[car_overhaul] Yellow 205 Rallye..

[Jackman 0]

Chapter 1

 

All Started about 6 months ago when i got the car.

 

I bought it originally to make a profit but things didn't turn out that way.

 

When i bought the car the details were:

 

K reg Yellow 205 Rallye.

 

83000 miles.

 

No Tax.

No Mot.

No Interior

 

 

It sat in my garage for a long time wasting away.

 

Then i wrote my Quiksilver off within 48 hours of owning it. and everything changed.

 

Out the Rallye came. was time to get her MOT'd.

 

Went out and got a battery so that we could get her started and move her around.

 

Borrowed a drivers seat and seatbelt off a mate. and i was away

 

Then i just flinged her in for MOT to see what i had got myself in for.

 

Turns out. a bargain.

 

It failed. but nowhere near as badly as i expected!

 

Nearside CV boot - split

Brake discs pitted.

Offside caliper binding.

 

Freed my weekend up fixed the above and back in she went.

 

PASSED

 

Excellent.

 

Swapped my insurance over, went and got tax. and she was alive and kicking.

 

 

Now just waiting for my cheque to come through the post so that i can get a few things sorted.

 

Currently have:

 

AX GT box and a new clutch waiting for go on.

Lowering springs to be fitted once Wolze gets over his fear of rain

Sparco Buckets and Luke harnesses to be fitted once my subframes are ordered and arrived.

Leaky sunroof to fix.

 

and the wheels.

[Jackman 0]

Chapter 2

 

So its been a while now!

 

done a small amount to the car in the last month!

 

Firstly i got the bucket seats fitted finally. and they look and feel great!

 

They seem more comfortable than previous seats ive had and sat in and hold very well!

really pleased with them at the price of £200!

 

I was going to have them fixed in, but then my dad offered to buy me subframes with sliding rails for christmas which seemed the more sensible option!

 

The harnesses are borrowed off a mate until i can decide on the ones i want!

 

[Jackman 0]

Chapter 3

 

So i haven't done alot with the car Recently as ive been waiting for my cheque to come through so i can give the Rallye the love it deserves.

 

First thing i set about doing was getting her lower to the ground.

 

Finally caught Wolze on a free day and let him do his magic.

 

I was ready for a hard days graft. but the Rallye had different ideas.

 

Much to all our amazement the torsion bars fell out!

 

Enough of the talking. Pictures say a thousand words!

 

 

I also ordered a new set of wheels as the black steelies were a temporary measure to get it through the MOT!

 

I was refurbing 2 S1 Steelies that i was donated but they are tucked away in the shed for now.

 

So i got a good friend of mine to order me a new set of the wider S2 steelies. and they finally arrived today!

 

heres the pictures!

 

 

Comments in my support thread would be much appreciated!

 

Support thread

[Jackman 0]

Chapter 3 Continued.

 

So today was the day for the car to finally look a bit different!

 

Got woken up by RS Rob early this morning telling me to put the wheels on. Decided not to hang around and got right to it!

 

Also removed the aweful 205 Mudflaps that were on the car!

 

Ill let the pictures do the rest of the talking, but i can't say how pleased i am with them!

 

 

 

Also decided to shed some weight and lose the doorcards and a few other bits of plastic bits i didnt need from the bootlid:

 

[Jackman 0]

So i've had a few new bit for the car recently. nothing special really.

 

Just some center caps for the steelies and a K&N Filter which screams its tits off to be fair.

 

I also dewipered her. i just need to find another grommit for the rear jet thingy lol.

 

Heres the pictures

 

Center Caps:

 

 

K&N:

 

 

Dewipered:

 

 

O and my new sticker!! from my track day on saturday!

 

 

And just 2 general pics after a quick wash today, due to the amount of dirt she picked up on track.

 

[Jackman 0]

Also.

 

Done a little more strippage today, nothing special.

 

Just a few plastic trimming that werent needed and the roof lining.

 

Going to bring some stuff home from work that will hopefully remove the remaining glue!

 

 

New brakes went on today.

 

266mm calipers off a 306 S16 with brembo discs and some pads that i duno what they are lol.

 

Braided hoses! i have got a full set but the fronts were all ready on when i decided to take pictures lol

 

 

 

How close they are under the steelies!

 

 

And ive found a site that does brand new decal kits. will be getting a set of them also !

[Jackman 0]

Sooooooo the time has come to finally release the secret ive been hiding from people for some reason.

 

It all started when i went and done this:

Basically the timing bent tensioner failed doing unknown damage to the engine. Because i couldn’t be bothered with stripping it down i went and done something stupid.

 

Yes i picked up a little something from Snitterfield.

I never took pictures of it out of the car really. So for your information its a Citroen Saxo VTS engine

So off the car went to my friends unit to let the build begin!

 

Before:

During:

After:

[swordfish210 20]

Looks really nice, i remember passing you at Llandow back in April

[Jackman 0]

And a few fun shots:

 

So now the engine was away from the engine bay:

 

Dai showing what he thinks of 8v power:

Rob and Wolze inspecting:

We starting pulling bits off the Rallye lump that we needed for the 16v conversion! Like the manifold that we later modified and the engine mounts etc etc.

 

So now the engine was out i had Group N engine mounts fitted to keep all that power stiffly in the engine bay.

Then we prepared the new heart to be dropped into her new home!

[Jackman 0]

And then in she slotted!

 

Mmmmm 16v!

 

Next came the one of the most annoying parts of the whole conversion. My stupid manifold design.

 

Excuse the picture. but my manifold looks like this

 

So i went and bought a Sportex 4-2-1 and left Wolze get to work with the grinder.

Which left us with:

 

Then Dai got happy with the welder and started putting the 2 sections together.

Which produced this beauty !

 

Took a bit of fiddling but in the end she was a perfect fit!

[Jackman 0]

Next was the part that caused us most grief i think lol. Wolze spent days and days doing the wiring and eventually crack it. Now i don’t know a great deal about this part as it was all done behind closed doors. I just saw it being put on and fiddled with!

 

So heres a few pictures!

My Rallye loom with about 5 sensors on it.

The 16v loom with a lovely 36 to be match up.

And a few of them being trial fitted on the car!

The man himself working away on a cold winters night 

 

Once the wiring was in i had to decide where i wanted to mount my ECU. now because ive mounted the battery in the boot, the battery seemed a good place to stick here. and she looks spot on if you ask me

 

[Jackman 0]

Finally came the fuelling. I changed my mind on this part so many times it was insane.

I was going to run a battery box in the boot with a fuel pump that i acquired with a fuel filter with the lines running inside like this:

But the fuel pump kept blowing the lines off under the pressure all the time due to the ends not being good enough to tighten the lines down on.

So i bought a 205 GTi fuel tank for £20 and did a tank conversion so that i could run a in-tank fuel pump. Not only was it easier but looking back now it looks so much tidier as you don’t even know its there!

 

So we fitted the new tank and then we had to swap the fuel lines as the Rallye runs 8mm lines and the GTi run’s 10mm. So they are all secured underneath the car again now so from the outside you can’t even tell the car has had a conversion. 1.4 8v FTW anybody?

 

 

Thats basically the whole conversion cut short. As ive forgot alot of stuff along the long process lol.

 

 

Finally id like to say the Thank you’s.

 

AS Developments AKA Wolze. Thank you so damn much. Ive seen the stress and pain ive put you through with this conversion lol.

Thank you for taking on the job and doing it to your spot on standards.

But its not over yet my friend!

 

Also a massive thank you to Dai. As without him none of this would of happened as easily. Your use of the unit was much appreciated keeping us warm on the long cold nights!

And thank you to the few other people that were involved aswell!

 

And a few final shots because i reached the picture limit

 

And how she looked when she was put back togeather!

 

[Jackman 0]

I do love Group N Stuff.

 

 

 

I do love parcels!

 

 

 

 

 

Today i picked up yet another bargain

 

As some of you might recall i did this.

 

 

So today i went and picked this up for a whole £20.

 

 

And its 100% mint!

 

I only really want the black bit on the top with the red strip going through ( which will be changed to yellow!

 

Hopefully i shall fit it tomorrow!

[Jackman 0]

So today i decided to tackle my bumper!

 

Stripped the old one off.

 

 

Took it apart to attach the bottom yellow part to my new bumper!

 

Then put it back togeather again.

 

 

Which left it looking like this

 

 

Until closer inspection, i discovered:

 

 

Stupid me didn't think it through properly and forgot about the arches on a GTi, which obviously clip into the bumper.

 

I didn't realise this, so now the search goes on for a bumper that actually fits lol.

 

It looks better than before though so im happier than this morning!

 

After a quick wash.

 

 

Just a small update that nobody probably cares about lol.

 

I came home today to find a gift on my doorstep.

 

Its something that i've actually wanted to change for a little while. However small and subtle it might be.

 

Basically. i hate the border and company name on my numberplates.

 

 

So a mate kindly made me these up in work today (Thanks you Robert )

 

 

Just trying to decide how to fix them on now.

 

Enjoy

[Jackman 0]

Been busy today, and stressed.

 

Finally got round to fitting half my suspension lol.

 

Had a battle with the rear shocks to get them off. they were an absolute pain in the arse.

 

Caused me calling help from 2 mates and my builder lol.

 

Eventually got them off. and they were ruined!

 

 

And put the new ones on! didnt get any comparisons sorry as i'd had enough and just wanted them on!

 

 

Then i got persuaded into losing some more weight.

 

 

GONE!

 

 

 

Next challenge is the fronts!

[Jackman 0]

So its been a while since i update so i got something small for you.

 

While i was at Trax i was on the look out for a length of Silicone hose to push my raceland induction kit out further to allow me to fit the Scoop.

 

So i went through all the garages and eventually found this for £13

 

 

I haven't had chance to fit it yet as i've been ill and i've got to cut it down and move a few bits to let the scoop eventually fit.

 

Also i picked up some gauges. now i'm not normally big on gauges and fancy bits and pieces, but with this car being used on track if and when i can i need to know whats going on.

 

And with my Car being a 'Rallye' the tight french gits never gave me any gauges at all.

 

So when i seen these for 2 for £25 i though why the hell not.

 

 

Unfortuantly they didn't have all 3 with white faces so i had to opt for silver, but at the price i got them i can't complain to much.

 

I've got:

 

Oil Temp

Water Temp

Vaccum (was the only decent one left so i just grabbed it to get the deal)

 

Also fitted my nice new plates! couldn't use sticky pads for the front unfortunately.

 

 

Big thanks to RS Rob for them

 

Still waiting on my Exhaust to arrive:

 

Also still have my stickers to put on as i'm not to sure on a respray after some thought.

 

And finally some pictures for you from the weekend.

 

[Jackman 0]

So today i had the mangaged to get a slot in Wolze very busy diary.

 

And headed for my mates unit that he lets us do a little work from.

 

Got the car up in the air and pulled the stuff out ready!

 

And got the stuff out ready to fit

 

then stripped the car down and pulled all the old parts off ready to be replaced!

 

Being replaced was:

 

Shocks with Group N Bilsteins

Springs from Spax to Eibach's

Top mounts to Group N Rubbers.

 

Not gona bore you to much so here's some pictures!

 

Difference between the shocks:

 

Difference in top mounts.

 

The ones on the right are origonals, which i could squash with my hands. the Group N's i couldn't get to budge!

 

 

Back togeather.

 

The difference is unbelievable. The car feels so planted compared to before. But thats probably because my old shocks were dead.

 

I compressed them and left them while we fitted the new ones. and they were still like these when they went in the bin.

 

Also fiddled about and had my Raceland scoop finally fitted.

 

Looks a bit strange with the long silicone hose. but its changed the noise and i love it lol!

 

 

More to come soon

 

 

Feel free to comment Support Thread!

[Jackman 0]

Just a quick update of how the car now sits on the bilsteins after the springs have settled a bit.

 

It's a little higher than i'd like, BUT it handles amazing so it will do

 

 

Sorry the pictures are terrible. my phone was being :censored:e.

I did just try polishing it, but i got bored and walked away after doing the bonnet lol.

 

Cheers mate.

 

The way it handles makes the height worth it!

 

Today.

 

I've gone from this.

 

 

To this.

 

 

It's not quite finished and i need to do the surrounding areas. but i am slowly killing off the rust.

 

Comments Here!

Edited October 18, 2008 by Jackman

[bren_1.3 1]

liking the exhaust manifold and downpipe, i have something similar lined up for my rallye car.

[Jackman 0]

Looks really nice, i remember passing you at Llandow back in April

 

 

Haha, thanks mate!

 

She's gained a bit more power since Llandow!

 

Can't wait to get back out there next year!

 

liking the exhaust manifold and downpipe, i have something similar lined up for my rallye car.

 

 

thanks mate.

 

I'm looking to get that changed for a stainless steel manifold rather than the mild steel as i've never been happy with the job.

 

Gona speak to a local custom exhaust place about having a Raceland Manifold modified to fit.

Edited October 18, 2008 by Jackman

[swordfish210 20]

Haha, thanks mate!

 

She's gained a bit more power since Llandow!

 

You'll need it, i passed you in a Volvo Looks really nice, anything else planned for the future? Also where did you get your A539's from, I can't seem to find them anymore

[Jackman 0]

You'll need it, i passed you in a Volvo Looks really nice, anything else planned for the future? Also where did you get your A539's from, I can't seem to find them anymore

 

Oh dear.

 

Thats not good lol!

 

I got my A539's from my tyres. Not sure if they still do them now that they have been discontinued.

 

Don't know what tyre's I'm guna for next now!

 

For the future? I've should be receiving my Group N Exhaust next week, Possibly a Rollcage, Fibreglass Bonnet and Boot, Carbon Doorcards, Possibly more engine work!

 

I really don't know.

 

I'm looking to buy a Road Car In Feb when my insurance is up, so this will probably go a full time track car then!

[Arahan 4]

Very nice, you've done/things I've wanted to do to a Rallye for ages! Probably will one day if I sell my GTi, or maybe do it as a side project!

 

Keep up the good work!

[cybernck 402 1 Cars]

wowzers! so clean and nice work and choice of parts too.

 

you should just refresh it with a set of new graphics - it will look loads better still!

 

 

by the way, does anyone else find this pic hillarious?

 

 

 

keep up the good work!

[Jrod 7]

Looking good, back end looks like it needs to come down a few mm though?

Edited October 19, 2008 by Jrod