[engine_work] My Project, Miami Blue Gti6-ish

[Super Josh 4]

Nice one Fox we expect a full report on how she goes too

 

 

 

 

Josh

[timb1046 1]

you work pretty fast! looks great. loving the pics of her parked up, must be one of the shineyest 205s around!

[Fox 3]

Well, my idea of finishing the car over Christmas didn't go down too well with the other half, so there's still loads to do.

 

Should be able to get a good session in tonight and (hopefully) sort the engine mount and exhaust finally.

 

Its really annoying, I'm so close to finishing it but seem to have lost the get up and go now its just boring fiddley bits! Being back at work doesn't help either!

 

Still to do...

 

Weld bottom mount up

Weld exhaust

Refit headlight / fan wiring etc

Fix battery box

Cooling pipes - Still unsure what I'm going to do with the heater etc

Fill gearbox with oil

Rev counter loom

 

Fingers crossed I'll be driving it Wednesday, with a big smile on my face!

[Fox 3]

Well, had a good evening yesterday and welded up the mount and got the exhaust fitted properly. A 106 rallye mount, cut up fits into the 205 fork and makes it about 10mm longer, perfect for the job!

 

Also secured the battery box, although it'll be coming out to do the plumbing today!

 

Still intending to go to work in it tomorrow, need to sort out a small petrol leak first, never a good idea to have one of those! I've found a new 106 filter in my spares, so I think I'll use that!

 

Edited December 30, 2008 by Fox

[Fox 3]

Well, I didn't manage to make it into work in the GTI, still got a few bits and bobs to finish, and seem to have a coolant leak from somewhere.

 

On a plus note, It sounds awesome! I backed it out the garage and swung it round in the road, the exhaust note has become distinctly raspier, and the induction roar (even under no load) is fantastic!

 

Looks like it wont be on the road this year though, sadly I have been defeated!

 

More next year (do you like what I did there!)

 

Edited December 31, 2008 by Fox

[Flix 0]

You've got until midnight yet Fox.

Got my engine out yesterday, as soon as I get a few more bits together mine will be underway.

[Fox 3]

It lives!

 

Finally managed to stop all the coolant leaks and get it on the road!

 

And what can I say! Fantastic! Not ideal in these slippy road conditions, when you actually get grip it pulls like a train, so much torque compared to the 8v, and a noise to die for!

 

Got a few bits to iron out this weekend, mainly the lack of VSS and lambda sensor, also I need to adjust the Master cylinder location slightly as the pedals vibrate a little, but apart from that its great! Even with no VSS its smoother than the old 8v

 

Just need to sort the brakes now, they are truly shocking

 

I don't seem to have any dials working correctly, I'm fairly sure the water temp and stop light are the wrong way round, the STOP glows and gets brighter as the water heats up...

[Fox 3]

Mini update -

 

I've been to my mates scrappy and got a lambda sensor, its the same plug as the loom so saves cutting the wires etc, from a Saxo if you ever need one!

 

 

Looked for a speedo sender, but could only find one or the other, not one with the plug AND speedo drive. I might just stick an electric one on for now, and use my sat nav for a speedo... We'll see. Its a shame I let one go a few weeks ago on a 106 rallye box I had

 

Also I'm getting quite a lot of vibration through the pedals, I think i'll have to adjust the master cylinder/servo location slightly to stop it fouling the cam cover.

 

It seems to have a random idle, sometimes spot on, and other times it sits about 2k, and has a bit of a missfire at high revs although hopefully I'll cure these with the lambda sensor when I get round to welding it in.

[Dan Ingram 1]

Have you got the nut to weld on to the exhaust to put the lambda sensor in? I'm struggling to find one that fits the threads.

[M@tt 77]

dan

 

ebay is your friend

http://cgi.ebay.co.uk/LAMBDA-SENSOR-THREAD...A1%7C240%3A1318

[Dan Ingram 1]

Good work Matt, Thanks

[Flix 0]

Have you found any senders Fox?

They should sort your gauges out.

[Fox 3]

Dan, I cut one off an old down pipe and welded it on, seemed to do the trick!

 

Flix, which ones do we need to swap? These are the three sensors from my 8v block (right is the gti6 guage one I believe), but I dont know which one did which, or what I need to swap!

 

 

Also found a speed sensor, that made a nice difference! Its from a 106 Rallye if you need one, you need to swap the cog for the 205 one though

 

 

Still got a missfire at high revs, I'm going to try and reset the ECU but i'm doubtfull it will cure it...

Edited January 4, 2009 by Fox

[Fox 3]

Hmm, it seems I forgot to update this!

 

I cured the missfire, and all is/was well apart from the crap cooling and lack of heater

 

Anywho, now i've got a new job and company car, the GTI is being stored in the garage during the back end of winter, no more snow and salt, whoop!

 

I decided to replace the front bumper, it fell apart when i dropped the 6 lump in, so i bought a replacement.

 

I also bought a new radiator, the old one was past its best and I thought I may as well, while I was on.

 

After I stripped the front end down, I thought I might as well paint the engine and bay up properly, my effort while doing the engine swap over chrimbo was rather quick, as I needed the car for work.

 

I also picked up a set of speedlines to get refurbed, I'm not a fan of the dark silver ones i've got on at the moment

 

So thats how it stands now, bare front end and gathering dust!

[Mark205 1]

Just read this topic from start to finish and it looks very good.

You work fast.

Love the picture of the miami next to the red rallye on the drive, (smart drive, is it yours).

[Fox 3]

Mark, sadly the drive is my dads, may become mine one day I suppose!

 

Anywho, a few (poor) photos, this is the state of it after the engine swap and a bit of nice salt and crap on the roads, note the special bolts to hold on the bumper!

 

 

And as now...

 

 

A few shiney bits

 

 

 

Just got a few more bits to tidy in the bay, and it should be going back together!

Edited March 24, 2009 by Fox

[Fox 3]

Been able to spend a few hours on this today, popped down to my mates scrappy and got a diesel twin fan and wiring, and a front cross member for a whopping £5!

 

 

Also picked up a new radiator, although its metal not plastic like the old one... Still should be better though, the repair on the old one looks very poor to me!

 

New

 

Old

 

 

Repair

 

 

Heres the modified engine mount bracket

 

 

The cat also decided he likes the garage, and knocked everything off the rafters for me

 

 

I also found these radiator rubber pads on the scrappy 205, never even knew these existed!

 

 

Got a set of alloys to get blasted now, will be getting them done silver when I get time!

 

 

And how it sits now, going back together, need to tidy that wiring and find some more silver paint!!!

 

Edited March 24, 2009 by Fox

[Fox 3]

Well its back together, just waiting on a few bumper bits, and I still need to paint the new slam panel.

 

Took a few photos yesterday, shame the sun went in as soon as I started taking photos!

 

 

 

[Tom Fenton 1,542]

Cat looks cool, car looks good too, although the pics make it look quite high at the back?

[Fox 3]

Cat looks cool, car looks good too, although the pics make it look quite high at the back?

 

Its really high at the back, It was high before I dropped the 6 lump in, now its nose diving!

 

The 1600 beam is only temporary until I find a cheap but useable 309 one, which could take some time!

 

Heres a photo from another angle to show how bad it is!

 

 

I really must sort the suspension...

[welshpug 1,657]

I'd just drop it 20-25 from there and not bother with a 309 beam.

[Fox 3]

I'd just drop it 20-25 from there and not bother with a 309 beam.

 

Hmm, I fancy the rear disks aswell though. I've got what I think is a warped drum on this beam, and dont fancy paying out for a drum and the bearing swap if i'm swaping the lot anyway.

 

Might have a play at the weekend to see how much I want it lowering, as you say 20-25mm to match the front should do it!

[SurGie 54]

Nice job there mate, do you know if the de-cat pipe for a gti 6 would work in the 205 for the lamba senser?

 

where does the crank senser go once fitted?

[hexhamstu 9]

put that number plate back where its meant to be!!!

 

other that good job!

[Fox 3]

put that number plate back where its meant to be!!!

 

other that good job!

 

There's a reason for the number plate, I'm waiting for a slightly smaller one to fit in the recess on the bumper, only an inch narrower but should fit a bit better!