[engine_work] 1.9 8v Gti Rebuild Pics

[ashley peddle 3]

Howdy

 

Just thought id share some rebuild pics of my 205. It started off as a stock 1.9 GTi when I first started out 2 years ago... since then I have managed to scrimp / save to build up quite a nice spec. Its insured as a second car. I only really drive it at the weekends... some of you may have seen it at various tracks (most recent being FCS last week; sneaked in 2 track sessions even though I was still running the new engine in )

 

The old engine was always strong (enough to see off most other stock 8v's and the likes of 106 gti's from a standing start) but I wanted more and always wanted carbs so last November I invested in a set of twin Weber DCOM carbs, appropriate inlet manifold, 274 Catcam, Vernier pulley and a twin fuel reg set up. A weeks hard work and a £280 rr session at Pete Baldwin saw a huge improvement.

 

Unfortunately 2 months ago the water pump died. Having planned a new engine anyways I had already sourced a rebuilt block and I had a head with QEP being skimmed, cleaned and 3 angle seats etc

 

Block and head:

 

 

 

At this point I must warn you that I have a bit of a cleaning/painting fetish

 

Carbs ready to be fitted

 

 

I was advised (and very rightly too) to get a 1.6 box to take full advantage of the lairy cam. I picked it up but it was mucky / grimy so I cleaned / painted it up to match the rest of the engine After a few more nights it was all made up and ready to drop in

 

 

 

 

I faffed about for 2 weeks trying to sort an oil leak that I thought was coming from the sump. It turned out that I actually had 3 oil leaks but none of them were from the sump, one was from the oil pressure sender (was only done up hand tight) The second was from an ill-fitting dipstick. The third was the most serious: it was coming from the crank oil seal (gearbox side!) so off come the gearbox to find the seal was on the wonk. A mate used a lump hammer and an old Mi16 liner to bash it back into place

 

I then handed the car to Anthony off here to put some more miles on it before FCS (he does lots of miles!)

 

The car made it to FCS and managed 2 30 minute sessions:

 

 

There is still some loosening up to do but im quite happy with the performance so far

 

Current spec is below; im hoping to get a diff some time soon but its a bit of a budget build so don't know if / when il be able to afford one

 

Full build pics here: http://www.anthonyshuttle.com/ash/

 

Peugeot 205 1.9 8v GT

 

Engine

 

Rebuilt XU9JA head with 3 angle seats

Rebuilt XU9JA bottom end

274 Degree Catcam

Twin 40 DCOM Carburettors (with twin FPRs)

XU10 Baffled Sump

 

Transmission

 

BE3 1.6 Gearbox

Pugracing gear rods

Extended gear lever

 

Suspension / brakes

 

Avo coilovers

Baker Gp N engine mounts, top mounts.

Group A rear beam mounts

Fully rebuilt rear beam

22mm rear Anti-roll bar

Koni adjustable rear shocks

306 S16 brake calipers

Brembo disks / Frodo pads

Braided hoses all round 5.1 fluid

 

extras

 

Safety Devices 6 point roll cage

Buckets / Harnesses

Fully stripped

Momo Italy steering wheel

Battery box in boot

glass fibre bonnet

3 bar grill

plated sunroof

Pugsport Gp N straight through exhaust

French Sports Club custom graphics

 

A huge thanks has to go out to all my mates and my girlfriend (who paints stuff for me ) Without their help it would nearly be done yet - you all know who you are

 

Roll on the Germany trip in a couple of weeks will earn my 205 its Ring sticker

 

Any comments welcome, but be nice - im still learning and its all on a budget

 

Cheers

 

Ash

[Alastairh 47]

Looks good mate

[jas-E 1]

that engine looks soo good..im half way rebuilding my MI16 engine and have painted it all silver..i tried painting a few bits red, but all the red spray cans i got turned out more orange then red..so just stuck to black and silver..

 

Excellent work though..And loving the white 15inch wheels in the back..!!

[ashley peddle 3]

lol cheers. i used silver radiator paint & hammerite red paint... its heat proof and sticks to anything

[Peetypug 5]

thats one clean engine

what did you use to clean it first?

got my engine out now and was going to steam slean it with one of those wallpaper steamers, but if theres a better way please let me know?

[ashley peddle 3]

the block was already clean but when doing my last one i found that a mix of wire wool, decent degreaser/paint brush and a wire wool extension on a drill works well

[Peetypug 5]

the block was already clean but when doing my last one i found that a mix of wire wool, decent degreaser/paint brush and a wire wool extension on a drill works well

 

i'd better show the wife how to use a drill then

[DaveK 0]

holy heck, how clean is that!

 

How much power did it make then mate?

[ashley peddle 3]

i have no idea what sort of power its making. im guessing once its run in it will be about 145/150 mark (well - i would hope it is!) Its got a LOT looser since the first few miles - it still only has 400-odd miles on the clock so about another 300 ish before it shows its true colours i gues? but to be honnest iv not really built it to go fast in a straight line - i like corners

Edited July 24, 2007 by ashley peddle

[SamGTi 0]

Very impressive! Nice to see that not everybody just shoves an Mi in and that's that!

[Silky 33 1 Cars]

Ash,

 

What sort of costs is this little lot

 

Engine:

Rebuilt XU9JA head with 3 angle seats

Rebuilt XU9JA bottom end

274 Degree Catcam

Twin 40 DCOM Carburettors (with twin FPRs)

XU10 Baffled Sump

 

Looks quite impressive, PM me if you prefer, wouldn't mind this sort of setup in my GTI

[ashley peddle 3]

Very impressive! Nice to see that not everybody just shoves an Mi in and that's that!

 

lol i can safely say that it sees off standard Mi's - was speaking on a chap on msn lastnight who was on track at FCS and his words were 'it aint shy - was trying to keep ahead but you still got me... git'

 

iv always had a soft spot for 8v's... i know Mi is easy cost effective power but its just not what i wanted

 

What sort of costs is this little lot

 

Rebuilt XU9JA head with 3 angle seats £150 from QEP

Rebuilt XU9JA bottom end £100 (I think)

274 Degree Catcam/pulley £150 off anthony

XU10 Baffled Sump £beer tokens (off anthony )

 

The carbs cost quite a bit as i didnt buy a whole set up...

 

Twin 40 DCOM Carbs £250

manifold £80

fuel pressure regulators £110

trumpets/filters £40

setting up £280

 

then add onto that about another £80 quid for fuel pipe/unions/fittings/gaskets/seals/cables etc etc

 

If you were to buy everything from new then your probably looking at around the £1500 mark gimmie a shout if you need help with anything

Edited July 24, 2007 by ashley peddle

[Silky 33 1 Cars]

gimmie a shout if you need help with anything

 

Cheers Ash, may just do that, will have to come take a look at your 205

[Baz 421]

Yet to see it in the flesh Ash! Looks Ace though!

 

Paint hides a multitude of sins ehh! Only kiddin!! I'm sure it has a soundtrack to be very proud of too!!

[ashley peddle 3]

Cheers Ash, may just do that, will have to come take a look at your 205

 

anytime - next poosc herts meet or i may lend it to someone to take to the fsc herts meet for me in a couple of weeks

 

Yet to see it in the flesh Ash! Looks Ace though!

 

Paint hides a multitude of sins ehh! Only kiddin!! I'm sure it has a soundtrack to be very proud of too!!

 

ummm yeah the soundtrack is pure porn its a bit of an animal at lower speeds scrabling for grip

 

plus the added bonus of popping / banging / flames is quite cool. There is a vid about of anthony following me at FCS and i shoot out a huge flames - aparently i was doing it all the way round

[Silky 33 1 Cars]

Well whichever meet you make next let me know, would like to take a look.

 

Maybe a mini meet one evening in the week, Baz might be interested too, seeing as it stays light quite late at the moment

[Baz 421]

Yeah sounds cool, i keep saying i'll make one of the Psooc meets but haven't as of yet!

[Silky 33 1 Cars]

Well why dont we meet up, any evenings good for you Baz ? How about you Ash, are some evenings better than others ?

[tom_m 0]

*cough*PSOOC herts meets every 2nd monday of the month

[ashley peddle 3]

tom the next meet is the day we get back from le ring... so 12th September is the next available date

[Silky 33 1 Cars]

Where ?

 

So Monday 13th Aug ?

Edited July 24, 2007 by Silky