205 1.9Td Gti Rep. (pic heavy)

[pugtk]

Hi All ,

Ive been quietly reading on this forum and the other forum now for the past few years ,but never uploaded any projects.

So I have been building my 205 over the past year.

To date the car has been striped back to a shell and rebuilt back up.

Shell/Suspension

• The first job was to treat the rust problems in the boot and the chassis legs.
  
• The rear axle has been rebuilt and mounted to the car on solid mounts.
  
• New handbrake cables
  
• New shoes/brake disks pads
  
• Replaced brake lines
  
• Modify the rear arches to allow the gti trim to fit
  

Engine/Drivetrain

• Engine built from a block back up
  
• New H/g and headbolts
  
• All gaskets replaced including crank seals
  
• New timing belt bit
  
• MBC Fitted
  
• Boost Gauge installed
  
• Gearbox resealed(diff cover and end cover)
  
• New driveshaft seals
  
• New c.v booths
  

Cosmetic

• Sprayed gti trim
  
• Sprayed 1/4 panel badges and put new stickers on
  
• General tidy and painting underneath the car, subframe, axles, hubs etc.
  
• Cut and buff the body
  

Misc

• General tidy up of the wiring inside the car.
  
• Replace speedo clocks
  
• Repaired fuel gauge
  
• Repair the heating system
  
• Stud and nut conversion/new chrome wheel nuts
  
• waxoiled the panels from the inside
  
• undersealed the car
  

Interior

• Seat have been restored
  
• dyed the interior
  
• dyed the carpet
  
• dyed the roof liner black
  
• Spayed the seat railing and other fittings
  

Plus load of other jobs, I would be here for to long to list all the work done to date.

Ill let some of the pictures do the talking

[procta]

get some pics up as I love builds like this!

[pugtk]

I had a file uploading for near 1 hr and I lost it .. haha

by no means is it a showroom car, I just wanted a fresh good driving respectable car

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[pugtk]

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[procta]

That's some work! how much has it costed you?

[pugtk]

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[td_dan]

Im breaking my 1.9dt 205 if theres anything you need mate

Lovely looking car

[pugtk]

Im breaking my 1.9dt 205 if theres anything you need mate

Lovely looking car

I'll pm you if I come across anything I need

Hopefully I will get around to uploading some decent pictures later on.

I always have great intentions of taking pictures, but that usually goes out the window once I start working on the car 

[td_dan]

Lol im the same

No worries pal iv built it up with new parts and it only saw the road for 100miles lol so its all for sale including a rear sd cage

[pugtk]

That's some work! how much has it costed you?

to date around €1500 including buying the car and engine  

The most expensive purchase's to date was the gaskets /timing belt to freshen up the engine

I have an excel sheet I'm keeping record of everything.

I was breaking a couple of 205 and I have been collecting parts for the build.

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That's some work! how much has it costed you?

to date around €1500 including buying the car and engine  Although I'm not finished yet, but I just put a small bit aside into a kitty each week then buy all I need to complete a certain job.

The most expensive purchase's to date was the gaskets /timing belt to freshen up the engine

I have an excel sheet I'm keeping record of everything.

I was breaking a couple of 205 and I have been collecting parts for the build.

[7057sam]

Top work mate

Car looks stunning

[Uberderv]

Nice work, whats the white bottle infront of the expansion tank for? :-)

[td_dan]

Epas id say

[pugtk]

Yea its eps the pump is beside it

I have to spray the pump yet, its the only rusty looking part in the bay. I just mocked it up to get it working

[procta]

that's got to be the cheapest restore I have seen! As most are well over that!
Are the new parts hard to get hold of?

[pugtk]

Parts are easily got.

To be fair allot of time has gone into this car time, pictures don't really give the time "put in" justice.

I was just lucky I picked a bargain donor car tbh. Only gave 600 for it, but to be fair it has technically been a reshell. with ever nut and bolt replaced along the way.

Mechanically this car was severely neglected.

Luckily paint on the outside was decent,a cut and buff tidied the paint up. This was the main reason why I bother with the shell(replacing rusted sections) So its respectable, you wouldn't be embarrassed by the car.

[Uberderv]

You've done a good job mate, got bits of rust on mine mainly at the front end under the lights but I plan on replacing the panels instead.

Where have you squeezed the air filter in?

[pugtk]

No where yet. Ill try and squeeze it over the g/box like the 306

[procta]

Parts are easily got.

To be fair allot of time has gone into this car time, pictures don't really give the time "put in" justice.

I was just lucky I picked a bargain donor car tbh. Only gave 600 for it, but to be fair it has technically been a reshell. with ever nut and bolt replaced along the way.

Mechanically this car was severely neglected.

Luckily paint on the outside was decent,a cut and buff tidied the paint up. This was the main reason why I bother with the shell(replacing rusted sections)  So its respectable, you wouldn't be embarrassed by the car.

you can tell you haven't mess about with it, you want to see what I did. if I had the equipment id have done a restore like this, i had to swop over the good bits from the old shell and bin what i didn't want,

[pugtk]

[quote pid='509178' dateline='1422219414']

you can tell you haven't mess about with it, you want to see what I did. if I had the equipment id have done a restore like this, i had to swop over the good bits from the old shell and bin what i didn't want,

 
I must have a look at your project thread.

I've been wanting to build this car for the last 4/5 years (I was a 306 head first).

[procta]

[quote pid='509178' dateline='1422219414']

you can tell you haven't mess about with it, you want to see what I did. if I had the equipment id have done a restore like this, i had to swop over the good bits from the old shell and bin what i didn't want,

 
I must have a look at your project thread.

I've been wanting to build this car since I was 19 (I was a 306 head first).

[/quote]
I have two on here, look for the gta 16v and then the street sleeper is reborn.

[pugtk]

O.k so after changing my engine, I have lost the rev counter.


So I tried to get to the bottom of it tonight, Checking over any connections and earths in the bay.

I tried different settings on the flywheel sensor, and eventually just pushed it in on the flywheel while the engine was running    to say the least there's no face left on it..haha

I also tried another sensor from a 306(unsure if it works) however no luck.

So time to order a new one.

Also got a set of helper springs off a forum member so hopefully they will arrive next week.

[attachment=21471]

[procta]

getting there! it is a bit of a head scratching moment, when rev counters and fuel gauges don't work after a rebuild. I had two days of trying to sort out why my interior light wouldn't work as it should, I found that I had put two wires on the wrong parts of the light, also my fuel gauge got stuck. That reminds me I should really replace that with the unit have bought! while it doesn't have any petrol in!

[pugtk]

Doesn't help that my wiring skills are limited

I also replaced my turbo oil return gasket,as it started leaking(the only gasket I didn't replace in the entire engine), however one of the bolts does not feel quite right when torquing it down, so to save me the hassle of taking the turbo off if it breaks, I am going to wait until next weekend and I will get two new bolts.

[pugtk]

This Project is mostly finished now, just some minor jobs left

Updates are due this weekend

[procta]

be great to see!

[pugtk]

be great to see!

This weekend for sure,

Just to finish fitting red strips and spray black trims

[procta]

be great to see!

This weekend for sure,

Just to finish fitting red strips and spray black trims

adding the finishing touches make the all the difference!

[pugtk]

So this car is pretty much finished now.

So I have to upload the full picture gallery.

Is it worth shimming the governor on a standard t2?

I was planning on grinding the lda pin also

[Poodle]

It should be, the t2 benefits from a helping hand via fuelling.

Look forward to seeing the pictures go up, sounds like a good little project.