold it up there ? This way up it will lock into topmount but looks wrong ...

Edited November 12 by Leslie green

[jord294 92]

Rod protector is upside down. Don't forget the large washer after you've slid bump stop over

[Leslie green 110]

Cheers  these are going to just float about as there is nothing to hold it , might just fit the others back on , the bump stops came with these are shorter so will use those .

Edited November 12 by Leslie green

[welshpug 1,657]

The bump stop holds them up.

[Leslie green 110]

Got one shock on and fitted the calipers ,cable tying the spring top coil to the spring plate till its fitted makes refiitting the springs much easier . I  had new guide pins for the calipers but noticed they are smaller diameter may be off a 1.6 maybe so fitted the originals , tried fitting one droplink but the nut on the anti roll bar end just spins as there is no flat to get a spanner on , other end has a flat and an allen hole .will put the ugga dugga on it later lol Got some new genuine discs years ago , little rust with storage which will clean off in use and some new wheel bolts ,amazing how many sellers on ebay are selling the wrong ones with the wide shank which wont go in a 205 alloy . I bought some used ones first but they were too rusty plus nearly every one was cross threaded .

 

The new pads have a wire sensor but I've nothing to attach it too and have no idea where it comes from but not a big deal at present.

 

20241113_141817 by Leslie, on Flickr

 

20241113_162833 by Leslie, on Flickr

Edited November 13 by Leslie green

[welshpug 1,657]

Pins won't be from a 1.6, they used a bendix caliper with very different sliders,   there does seem to be a variance in the pin diameter for the girling 1.9 calipers even though there's only one part number for the body and slider pins.

[Leslie green 110]

Thanks just one of those things with the pins , I've another issue fitted the droplinks for front antiroll bar and on lock both sides are catching the strut bolt ,at first i had the nut on the other side and thought that was the issue but its still catching . They seem to be same length as the originals so not sure whats up .

[welshpug 1,657]

i have seen this quite a few times, a washer or two between the droplink and the tab on the damper to space it out is usually enough, I think either the droplink tab is welded at the wrong angle or the locating tab.

 

 I have also seen the locator tab welded too low on the damper body making the damper not sit fully in the Hub carrier clamp, not a huge issue on the 205 hub carrier but the 96 on 306 had a hollow casting so the damper was only clamped by the upper section     after a decent impact the bottom of the damper bend and came out of the hub.

[Leslie green 110]

That's doesn't sound good about the 306, the dampers  seem to be sitting fully down the same amount each side on this  . I have one original droplink the tapered type but it looks well worn and it just tapers to the same diameter as these so its not the rod diameter is the issue  , most likely is these are not made quite right and a coupe of washers is an easy fix.

 

 

[Tom Fenton 1,542]

On 11/22/2024 at 7:28 PM, Leslie green said:

Thanks just one of those things with the pins , I've another issue fitted the droplinks for front antiroll bar and on lock both sides are catching the strut bolt ,at first i had the nut on the other side and thought that was the issue but its still catching . They seem to be same length as the originals so not sure whats up .

I think this sometimes is only an issue with the suspension at full droop eg car jacked up. Try spacing off with a washer or two, but I'd also put it on its wheels and try again.