205 gti-6 restoration

[Phil GTI-6 4]

Hi, I thought I should start a thread about my restoration project just on the off chance that it may be of interest to anyone out there.
 

My car is a 1991 red 205 1.9gti which I’ve owned since 1996, and in to which I installed a 306 gti-6 engine back in 1998 when the only other gti-6 conversion to my knowledge was the first Eccosse one. I did actually acquire my sub-1000 mile engine from Rab Elliot of Eccosse fame. The only other mod was the installation of 306 gti-6 brakes.

 

The last time the car was on the road was 2005 since which I have had it stored undercover in a de-humidified container. I stripped it down 10 years ago with a view to addressing a few bits of rust and making her all perfect once again. A short notice move overseas saw progress paused at that point. 6 years overseas on 3 different continents and now finally circumstances appear to lend themselves to what will hopefully be a high quality restoration. 
 

I have been steadily acquiring parts over the years such that all wearing parts will be new. All others painted, powder coated or zinc plated. 
 

Phil

Edited August 29, 2020 by Phil GTI-6
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[MrStock 5]

Doesnt look bad on the rust side.

[Phil GTI-6 4]

No it wasn’t too bad when I took it off the road and it seems the dehumidifier did it’s intended job. I’ll put more pics up when I get chance.

[Phil GTI-6 4]

Because the strip down took place so long ago without me thinking of taking pics my thread will maybe feel like a resto job half way through. I’m still working on who will do the bodywork and paint so in the mean time I’m working on the other jobs which will hopefully mean that once the bodywork is done it’ll be a case of reassembling the whole thing with all the other bits already cleaned up and sorted. 
 

one job for this week is manufacturing some bump stop cups. As you can see from the pics below the originals are well past their best. I can’t bring myself to pay what people are asking for genuine parts and I think I can make a better part on the lathe so I’ll post pics once that job is done.

Edited August 30, 2020 by Phil GTI-6

[Phil GTI-6 4]

First attempt at new rear bump stop holders went pretty well. I made the spacer to the original dimensions but made the actual bump stop holder from 3mm thick section so as to be a bit less thin and flimsy than the originals.

[bacardincoke 42 1 Cars]

Having just replaced mine, it's sods law you've come along with these.

 

You're absolutely right about the prices of originals, good to see there's potentially an alternative to compete, if you were minded to make more to sell on.

[Phil GTI-6 4]

Although I’m happy with the bump-stop cups that I’ve made, they took a while as I was only using an old manual lathe. I think if demand was there for a bigger batch it might make sense to get them knocked out on a CNC lathe. I would imagine it would be the sort of thing which BakerBM could bring to market. If anyone was desperate I’d try and help out.

[Phil GTI-6 4]

The engine and gearbox had been sitting attached to one another on a pallet for ages so today I split them and got the engine on to a stand so that the clean up can commence. Other than the usual water pump, cam belt and tensioner pulley it should be ok mechanically as it’s only done about 30,000 miles since new. The gearbox, having done about 85,000 miles will be treated to new bearings and seals etc and maybe a Quaife LSD if funds permit.

[Da Bootou 1]

Looks like a good project to get your teeth into.

 

I also have a 1991 red Gti underway for rebuild, very similar situation to yours, having sat around for 14 years.

Ours cars don't have the same rust issues as UK, parts just clean up and plate without much bother, although plastic seems to crumble to dust in the harsh sun light.

 

Do you still have the original 8V engine and is this going back in?

 

I'll be keen to follow your progress on this

 

Cheers

[Philpooma 30]

Looks like a great project. You were very wise to store in an air conditioned container, as you say its probably held it in the condition in which in was out away.

Nice to not have to rebuild the engine too.

Will watch with interest 

[Leslie green 109]

Nice project and doesn't look too bad at all.

[cybernck 402 1 Cars]

Sooo... any more progress?

[Phil GTI-6 4]

I’ve been putting some updates on my Instagram page @205_gti_restoration but I do need to update this page too. Never enough time!!