Bit of fun 205 dt

[td_dan]

Please bear with me as im copying this over from another site

i then went on to buy another in alot better condition for a steal of £300, So with the DTi6 also gone now i can finally begin work

First things first clean up the workshop and temp up a ramp to allowing pushing in and out a bit easier lol.





then pushed the back of the car in to begin emptying to see what goodies were inside





bodypanels



Mechanicals, Rad looks brand new almost and also thats a set of s1 Rallye Steelies aswell That camshaft is also gonna be put to some use aswell



Scrap



Well next job earn some money back so can start spending lol, Sunroof sold so this had to be removed





bosha job jobbed thats where i am at the min, iv ordered LOTS more shinies so im gonna try and keep this as updated as poss

comments welcome as usual

[ginge191]

If this is the 205 i think it is :love:

[td_dan]

Right then little update.

Standard issue gov modded the other pump which was originally untouched, whoopsie






and sorted out the first subframe for the new bargain buckets (£52 the pair )


Stainless braided brake lines from front to back

[Piggy]

This looks like it will be a hell load of fun

[td_dan]

also started my 306 dt box conversion to work in the 306

start with 1 xud box


remove 3 13mm bolts from speedo housing and lift off




turn box and remove 4 16mm bolts on the diff housing


then remove the 11mms on the diff housing


and lift off to show the diff and crownwheel which will simply lift out


next job is remove the 8 17mm bolts from the crownwheel (be careful as the threads have been known to strip)




then put the diff to one side and keep the crownwheel close




repeat the same with the 205 box only put the crownwheel to one side and keep the diff ready for refitting.

comment welcome

---

right then decided to pu the gearbox back together now that i have removed the 205 diff,


Firstly i put the diffs side by side to see why i was unable to use the original 306 one and also as alot of people are unsure as to why the 205 shafts doesnt fit a standard 306 box so heres photograhic evidence,

The 306 diff is on the right and as you can see the pin in the middle is what causes the 205 driverside shaft to not fit due to the diff not being as 'deep' as the 205 one.


once the 306 crownwheel is cleaned up put it on to the 205 diff and refit the 8 17mm bolts and torque them up to 65nm


then add sealant to your diff housing, i used Loctite Black Sealant as i use it for waterpumps and its great stuff


new diff all cleaned up and fitted


all back together and cleaned up a little bit with the 205 speedo housing fitted aswell


right no the box is back together you need to pinch a few other bits from the 205,

replace the 306 arm


with the 205 one


these are an absolutle ******* to remove and i ended up chopping my arm up a little bit then had to improvise to get the gear selector to work properly, when i get my welder back i will secure properly


and also need to fit this sensor to the 306 box


and that was it for tonight and also a second coat on the brakes

---

Right sunday was car day so went shopping and bought all the service stuff for the leon inc brakes all round and also some bits for the 205 and cracked on

First job was to cut and shape my roof sheet and get it drilled ready


Next job silicone roof, and pop rivet this badboy down


Job jobbed, whilst outside thought i would trial fit the bonnet , not to bad


Then finished some painting, brakes, engine mount bracket and steering wheel plastics






Then last job for the 205 was finish making the seat base for passenger seat


Finally both fitted, i also cut a sheet for my switches in the dash.

Finished the day giving the leon a full service with brakes aswell only to find LOTS of mayo in the oil filler neck but doesnt bother me as its just a workhorse so will just run it til it dies but still sorted it anyway


and thats upto date now, comments welcome

[Chris_90]

Great stuff there, handy with the gear box stuff might help of I ever find a Hdi box.

Will keep my eye on this, keep up the good work

[td_dan]

no probs mate just makes things easier for people

[ginge191]

Loved seeing this and the engine when i popped up, can't wait to see this all together!

[Piggy]

Cant wait to see this progress....

Im itching to start a 205 project

[td_dan]

Thanks gents, tomorow the front subframe should be off ready for a good clean and also the gearbox will be painted

[zx_volcane]

Good lad Dan, cracking on fast with this one

[td_dan]

Got to mate fcs is soon lol, aint tried that tool yet mate but will be soon

[Piggy]

Get that subframe seam welded whilst its out!

[td_dan]

Right, headed down the garage tonight to do a few bits, first things 1st paint up the newly built gearbox



next up was time to remove the subframe, had a right ballache removing 2 nuts as the bush was fcuked so had to completly remove them.





21 year old subframe



steering rack was looking a little worse for wear so started with removing that



start the strip down





already have new track ends and droplinks so now need to order new wishbones and inner tie rods



then i was 9pm and considering i have to be up at 5am i left to go home and have a shower lol

comments welcome as usual

[Chris_90]

Looking good as usual, how much did them drop links cost you? I'm looking for some at the min

[td_dan]

15quid of the 205 site but bought gearlinkages aswell

[td_dan]

Update time,

Stripped the rest of the subframe, so i could start to work on replacing what was needed


finally removed the bushes


next up need to get the remainder of the driveshafts out of the hubs, que the massive bar and hammer to loosen the driveshaft nut


voila


the wishbones will be getting binned as the fcuked, the fronts struts will be having new top mounts (bought) and 50mm GTi lowering springs (bought).

next up was turbo time

i had initially put a k14 on just to get it back in the car and running but then a t25 popped up for sale so ended up buying that all tho not quite bolt on as advertised but nothing i couldnt sort out.

k14


k14 and t25 gonna be some serious fun when it gets on boost as it the t25 from an sr20det


and on


the main issue is the outlet and inlet need to be purchased but looks like it might be tight


and this is whats needed
http://www.ebay.com/itm/Turbo-Compressor...1208498429

and then a little view from the drivers seat (gauges not wired up was just playing with positioning


also drilled the bulkhead and ran my stainless brakelines inside ready for when i start the rear beam

comments welcome as usual

[Craigus]

Looks like good progress

[mikey b]

Looks good gonna be fun when she spools up

[silverzx]

Good work with the turbo and subframe!

The T25 was used on the CA18DET S13.
The T28 was used on the SR20DET S14.

[td_dan]

Cheers for the info mate

[ozonehostile]

Nice to see this coming along :-)

[Pugmarshall]

Looking good Dan, how many gauges are you going for? I'm running out of decent positions for mine...

[td_dan]

Well iv got another 2 to put in yet and i think thats it

[td_dan]

right so another update

Decided to strip the suspension and fit new bearings and my gti lowering springs

old strut


old spring off


old bearing and rubber




new bearings and rubber


new springs put on to the struts


ready for fitting just need a little paint


also started cleaning the steering rack


then decided i needed to get the clutch onto the engine and found this little gem in my box of bits

Valeo




then left the workshop with this on the floor ready for refitting tomorrow cant wait


comments welcome

[padge]

nice progress dan

[Tom]

Looks good pal, exciting bit now!

[Piggy]

Going non PAS then?

[td_dan]

Na piggy no pas at then min see how she goes first, i didnt on my last one and preferred it especially on track

[zx_volcane]

Turbo looks like its at an awkward angle for the downpipe

Didn't you have a gt20 kicking about?

Mighty progress there though Dan, moving along swiftly as usual!