[Project] Starting My Xu5T Build

[Tom Fenton 1,541]

Woooo more shineys from postman pat today!!!!

 

205T by Tom Fenton, on Flickr

[j_turnell 137 3 Cars]

Nice! its coming together well! look forward to see the engine in.

[platty 1]

Where did you get the fuel lines/fittings from Tom?

 

Thats next months expenditure for me.

 

Downpipe looks very clean and tidy

[Tom Fenton 1,541]

Thats all actually for the brake lines, I sourced them via a hydraulic supplier I spend a lot of money with at work, they did a deal on it all for me, even so it was still £60-odd. I'm pleased with the downpipe, apart from the flange to the turbo which is cast steel it is all stainless.

[BackStreetRacecars 3]

this build gets better every read!! lovving the progress... can i ask Tom what do you do?

[M@tt 77]

he's a gigalo! very reasonable rates i hear.

 

Dirty finger nails though!!

[BackStreetRacecars 3]

damn good at tig welding from being a giggolo then eh.... thought they could only mma....

[M@tt 77]

 

i'm sure he'll be along shortly to tell you his correct job title but i know he works as a manger in a dirty great Corus steel foundry in Shef

[Tom Fenton 1,541]

Unfortunately although a gigalo would be more entertaining, I actually work in engineering for the melting shop at a steelworks.

[DrSarty 90 1 Cars]

I think you ARE a gigolo.

 

You are wooing your 1.6 into a whirlwind romance with a turbo. You could say, through induction, you are forcing her to suck harder (?).

[Tom Fenton 1,541]

GROAN!!!

[phil withers 0]

Having known Tom for far too long, I can honestly say he is much better at fixing cars than being a gigalo - probably

[Tom Fenton 1,541]

Damn, its a fair cop

[Tom Fenton 1,541]

Bulkhead stiffening plate has been tonights job

 

First clamp in place and mark out the holes from inside

205T by Tom Fenton, on Flickr

Gives you this

205T by Tom Fenton, on Flickr

 

Then centre pop and drill the holes, TBH I was suprised it didn't come already drilled.

Clean off the paint where it will need welding and spray in weld thru primer

205T by Tom Fenton, on Flickr

 

Weld into place. Since I got my TIG I've hardly used my MIG. Therefore my MIG welding has gone to sh1t! Oh well its certainly strong if not neat

Blast over with some rattle can rouge, done!

205T by Tom Fenton, on Flickr

[Tom Fenton 1,541]

Well it has been one of those days today, when it seems like I've spent all day on the car, but there is not a lot to show.

 

The pedal box is now bolted in place, and I have made up and fitted the -4 aeroquip from the remote reservoirs to the master cylinders.

205T by Tom Fenton, on Flickr

 

With that done I did some heat protection, the fuel lines have been sleeved, I've made up a bit of a shield to sit in front of them, and I've also wrapped the clutch cable in the "hot" area. Should all help things survive.

205T by Tom Fenton, on Flickr

 

I then set about the calipers, I'd made a bit of a start cleaning them up but cracked on with them this afternoon and then painted them.

205T by Tom Fenton, on Flickr

 

Final job was to start taking off the old suspension and brakes, from standard 1600 it is going to 309 arms and shafts, 1900 uprights, and 266mm brakes.

Whilst doing this I also discovered the rack is buggered, I do have a spare in the shed so I'll have to dig that out and see if it is any good or not.

[edbar 6]

Looking good Tom!

[Tom Fenton 1,541]

Bit more progress to report

 

309 wishbones, 1900 hubs, and 266mm brakes fitted

 

205T by Tom Fenton, on Flickr

 

Whilst I was messing with the wishbones, I fitted a lower brace I've had for about 12 months! I'm not convinced it will do much from the design of it, the bar seems to hang out in front of the pickups too far to achieve much really.

205T by Tom Fenton, on Flickr

 

Then finished off the braided lines to the brakes, well nearly, just need one more fitting to finish.

 

205T by Tom Fenton, on Flickr

 

Soon it will be engine back in time..........

Edited July 24, 2017 by Tom Fenton

[Tom Fenton 1,541]

New steering rack arrived and fitted, I wasn't terribly impressed by the standard of finish, but then it was £42.

PICTURE MIA

 

I've also made a small plate to fill the large hole that the loom usually goes through, I need to order another gland fitting to go next to the one that is there. Fiddly to bolt in but will keep the noise out.

205T by Tom Fenton, on Flickr

 

Next I turned my attention to the diff. First off took it apart, it was on 60/30 ramps which aren't ideal for a road car! It had supposedly been just rebuilt, and on taking it apart this showed to be true with new plates in it.

205T by Tom Fenton, on Flickr

 

Next fitting the diff bearings, a simple job with a press, and those of you that own one of my torsion bar pullers will be pleased to hear that it will also double up as a suitable press tool to fit diff bearings as well!

205T by Tom Fenton, on Flickr

 

Then I trial fitted the diff to see how much the casing needed trimming. Here shown the area in question

205T by Tom Fenton, on Flickr

I used my trusty powerfile, didn't need much off at all in the end.

205T by Tom Fenton, on Flickr

[Tom Fenton 1,541]

Well since the last installment the diff is now built and in the box, and the box is now sat on the end of the engine with the clutch installed, I've never tried putting the engine and box in the car as one, but people have said it can be done, so I'm going to give it a try.

 

Aside from all that I've a clutch to change on a 306 GTI6 and it has dawned on me that I've no way of moving the 205 out of the garage now, as I've no 15" wheels to go on the front to clear the brakes. So with this in mind I thought I had better pull my finger out and get on with the wheels.

 

I've very little to no patience when it comes to paint prep so they won't be perfect, but here is where I am at

 

Wheels prepped with the DA, luckily for me the majority of them could be done with the DA rather than by hand! 180 then 320 grit, then 600 grit wet. Also dressed the outer rims up with the DA to get rid of any nasty scuffs.

205T by Tom Fenton, on Flickr

 

Next a drop of etch primer

205T by Tom Fenton, on Flickr

 

And finally for tonight some 2k basecoat, in this case EVE silver which I believe is the original colour for these wheels?

205T by Tom Fenton, on Flickr

 

They are by no means mint but should look presentable enough for my old shed. Will need clear lacquer tomorrow, I'm just off out now to give them another coat of silver.

[EdCherry 34 1 Cars]

You can fit the engine and box in together, I found that it had to sit with the gearbox at a slight angle down, has to go in with the gearbox pointing at the bulkhead and lowered slowly while you turn it to go under the tray, then with a jack just make it level and start bolting stuff in!

 

Good progress tom, not long to go now!

[tom_m 0]

Well since the last installment the diff is now built and in the box, and the box is now sat on the end of the engine with the clutch installed, I've never tried putting the engine and box in the car as one, but people have said it can be done, so I'm going to give it a try.

 

dead easy tom, it's the only way i do it, sod farting about with the box first.

 

it's easier if you unbolt the gearbox mount tray first, drop the engine in like ed says box down, once straight lower it in the bay and try and line up the lower mount at this point. if you're keeping the lower brace it's a handy place to sit the gearbox while you bolt the tray back in. then lift it up to attach the gearbox mount and drop it back on to the top mount.

[Tom Fenton 1,541]

WOO shiny lacquered wheels

 

205T by Tom Fenton, on Flickr

[Tom Fenton 1,541]

Well I've had a busy weekend but not on the car, on Saturday we were fitting some new Ti bottom arms to my mates Fiesta, super sexy and much better geometry!

205T by Tom Fenton, on Flickr

 

Anyway I've had a hour or two this afternoon on my car. Because I'm going to 1900 wheels I wanted to change the rear brakes to discs to get the offset right so the wheels sit properly in the arches, I think they don't look right when used on a 1600 beam.

 

So I had a dig through my selection of crap to see what I could make a beam out of, came up with a pair of Xsara VTS rear trailing arms, one with a decent shaft, a 309 cross tube, a pair of vented front discs, and a knackered pair of 1600 front Bendix calipers.

 

Being the tight git I am I decided to see if I could fit the new discs I had to use them, rather than forking out for a new pair of rear discs.

 

So lo and behold

205T by Tom Fenton, on Flickr

 

and

 

205T by Tom Fenton, on Flickr

 

I also started cleaning up one of my 309 beam tubes, this one was in very clean condition, a wipe over with a rag and some duck oil and it looked like this! I'm wondering if it was replaced at some point as it certainly doesn't look 15 years old.

 

205T by Tom Fenton, on Flickr

[DrSarty 90 1 Cars]

this one was in very clean condition, a wipe over with a rag and some duck oil and it looked like this!

 

Duck murderer!

[Tom Fenton 1,541]

Bom bom!