[car_overhaul] The Winter Project

[marksorrento205 80]

So here's the plan. My car is a 1992 sorrento green 1.9 205. I bought it in April 2008. I got the car for a good price but it had a small 50p size rust spot on the o/s inner wing suspension turret where the jack had been rubbing on the metal work wearing away the paint. When I peeled the sticker back more of the metal came with it - o dear. So I had the complete inner wing replaced.

 

I removed the engine to assist the inner wing replacement so I bolted a 1.9 MI16 instead of the std 1.9. I bolted on my throttle bodies, my omex 600 ecu and BBM hose kit. When I had the car set up it pulled 159.2 BHP on the rollers. I was a little disapointed but the compression was not a high as it could be.

 

I then bought my 306 Rallye cheap of a mate with an engine fault. It needed a rebuilt. So I got a belting engine for it and swapped it. This left me with a gti6 engine needing a rebuild and only one place for it to go...........

 

Since then I have had a transit van lightly go into the back of the 205. Its currently in the bodyshop having a new rear panel, boot floor and tailgate.

 

The Idea is to spend the winter doing a few upgrades and repairs.

[marksorrento205 80]

A pic of the car just after I got it

 

 

How the engine was

 

 

The inner wing corrosion

 

 

The new shinny inner wing

 

 

The MI16 engine

 

[marksorrento205 80]

One of my upgrades is the 309 gti rear beam. Once I got it I stripped it to find it needed attention. The bearing where none existant worn right through. So a big list of parts from pug followed inc a new crossmember, new shafts and it ended up with new torsion bars. I have opted for the partner 21.3 ones with a gti6 24 mm antiroll bar.

 

The beam as bought

 

 

Corrosion on the shaft

 

 

Pushing old shaft out

 

 

Old V new shaft

 

 

New shafts fitted

 

[matty_gti 20]

Nice work, wish i had a press . Keep the pics coming.

[Baz 421]

Nice work Mark, btw you might get better results from using longer trumpets on your TB's.

[marksorrento205 80]

Cheers, yeah I belive so. When the GTI6 lump goes in and it gets remapped that will be the time

[Tesstuff 222]

By the way, passed my MOT today not even any advisories, happy days

[jimistdt 1]

Nice car already, cant wait to see when its done

[marksorrento205 80]

Daz good news about the car. But your well chuffed. I could have done with you here to show me the ropes of this internet malarky

[marksorrento205 80]

Nice car already, cant wait to see when its done

 

 

Thanks im just gagging to get it back from the bodyshop post repairs!!

[Tesstuff 222]

Daz good news about the car. But your well chuffed. I could have done with you here to show me the ropes of this internet malarky

 

I was rather happy to put it mildly and you only had to ask about pc assistance i could have logged onto your pc and helped you from my end.

 

 

Thanks im just gagging to get it back from the bodyshop post repairs!!

 

I am having sleepless nights awaiting your pictures of an immaculate rear end in shiny minty Sorrento

 

Cant waitttttttttttttttt

[marksorrento205 80]

I am having sleepless nights awaiting your pictures of an immaculate rear end in shiny minty Sorrento

 

Cant waitttttttttttttttt

 

Niether can I. They have just rang me and reckon it will be friday. They said it has been painted but has to be cleaned, put back together and go through there quality department. And they are well aware it has to go through my quality department

 

[Tesstuff 222]

Haha, and i am confident in saying that there will be no sterner test than them getting a 'pass' from your quality control manager

 

Overspray and underspray and runs and orange peel wont have a cat in hells chance of getting past you mate

[marksorrento205 80]

Another little job I need to do is fit my gti6 front brakes. When I went to look at fitting them I noticed one of the pistons had popped out so a rebuild was needed.

 

Here are the calipers as I bought them

 

 

And one of the shinny rebuild kits from pug

 

Edited November 6, 2008 by marksorrento205

[Tesstuff 222]

Nice to see the pictures working properly now mate

 

I can sleep at night now i know you sorted that haha

[marksorrento205 80]

Cheers dude. The other ones were saved as 120 x 160 so they were always going to be small

 

 

Just finnished rebuilding my calipers

 

A bit of compressed air to blow the piston out

 

 

Everything removed

 

 

New seal in place

 

 

The piston

 

 

The new dust seal

 

 

The piston sat in the dust seal waiting to be pushed home

 

 

A bit of pressure to check everything is sealing and that the dust seal is in the groove. The bit of wood is to stop the piston coming to far out and past the seals

 

 

Old dust seals

 

 

New dust seals fitted as well as cleaning up the shaft and re greasing it

 

 

Hey presto. Just need a quick lick of paint and I also want to replace the bleed screws with new ones to help against them seizing.

 

 

For info pt no for the seal kit is 444879

Edited November 6, 2008 by marksorrento205

[marksorrento205 80]

The day has come. The car is ready (so they say) Im watching the clock untill 08.30 then I can go and pick it up. Fingers crossed there wont be any problems.

[marksorrento205 80]

Well, went to pick up my car, looked round it all seamed well, took the hire car back, got a lift back and the sun had come out Went to get in my car and WTF!

 

Where they had polished the car all over there was a load of big dull patches on my paintwork. So it was oi di ck head what have you done to my car?? the list got bigger as I looked round it. My spoiler was scatched as was my rear valance, they had not put the rear heated window cables back in, the n/s rear arch was not fixed on propally. So its still there

 

The funny thing is I was due to get the car back last friday but they told me it had failed there quality dept check and was going in for polishing. It has since been through quality again. What it was like the first time??

 

As we said daz, got to pass my quality dept :lol:

[Tesstuff 222]

OH MY GOD!!

 

Who are these monkeys? I bet you its the usual 'its an old Peugeot 205 we dont have to do a great job on it' scenario.

 

But true to form the important 'quality control manager' Mark did his job LOL.

 

I had the exact same crap happen with one of my cars a couple of years ago, i took an immaculate car in, and all i wanted doing was a stone chipped bumper respraying, the rest of the bodywork was as good as possible, they proceeded to paint the bumper,half the bonnet, and both wings in a dull and different shade of red.It was hoorendous, i almost cried with rage.Needless to say the manager was told the score, my requirements and given a week to make it mint,they knew they couldnt do it so the car was sent to one of the top places in Leicester at his expense

 

So make sure you get exactly what you want Mark, and thats a shiny minty rear end that looks like it has just come out of the factory on concourse day

 

While i am here, there is a very nice looking bonnet for us on eBay , been on a couple of days , i wondered if you had seen it.

 

Keep me updated and at least you dont run out of petrol like some numptys in the Sorrento Club do

[eddie bullit 37]

Well, went to pick up my car, looked round it all seamed well, took the hire car back, got a lift back and the sun had come out Went to get in my car and WTF!

 

Where they had polished the car all over there was a load of big dull patches on my paintwork. So it was oi di ck head what have you done to my car?? the list got bigger as I looked round it. My spoiler was scatched as was my rear valance, they had not put the rear heated window cables back in, the n/s rear arch was not fixed on propally. So its still there :lol:

 

The funny thing is I was due to get the car back last friday but they told me it had failed there quality dept check and was going in for polishing. It has since been through quality again. What it was like the first time??

 

As we said daz, got to pass my quality dept

Who can you trust to do a quality job these day Hope it turns out ok for you pal. I had loads of trouble with the so called bodyshop that did mine. If I had the cash I'd have it all done again I just wish paintguy had his own place, I'd be up to his neck of the woods in a flash.

Good luck mate. keep us posted.

[marksorrento205 80]

Its gonna be a fun road If I keep finding faults, their is only so much paint you can polish, then what a respray They know the standards now so there should be no repeat performances. The metal work side of things is spot in inc my nice rust free shiny boot floor.

[marksorrento205 80]

While i am here, there is a very nice looking bonnet for us on eBay , been on a couple of days , i wondered if you had seen it.

 

 

Yes I have, Are you going for it?

 

Any way here are a couple of pics of one area of bad workmanship

 

 

 

However.......

 

One phone call today to tell me my car is ready provided the following

 

Nice shinny car

 

 

New boot floor - I know its upside down dont know why ive rotated it???

 

 

The car was mint!! the spoiler and rear valance were sprayed, the rear heated screen cables are fitted and they have really done a nice job of polishing the car. They have bent over backwards and would have tried to polish a turd for me if I told them too. It shouldn't have taken two attemps but what the hell. And I have a 3 yr guarentee on the work. Plently of time to pick faults

 

I will get some more pics in proper daylight.

Edited November 14, 2008 by marksorrento205

[Tesstuff 222]

Hey go you it looks very nice , i bet its loads better in the 'flesh' so to speak

 

I want

 

I am definitely seeing this one close up when you complete it, the wait will be worth it

 

I wont be going for the ebay item, tooooooooooooooo far away lol, but i would like it obviously.

 

So now i am out the running you have a chance

[marksorrento205 80]

I wont be going for the ebay item, tooooooooooooooo far away lol, but i would like it obviously.

 

So now i am out the running you have a chance

 

 

Thats the same for me. I dont want to travel all the way to find its crap. Have asked about sending a custom wooden box to send it to me but will see what they say. I dont hold much hope.

[marksorrento205 80]

Today I have sent some things to the powder coaters. I can only balme carl (mechanicalrepairs) for his mint car / engine for re lighting my powdercoat fetish - I thought I had past this stage Im getting an omp steering wheel thanks to djinuk which is in the post and I have sourced an omp rollcage from a mate who has had it sat around for the last 3 years and only done about 200 miles in is car so looking forward to getting my hands on it.

Edited November 21, 2008 by marksorrento205