Nobbly 22 2 Cars Posted June 7, 2018 Hi 205'ers, I have been meaning to do this for a while having gone through the same process with my old VW camper a couple of years ago ( http://forum.earlybay.com/viewtopic.php?f=2&t=69499 ), I found it a great way of recording what I'd achieved and the help and advice received made a huge difference! I always wanted a 205 when I was a 'yoof' in the early 1990's, but (working in a Ford dealership) tended toward the blue oval (RS1600i, 2 x S1 RS Turbo, Capri Mk2... wish I still had them, I'd be well off now!). Even then I knew the Pug was a better car than the Escort, but I wouldn't admit it, even to myself. So, I stumbled on a bit of a 205 project about a year ago, a chap had started the resto but needed space for other projects (RS2000 Mk2, De Tomaso Pantera,...). It was quite local and at a price I was happy with to get me into 205 land. Basically it was: A 1.6 phase 2 from 1991, 79k with no history. (However, looking at the condition of the interior, engine and gbx internals and the body I'm as sure as you can be this is genuine) It had had a bump in 2004 and was written off Cat C - the damage was minimal and limited to the o/s/r 1/4 panel and rear bumper. The tailgate fitted was non-GTI. Engine, front suspension and interior already stripped out. Engine had been stripped, vapour blasted, all new parts (cylinder liners, bearings, gaskets) were supplied. Crank had been checked/polished and the head fully rebuilt. Gearbox not touched. Rear beam (seized), also not touched. Front suspension had been overhauled with new brakes, wheel bearings and the subframe p/coated. The shell was in good condition, tiny bit of corrosion on the n/s inner wing and boot floor needed 2 x 5cm square patches. The guy had already wire-wheeled the underside - which i was very happy about! Here she is as bought... 1 Share this post Link to post Share on other sites
Nobbly 22 2 Cars Posted June 7, 2018 So I got it home and started tearing bits off, fixing the rust on the inner wing and boot floor. I found a bit under the rear seat too that when prodded was a bit 'soft', so fixed that. All in the welding and making good took about a day - light relief after a VW camper I can tell you!! Share this post Link to post Share on other sites
Nobbly 22 2 Cars Posted June 7, 2018 After a bit of scraping and wire-wheeling I could see progress in the engine bay and under the back-end Share this post Link to post Share on other sites
Nobbly 22 2 Cars Posted June 7, 2018 (edited) Then it was time to get shiny... IMG_2047 by David Noble, on Flickr IMG_2049 by David Noble, on Flickr IMG_2050 by David Noble, on Flickr Phew, image hosting thing works!! Edited June 7, 2018 by Nobbly add photo Share this post Link to post Share on other sites
Nobbly 22 2 Cars Posted June 7, 2018 repaired bit from underneath, tidy! IMG_2057 by David Noble, on Flickr General shininess... IMG_2054 by David Noble, on Flickr IMG_2062 by David Noble, on Flickr Share this post Link to post Share on other sites
Nobbly 22 2 Cars Posted June 7, 2018 repaired bit from underneath, tidy! IMG_2057 by David Noble, on Flickr General shininess... IMG_2054 by David Noble, on Flickr IMG_2062 by David Noble, on Flickr Share this post Link to post Share on other sites
Nobbly 22 2 Cars Posted June 7, 2018 Then the front suspension went back in so I can get her to the paintshop where the experts can sort the minor dings and the dents in the 1/4 panel - it's hilarious that this could write the car off! IMG_1997 by David Noble, on Flickr While I get cracking on with this... B9F125F7-96D4-4673-8051-7139987CF373 by David Noble, on Flickr 1 Share this post Link to post Share on other sites
Nobbly 22 2 Cars Posted June 7, 2018 Several shifts later... IMG_1057 by David Noble, on Flickr IMG_1211 by David Noble, on Flickr IMG_1212 by David Noble, on Flickr IMG_1214 by David Noble, on Flickr Ta-daa! IMG_1216 (1) by David Noble, on Flickr 1 Share this post Link to post Share on other sites
Nobbly 22 2 Cars Posted June 7, 2018 So, we're nearly up to date. Car is at the bodyshop, looking like this... IMG_2225 by David Noble, on Flickr IMG_2226 by David Noble, on Flickr ... and I'm just about to build the gearbox after the casing comes back from the vapour blasters. Stay tuned! 2 Share this post Link to post Share on other sites
Nobbly 22 2 Cars Posted June 7, 2018 Bodyshop update... now in primer! DJ6 by David Noble, on Flickr Share this post Link to post Share on other sites
pugdamo 111 2 Cars Posted June 8, 2018 I love these sort of write ups, it goes from start to finish really quick, loads of decent pictures and all the work to a really high standard. Hope it's finished soon so you can enjoy it through summer. 1 Share this post Link to post Share on other sites
forbeslongden 32 13 Cars Posted June 8, 2018 It's great when someone buys one to put back on the road again! Share this post Link to post Share on other sites
Richie-Van-GTi 71 2 Cars Posted June 8, 2018 Nobbly, do you mind saying how much the paint job is costing you? Looking real good so far, hoping mine will be going through these stages in early August Share this post Link to post Share on other sites
Leslie green 110 Posted June 8, 2018 Going to be very nice when finished Share this post Link to post Share on other sites
Telf 224 2 Cars Posted June 9, 2018 looks great- have you painted or treated your block? Share this post Link to post Share on other sites
Nobbly 22 2 Cars Posted June 12, 2018 On 6/8/2018 at 4:21 PM, Richie-Van-GTi said: Nobbly, do you mind saying how much the paint job is costing you? Looking real good so far, hoping mine will be going through these stages in early August I'd rather not say ... .... well, actually I don't know... ... until it's done... I trust the guy and we've agreed a ball park figure based on his hourly rate - but a good job is cheaper than a cheap job. I want a good job. 1 Share this post Link to post Share on other sites
Nobbly 22 2 Cars Posted June 12, 2018 (edited) Gearbox night tonight... Bearings from various sources (Brammer, BRT, Peugeot) all seals and other bits from Pug too. Plus a nice tube of Loctite 518 to seal the case. Cheap diff bearings! Ford wheel bearing kit of some sort has them in - £24 for the pair from BRT IMG_2270 by David Noble, on Flickr Genuine US made Timken bearings too.. IMG_2271 by David Noble, on Flickr The paint dot is so I keep the bearing with it's cup (i.e don't mix them up between now and putting the diff in). Diff bearings on... IMG_2267 by David Noble, on Flickr Bearings on the shafts... IMG_2266 by David Noble, on Flickr Nice clean casings IMG_2268 by David Noble, on Flickr Clusters in - and out about 3 times. Bit of a faff with the selectors (not done one of these before) IMG_2272 by David Noble, on Flickr Getting late now, I'll do 5th gear another day! IMG_2274 by David Noble, on Flickr Edited June 12, 2018 by Nobbly photo duplicated Share this post Link to post Share on other sites
Nobbly 22 2 Cars Posted June 14, 2018 On 6/9/2018 at 8:00 AM, Telf said: looks great- have you painted or treated your block? Hi Telf, Not done anything to the block so far, I have seen that some folk just give it a coat of WD40 from time to time. I'm more partial to GT85 as: It doesn't eat all your rubber and silicon parts It smells better - I sometimes use it instead of deodorant Nobbly 1 Share this post Link to post Share on other sites
Nobbly 22 2 Cars Posted June 14, 2018 Gearbox finished tonight IMG_2281 by David Noble, on Flickr IMG_2282 by David Noble, on Flickr ... and no parts left over! Well, apart from the shim pack for the diff that [apparently] you don't need in a late 'box. Didn't do my homework there now, did I? Share this post Link to post Share on other sites
ian010778 21 Posted June 18, 2018 On 6/8/2018 at 7:18 AM, pugdamo said: I love these sort of write ups, it goes from start to finish really quick, loads of decent pictures and all the work to a really high standard. Hope it's finished soon so you can enjoy it through summer. Wish mine was going this quick ;-) Share this post Link to post Share on other sites
Nobbly 22 2 Cars Posted June 24, 2018 Exciting day yesterday... picked her up from the paintshop . This is us popping in by the house for lunch on the way home... IMG_2372 by David Noble, on Flickr Then up to the workshop... IMG_2378 by David Noble, on Flickr And onto the ramp to get the axle out for refurb and start putting twinkly bits back on 36bbd93f-4caf-488f-8a28-bb0a9c3cb5a8 by David Noble, on Flickr ff0d650d-5116-4f03-847b-97425a4c75ac by David Noble, on Flickr IMG_2382 by David Noble, on Flickr IMG_2383 by David Noble, on Flickr Loving the brightness of the red! Share this post Link to post Share on other sites
Nobbly 22 2 Cars Posted June 24, 2018 Question? See this stabiliser arm thing on the beam... IMG_2422 by David Noble, on Flickr Should there be a bush or something in the eye where it attaches to the bracket on the tube?? Share this post Link to post Share on other sites
Telf 224 2 Cars Posted June 25, 2018 nope that's how it comes- no bush Share this post Link to post Share on other sites
Tom Fenton 1,542 Posted June 25, 2018 That is how it is. To be honest the purpose of that strap is somewhat vague as to what it actually achieves. On my standard cars I have retained it for originality sake, but on my modified ones it gets removed and left off with no ill effects. 1 Share this post Link to post Share on other sites
205Rallee 59 Posted June 25, 2018 Car is looking brilliant. Will have to meet up when you've finished. Mines MOTD and insured and in mothers garage as Rallye is getting used this year. Moving later in the summer and will have two garages so I'll be able to keep the two together for the first time ever. Share this post Link to post Share on other sites
