[trackday_prep] How £75 Soon Becomes £7500!

[EdCherry 34 1 Cars]

Ok maybe the title is a slight exageration, but it seems to cost an arm and a leg.

 

Heres the story so far of my £75 maybe not so bargain to 1600 8v box of tricks... maybe. (Most of this copied from my PSOOC topic)

 

The day started for me at 6.20am after an hours sleep... down to tescos to withdraw money, get some food for the road and off I went after loading up the car at 7.30am. What a glorious day it all was!

 

http://i450.photobucket.com/albums/qq227/D...08/DSCN1639.jpg

 

Meet up at pugtop's place 30 minutes early, since it only took me 1:10 to get there. Once welshpug turned up off we set to pickup the trailer. What an amazing yard it was stored at, amazing projects and cars there!

 

http://i450.photobucket.com/albums/qq227/D...08/DSCN1645.jpg

 

Anyway arriving at our destination in pinner we found an empty garage instead of the packed garage 2 weeks before! Heres the pictures of the car as we found it.

 

 

We got the engine in after alot of blocking with wood, swearing and sweat! Big thanks to welshpug and pugtop here! I couldn't have done it myself!

 

 

Not even the use of an engine crane to get that block back up On the trailer it goes, it has no steering rack, and the brakes were seized on the front, luckily lee (the guy that owns it) had just turned up with a TR7 on a low loader with electric winch! Hooked it on and pulled it free. We then pushed it down the road with adjustments made to the front via pushing tyres in an out.

 

First time the car has seen daylight in 5 years!

 

http://i450.photobucket.com/albums/qq227/D...08/DSCN1655.jpg

http://i450.photobucket.com/albums/qq227/D...08/DSCN1656.jpg

http://i450.photobucket.com/albums/qq227/D...08/DSCN1658.jpg

 

On the road now! the 90 mile journey took a while due to traffic on the M25 and M3 (So we stopped at fleet services ).

 

http://i450.photobucket.com/albums/qq227/D...08/DSCN1664.jpg

http://i450.photobucket.com/albums/qq227/D...08/DSCN1670.jpg

 

And back home after an interesting drive into the village!

 

http://i450.photobucket.com/albums/qq227/D...08/DSCN1671.jpg

http://i450.photobucket.com/albums/qq227/D...08/DSCN1672.jpg

 

I got a few things that need to be bought, well make that alot! But thats the case with anything, first jobs are to clean it up and some temporary rust prevention on the underside and exposed areas while im away (it is under a tarpaulin to keep the rain off). Tomorrow I will be emptying the interior and putting it back in temporarily so we can work inside easier!

[EdCherry 34 1 Cars]

Ok well first off i've been buying parts to get the engine running woo! Came to a total of £120.31 cause I forgot to ask for discount the first time I went there! DOH! Anyway here is the first batch of goodies.

 

 

Last night while Chris (the other half of this project) arrived to view what he had let himself in for we bought an 8mm square socket to remove the sump plug. I thought there would be no oil inside but was infact proved wrong, with my lovely £1.20 drip trip this is what was removed.

 

http://i450.photobucket.com/albums/qq227/D...08/DSCN1708.jpg

 

Yesterday I tried to do a bit of work on the car, so I could move it off the road. This included moving the ARB to the correct position and getting the droplinks off.

 

http://i450.photobucket.com/albums/qq227/D...08/DSCN1702.jpg

 

Which then became this.

 

http://i450.photobucket.com/albums/qq227/D...08/DSCN1705.jpg

 

I cut the rubber off with my dremel and couldn't get the droplink off at all so gave up and will leave it for another day! At the moment the ARB is cable tied to the wishbones to stop it fowling the floor for when we move it later tomorrow.

 

I also tried rotating the dizzy (as instructed to do so by pugtop and welshpug), but me being an idiot thought it wouldn't fit. I forgot to rotate the shaft 180 degrees! Silly me, anyway heres the pictures.

 

http://i450.photobucket.com/albums/qq227/D...08/DSCN1690.jpg

 

http://i450.photobucket.com/albums/qq227/D...08/DSCN1691.jpg

 

http://i450.photobucket.com/albums/qq227/D...08/DSCN1696.jpg

 

http://i450.photobucket.com/albums/qq227/D...08/DSCN1697.jpg

[EdCherry 34 1 Cars]

Ok update time!

 

28-08-08, the day before I went on holiday, we got the car off the road before we went down the pub!

 

http://i450.photobucket.com/albums/qq227/D...08/DSCN1710.jpg

 

My make shift steering mechanism!

 

http://i450.photobucket.com/albums/qq227/D...08/DSCN1711.jpg

 

Undercover!

 

http://i450.photobucket.com/albums/qq227/D...08/DSCN1712.jpg

 

14-09-08

 

We started the day with a few plans. Get the dash out, see the extent of wiring needing to be done. Steering wheel in the right place. Oil, sparks, oil filter and dizzy sorted.

 

http://i450.photobucket.com/albums/qq227/D...08/A02_6997.jpg

 

http://i450.photobucket.com/albums/qq227/D...08/A02_6998.jpg

 

The rusty drivers door

 

http://i450.photobucket.com/albums/qq227/D...08/A02_7004.jpg

 

Phase 1 dash out

 

http://i450.photobucket.com/albums/qq227/D...08/A02_7008.jpg

 

Parts to go in!

 

http://i450.photobucket.com/albums/qq227/D...08/A02_7011.jpg

 

and there they are in! Who needs a oil filter wrench, hammer + screwdriver did the job in seconds.

 

http://i450.photobucket.com/albums/qq227/D...08/A02_7012.jpg

 

http://i450.photobucket.com/albums/qq227/D...08/A02_7014.jpg

 

Horrible oil filler!

 

http://i450.photobucket.com/albums/qq227/D...08/A02_7017.jpg

 

http://i450.photobucket.com/albums/qq227/D...08/A02_7019.jpg

 

Another random picture

 

http://i450.photobucket.com/albums/qq227/D...08/A02_7023.jpg

 

Heater thingy out

 

http://i450.photobucket.com/albums/qq227/D...08/A02_7025.jpg

 

http://i450.photobucket.com/albums/qq227/D...08/A02_7026.jpg

 

http://i450.photobucket.com/albums/qq227/D...08/A02_7028.jpg

 

http://i450.photobucket.com/albums/qq227/D...08/A02_7032.jpg

 

The amazing wiring to sort!

 

http://i450.photobucket.com/albums/qq227/D...08/A02_7034.jpg

 

and this is why we need to sort it

 

http://i450.photobucket.com/albums/qq227/D...08/A02_7036.jpg

 

And now for the 'what is this' kinda thing for this update... with a twist! How to get this off...

 

http://i450.photobucket.com/albums/qq227/D...08/A02_7038.jpg

 

The front left wheel is held on by 3 bolts!

 

Ed.

[EdCherry 34 1 Cars]

Friday's Work.

 

I emptied out the interior slightly to check what engine parts were there and which were not.

 

Onto the rust.

 

 

http://i450.photobucket.com/albums/qq227/D...th_A02_7093.jpg

http://i450.photobucket.com/albums/qq227/D...th_A02_7094.jpg

http://i450.photobucket.com/albums/qq227/D...th_A02_7095.jpg

http://i450.photobucket.com/albums/qq227/D...th_A02_7096.jpg

 

http://i450.photobucket.com/albums/qq227/D...th_A02_7097.jpg

http://i450.photobucket.com/albums/qq227/D...th_A02_7098.jpg

http://i450.photobucket.com/albums/qq227/D...th_A02_7099.jpg

http://i450.photobucket.com/albums/qq227/D...th_A02_7100.jpg

 

And where is this rust? Looking at drivers side footwell.

 

http://i450.photobucket.com/albums/qq227/D...th_A02_7102.jpg

 

Then onto grinding and spraying with zinc primer.

 

http://i450.photobucket.com/albums/qq227/D...th_A02_7118.jpg

http://i450.photobucket.com/albums/qq227/D...th_A02_7124.jpg

 

Saturday.

 

We went to gaz-2006's house from 205gtidrivers to pickup some car parts, didnt get pictures of the other parts but got the alloys, cleaned em a bit too!

 

 

http://i450.photobucket.com/albums/qq227/D...th_A02_7125.jpg

http://i450.photobucket.com/albums/qq227/D...th_A02_7126.jpg

http://i450.photobucket.com/albums/qq227/D...th_A02_7127.jpg

http://i450.photobucket.com/albums/qq227/D...th_A02_7128.jpg

http://i450.photobucket.com/albums/qq227/D...th_A02_7130.jpg

 

 

http://i450.photobucket.com/albums/qq227/D...th_A02_7131.jpg

http://i450.photobucket.com/albums/qq227/D...th_A02_7132.jpg

 

Some of them just refused to get cleaned, and im just trying to buy some stronger wheel cleaner although I think im going to just get the acid dipped.

 

 

Thursday.

 

Todays goodies thanks to Miles!!!

 

 

http://i450.photobucket.com/albums/qq227/D...th_A02_7133.jpg

Edited November 20, 2008 by EdCherry

[EdCherry 34 1 Cars]

Saturday 28th September.

 

Feel the rhythm! Feel the rhyme! Get on up, its cambelt time!

 

Task 1 - Take it apart.

 

http://i450.photobucket.com/albums/qq227/D...th_A02_7138.jpg

http://i450.photobucket.com/albums/qq227/D...th_A02_7140.jpg

http://i450.photobucket.com/albums/qq227/D...th_A02_7141.jpg

 

and while your at it take off the ****ed brake caliper.

 

http://i450.photobucket.com/albums/qq227/D...th_A02_7142.jpg

 

Flywheel cover off to jam things in it!

 

 

http://i450.photobucket.com/albums/qq227/D...th_A02_7143.jpg

http://i450.photobucket.com/albums/qq227/D...th_A02_7145.jpg

 

This was the hardest ever bottom pulley to get off! I snapped a drill bit being an idiot.

 

http://i450.photobucket.com/albums/qq227/D...th_A02_7146.jpg

http://i450.photobucket.com/albums/qq227/D...th_A02_7147.jpg

 

Max was helping by eating the butterflies

 

 

http://i450.photobucket.com/albums/qq227/D...th_A02_7148.jpg

 

The offending bottom pulley and bolt!

 

 

http://i450.photobucket.com/albums/qq227/D...th_A02_7149.jpg

http://i450.photobucket.com/albums/qq227/D...th_A02_7150.jpg

 

Cambelt off!

 

 

http://i450.photobucket.com/albums/qq227/D...th_A02_7151.jpg

http://i450.photobucket.com/albums/qq227/D...th_A02_7152.jpg

 

Waterpump out!

 

 

http://i450.photobucket.com/albums/qq227/D...th_A02_7154.jpg

http://i450.photobucket.com/albums/qq227/D...th_A02_7155.jpg

 

The mess!

 

http://i450.photobucket.com/albums/qq227/D...th_A02_7157.jpg

http://i450.photobucket.com/albums/qq227/D...th_A02_7158.jpg

http://i450.photobucket.com/albums/qq227/D...th_A02_7159.jpg

 

New shiny stuff going on!

 

 

http://i450.photobucket.com/albums/qq227/D...th_A02_7160.jpg

http://i450.photobucket.com/albums/qq227/D...th_A02_7164.jpg

http://i450.photobucket.com/albums/qq227/D...th_A02_7165.jpg

http://i450.photobucket.com/albums/qq227/D...th_A02_7167.jpg

http://i450.photobucket.com/albums/qq227/D...th_A02_7168.jpg

http://i450.photobucket.com/albums/qq227/D...th_A02_7169.jpg

http://i450.photobucket.com/albums/qq227/D...th_A02_7171.jpg

 

And the bits taken off

 

 

http://i450.photobucket.com/albums/qq227/D...th_A02_7174.jpg

 

Total time 5 hours, and IMO good first change! Will be quicker next time now we know how to do it!

Edited November 20, 2008 by EdCherry

[EdCherry 34 1 Cars]

Done a load just havn't been worthy of pictures.

 

Heres a few.

 

Rad

http://i450.photobucket.com/albums/qq227/D...08/A02_7682.jpg

 

Fan

http://i450.photobucket.com/albums/qq227/D...08/A02_7683.jpg

 

Spot whats different inside the car!

 

http://i450.photobucket.com/albums/qq227/D...08/A02_7686.jpg

 

http://i450.photobucket.com/albums/qq227/D...08/A02_7691.jpg

 

http://i450.photobucket.com/albums/qq227/D...08/A02_7693.jpg

 

Ok so what does this hose do, from brake servo

http://i450.photobucket.com/albums/qq227/D...08/A02_7702.jpg

 

Some nice wires here... NOT

http://i450.photobucket.com/albums/qq227/D...08/A02_7698.jpg

 

Does this plug labelled fuel pump go here?

http://i450.photobucket.com/albums/qq227/D...08/A02_7701.jpg

 

http://i450.photobucket.com/albums/qq227/D...08/A02_7699.jpg

 

http://i450.photobucket.com/albums/qq227/D...08/A02_7700.jpg

 

Engine Bay Now

http://i450.photobucket.com/albums/qq227/D...08/A02_7705.jpg

 

Where exactly does this connect too?

http://i450.photobucket.com/albums/qq227/D...08/A02_7710.jpg

 

http://i450.photobucket.com/albums/qq227/D...08/A02_7709.jpg

 

http://i450.photobucket.com/albums/qq227/D...08/A02_7708.jpg

 

http://i450.photobucket.com/albums/qq227/D...08/A02_7707.jpg

 

Should see here started before the end of the month... CROSSES FINGERS!!!

[EdCherry 34 1 Cars]

Update

 

Loads of small bits done, not many pictures! Battery connected and this is what we got!

 

 

 

 

Only 2 injectors will have be firing, due to no connectors in 2 injectors connector blocks.

 

All 4 spark plugs are indeed sparking, with blue sparks. Although plug 2 was covered in alot more oil than the rest of them.

 

All the electrodes were bone dry, leading me to believe that no fuel was entering any chambers.

 

Need a new distributor really, as the cables coming from it to the ingition amp might be shorting, seeing as they have lost their insulation in places.

 

Also on the look out for a complete phase 1 loom, ECU and main loom. If you know anyone thats got 1 for sale in good condition point them my way.

 

Tempted to replace the ignition amp and coil pack as well... is there anyway of testing them?

 

Can't get the injectors out, these O rings are tight. not sure what to do about them really, as I need to check they are firing.

[DrSarty 90 1 Cars]

Good stuff. It's called passion, and I love it!

 

Must be handy having Miles nearby to suck you dry...........of even more money.

[EdCherry 34 1 Cars]

Sure is! but hes saved me more money than I've spent with him!

 

Big thanks to him, and pugtop, and welshpug!!!

 

Without them I couldn't have got this far! even if welshpug confuses me and frustrates me often!

[welshpug 1,661]

It baffles me how someone with practically no mechanical aptitude or any previous knowledge would take on such a project!

 

But you're doing pretty well for someone who doesn't have a clue Ed Keep it coming!

[MrG 3]

well done Ed, I'm a little more advanced than you in the car assembly bit but not in my mechanical aptitude although improving it's way behind others on here!

 

I'm always amazed at the lengths we go to, to buy an old car and do 'it up' for whatever reason when if we paid a bit more in the first place we could save ourselves all the time and cash outlay by buying one already sorted. But then again whats the fun in that?

 

was you after a Ph1 specifically or was this there and it was a case of just wanting it?

[EdCherry 34 1 Cars]

wasn't after a phase 1 specifically although they have a certain place in my heart! its a track car after all, it isnt going to be that pretty but its going to have character!

 

Im hoping to sell on all the phase 1 interior pieces to fund a custom made dash... well kind of, just so I dont have to ruin a perfecty good phase 1 dash, no point in destroying a dieing car!

 

This car has been such a pain, but also provided so much joy as well!

 

Thanks for the replies

[Miles 331 1 Cars]

Keep going!!, But thank's for the comment 'but hes saved me more money than I've spent with him!' this is one of my main Priorities in business unlike allot who will just sell you everything aand anything even if you don;t need it.

[EdCherry 34 1 Cars]

So true miles! im glad theres someone like you in the 205 business! it makes building and looking after your 205 such an easy task!

 

Im sure the money you saved me will come your direction anyway! those gear rods, engine mounts and brake lines are calling me!

[EdCherry 34 1 Cars]

To Complete Phase 1 -

 

Parts Needed:

Battery - Open to suggestions on what to get

New Engine Mounts - Group N from Miles

Complete Gear Stick - Cut, Shut, Lengthen + Bronze Bush

L Quadrant - New Ball + Bronze Bush

Gear Linkages - Miles Steel Locking Linkages

Top Mounts - Complete Rebuild, BBM Baker Rubbers and GSF Bearings

Master Cylinder - 20.6mm Piston

Braided Hoses - Miles Hoses

1600 Calipers - Good Condition S/H

1600 Std Discs - Std discs, with new bolts for the hubs

1600 Std Pads - Std pads, open to suggestions

Brake Shoes - Not sure on condition, needs investigating

Exchange Driveshafts - Old for new

Driveshaft Seals - To aid above

ARB Drop Links - Had to grind mine off

Battery Box - To store battery

Heated Windscreen - Waiting on group buy

Cobra Monaco - Or such like, wider seat for a larger man. Only need 1

Harness - Would like a matching safety devices, but 4 point/3 point harness will do

Cage Plate Kit - To put my cage into the car with

1mm Steel Plate - Repair Patchs?

Exhaust Manifold - Mine has seen better days

Dished Steering Wheel - Sourced, just need to buy

Quick Release Boss - Sourced, just need to buy

Trim Fixing Kit - To fit the trim back on

2 Red GTi Doors - Mine are rusty

Red GTi Rear Valance - Mines cut up

Phase 1 Rear Valance Bumper Plastic Bit - Mines cracked

FIA Approved Cage Padding - Says it all

Non FIA Approved Cage Padding - For the not some important bits

Gearbox Oil - Have None

Engine Oil - Replacement

Switchs, Safety + Misc - Broken Stalks, Safety and Ease of Relocation

Tyres - Wet/Dry or Just Roads, Suggestions

Bulbs - Im sure im gonna need some

Bolts - Missing Loads

Slam Panel Air Intake Attachment - Mines been cut with a hacksaw LOL

Window Wipers - The rain in spain is mainly on the plain.

 

 

Stuff To Do:

Wheels - Locking wheel bolts off, Stud and Nut conversion on.

Exhaust Manifold Replacement - Will be blowing most likely

Fit Radiator - Says it all

Coolant - Fill 50/50 Ratio, Bleed

Rust - Finish Cleaning it up ready for repair, boot floor urgent

Remove Fuel Tank - Ready for cage welding

Fit Brake System - Says it all

Rust Repair - Repair patchs

Fit Cage - Plates welded in

Fit Seats - Seats welded in

Gearbox - G'Stick back in, along with rods and L plate

Bolt Check - Find missing bolts, and replace

Steering Wheel and Boss - Install, Weld Possibly?

Spray Interior - After all the welding, going to need a bit of a spruce up

Trim Back On - Finishing Touchs Exterior Wise

 

 

Im sure theres loads more to be done but im stumped after writing all that out. Will add to it

[EdCherry 34 1 Cars]

Todays update

 

ECU loom out to get some work done on it (repairs) and thought id go round the car and hunt out the rest of the rust.

 

http://i450.photobucket.com/albums/qq227/D...08/DSCN1725.jpg

 

http://i450.photobucket.com/albums/qq227/D...08/DSCN1726.jpg

 

Would like to know exactly where this bar is meant to sit

 

http://i450.photobucket.com/albums/qq227/D...08/DSCN1729.jpg

 

Rust, im just being picky really, most of it just needs cleaning out and painting up being surface rust, one or 2 parts im worried about!

 

http://i450.photobucket.com/albums/qq227/D...08/DSCN1731.jpg

 

http://i450.photobucket.com/albums/qq227/D...08/DSCN1732.jpg

 

http://i450.photobucket.com/albums/qq227/D...08/DSCN1733.jpg

 

http://i450.photobucket.com/albums/qq227/D...08/DSCN1735.jpg

 

http://i450.photobucket.com/albums/qq227/D...08/DSCN1736.jpg

 

All tucked up!

 

http://i450.photobucket.com/albums/qq227/D...08/DSCN1738.jpg

 

And for a laugh!

 

[munster 0]

Not tax? On a public road? tut tut

I hope your neighbours dont grass you up..

[DrSarty 90 1 Cars]

Doesn't look the kinda place 'grassers' live.

 

And you could thin out some of that fan cowling as you really only need one. Another way would be a slimline 'pull' fan on the 'inside' of the radiator (engine side) as it's all wasted fuel carrying sh1te you don't need about.

 

Nice peg leg by the way. Is that showing some toe in?

[EdCherry 34 1 Cars]

Its got tax... honest

 

Its got 5 degrees negative camber sarty. The hat and eye patch add 15bhp!!!

 

Once the car is running props the butchering of doors, boots, bonnets, fan fowlings, dashs and such will begin!!!

[happygoron 2]

Once the car is running props the butchering of doors, boots, bonnets, fan fowlings, dashs and such will begin!!!

 

Dashs? What dashs?!!

[EdCherry 34 1 Cars]

Ok,

 

got the ECU loom off to Miles for a bit of repair work, and got it back yesterday.

 

Fitted it back in today and got the injectors out.

 

Cranked the engine no fuel! (Video Below)

 

http://s450.photobucket.com/albums/qq227/D...nt=DSCN1750.flv

 

Now its either the injectors... which look funked (one left its o ring in the inlet manifold), or the wiring. The fuel pump is going and I can hear fuel going through the fuel rail.

 

Is there any vital wiring that could be stopping it starting?

 

[EdCherry 34 1 Cars]

Update time!

 

Thanks to Wide Arch 205, I now have a box of spares and the all important Irwin Bolt Gripper.

 

15 minutes work and the remaining 2 locking wheel nuts were off! Job done.

 

 

So I got my stuff together to put the stud and nut conversion in that I got from Miles! I had lost my 271 Threadlock so got another, and £6 for the M12x1.25 while I was at it. Brake cleaner at the ready and I was off!

 

 

 

 

Test fitted a stud here, looks ok doesnt it?

 

 

 

 

The drums were stiff as **** to clean out, but the front hubs were easy peasy! They look quite clean now, will go round the edges with some paper towel and more brake cleaner.

 

The studs will go in after they are all dry and the 1600 wheels will go on tonight once the 3 hours drying period has lapsed. More updates later tonight!

[EdCherry 34 1 Cars]

More piccies when I went to move the 206! The studs are in and the bearing fit is drying!

 

 

 

[EdCherry 34 1 Cars]

Update!

 

Got the 1600 wheels on... BOTH SIDES

 

Pictures will explain

 

 

On

 

 

 

Tsw's

 

 

 

OFF!!! WOOO!!!

 

 

 

Cleaned

 

 

 

Studded

 

 

 

Studded aswell! Horrible brake disc bolts snapped in the hub though

 

 

 

On

 

Good day so far, need to tigthen the drivers side wheels up at 5-6pm when the glue is dry and then it will sit on the floor

[EdCherry 34 1 Cars]

UPDATE:

 

Runs like a bag of spanners (and a bad bag of spanners at that!) missfiring, pretty sure injector on chamber 2 isnt firing consistantly. Wont start with the SAD either so I assume its f***ed. Hand over the 90 degree bend and she starts!

 

 

 

 

 

The Safety Gear