£250 Base model build

[Omorgan 1 1 Cars]

Hi guys, I'm new to this group but thought I'd begin to post about my build that I have started on my base model 205 I bought for £250

 

The photo below shows the 205 as I bought it. A bit tatty around the edges and needed a head gasket but a bargain really.

 

   

 

 It already had the foggies fitted and the aftermarket sunroof it seems so that saved me some future work.

The first thing to do was the head gasket, the water pump was non-existent, which explains why the head gasket went.

I blew through the block cooling jackets to clear them all out and reassembled it, it ran a treat after I finally got the timing correct. (it was 1 tooth out).

The breaks were awful after sitting so I had to drive it carefully.

 

The seat covers are relatively fruity, but conceal some really poor quality seats below. I will be upgrading the seats in the future.

 

The next mission was to fit some driving lights in the aftermarket GTI front bumper - I got them off eBay and wired them up to a fused relay which I tapped into the side lights.

They look great . I also de-sticker bombed the reflective band on the boot, showing that it was cracked but I think it looks a lot better.

 

 

 

I then left the car stored at work for a while while I sorted my other car (PD150 Mk4 Golf) and when I got back into it to drive it again, the rear footwells were flooded. I started to strip the seats and belts and carpets to get access.

I saw that the floor drain bungs were loose which had clearly allowed water into the car making the floor rust. I ground back the all the rust I could find, treated it with rust convertor and etch primer before reassembling.

I also laser cut some new bungs and used tigerseal to seal both sides.

 

    

 

Next I wanted to change the carb and dizzy as it had a tendency to hesitate on throttle. I went to the local scrappy (Silverlake) and got a new carb and dizzy for £20 off of a 96 1.1 205. The result was the car being about a 1/3rd quicker from my bum dyno, and a much reduced hesitation, although its still there when cold but I guess that's from the fact it is carby.

 

Next was a brake upgrade. The OEM brakes were dangerous and the rear pistons were leaking meaning it was consuming fluid and the pedal feel was rubbish.  I got a set of Peugeot 306 GTIs front callipers, disks and yellow stuff pads, as well as a 205 GTI master cylinder from some local legends and painted them red (why not). I spent a day removing the standard brakes and master cylinder and replacing them with my new units, installing some Speedline 1.9 GTI wheels to clear them too. After bleeding, they felt great, however the leaking rear pistons were still affecting pedal feel. 

 

    

 

After doing the brakes, I wanted to underseal the car.  I got some Tetroseal white rock chip from halfrauds and wire brushed my wheel arches and under the boot floor, after removing the spare wheel. I wiped it all down with brake cleaner and sprayed it on and it stuck well. I also designed and 3D printed some hub caps for my new wheels and painted them white, dipping them in red calliper paint to try and match OEM. saved be about £20.

 

 

      

 

Next I bought two 1.6 GTI rear beams, one with a broken stub axel from Nick and John who were breaking their race car as well as a GTI front subframe and Peugeot 309 front arms. I stripped, sandblasted and painted all the components at work and pressed out one stub axel from the worse looking beam, pressing it into the newer one. The install was pretty straight forward , except for bending back the drum backing plates after Nick and Johns crash. 

 

         

 

My new Bilstein group N tarmac rally shocks arrived so I undersealed the front wheel arches, painted the knuckles and top mount setup, replaced track rod ends, and installed it all.  As well as fitting the new GTI front subframe. The car now sits how I want at the front, and I raised the rear one nick so it didn't scrape anymore. I had to cut and weld the gear linkage bracket from the standard subframe to the new GTI one and it all fitted back together well.

 

          

 

So far this is where I have gotten to. I have loads more planned in the future such as a TU5JP4 engine from a 106 GTI, ITB's and a 5 speed MA box. I will keep you updated as I go.

 

 

 

 

 

 

Edited January 30 by Omorgan

[Leslie green 109]

Thats a mountain of work you have done sure you can't wait to get it on the road.

[Omorgan 1 1 Cars]

It's keeping me nice and busy, and its really good to work on. I think about two weekends of work for the brakes and suspension and undersealing so far. I hope to find a TU5JP4 engine soon and build that up ready to install soon and then hopefully it'll be nippy too.

[Omorgan 1 1 Cars]

Today I bought a Peugeot 405 master cylinder & brake booster to upgrade my setup. Currently I have the 1.6 GTI master cylinder and booster paired with the GTI6 brakes but I found the pedal would depress a long way before doing much. I also had a T-piece hooked up to the rear output of the master with the 1.6 biasing valve, however I didnt think it was the ideal situation. 

 

 

The new booster bolted straight up, I just had to change over the clutch cable to suit my MA gearbox. Because the 405 master has two front and rear outputs, I could delete the t piece and biasing valve which makes it look a lot cleaner. 

 

The pedal is very firm and nice and high so it was definitely worth doing. The last photo shows the standard 1.1 booster and master, the 1.6 GTI booster and master and the new 405 booster and master.