205 Sport Van, Supercharged GTI6

[allye]

Summer is coming to a end so I'm going to have some time to get on with the van. Starting to collect some bits, 99p cosworth intercooler!



Also got a 9mm pump sorted, that's about as far as tuning will go with this, maybe some arp head studs at some point for added reliability. Front seats also sorted, full leather heated 405 seats, not far off Goodwood front seats.

[allye]

Pulled the van out of the hedge, stuck it on some nice high axel stands (and some breeze blocks and started work!)



Some small amount of rust to tackle, normal 205 spots, this is the some total on the entire van thankfully.




Entire phase 1.5 GTI interior which will eventually go in.



Trial fitted the 405 seat, I will be moving the bulk head back to allow more leg room for my extra long legs. These seats look like goodwood seats but are a lot softer and mega comfy.



For anyone interested this is what make it a 205 van! That and lack of windows, also says car derived van on the V5

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Salavaged a couiple bits to sand blast paint a re use, all the suspension will be rebuilt, standard GTI suspension so the sub frame went in the bin.



stripped the interior, found under the carpet to be soaked unfortunatly.



But the floor is in perfect condition which is good.



And then the big news! After much deliberation I've decided to sack off the the smokey old XUD and will be fitting a HDI on a stage 1 with no intercooler, should be plenty to punt the van along with 60mpg+ MPG is what I'm aiming for on this.



Picked it up for £200 of Gumtree, bit too good to break! Sold with a noisy 3rd gear, its absolutly fine though, just a knackered release bearing!

Beam and tank off ready for a wire wheel and underseal.

[Uberderv]

Good stuff, was waiting for pics

[andyyy]

Always liked the van versions of these, always thought they'd look nice with gti body kit also make epic sleepers!

[allye]

Cheers guys. Uberderv is guiding me through this as he's done it before! Ive been talking to him for a bit amd it persuaded me to go for the HDI.

I had a 205 van for my first car when i was 17 and crashed it so its only right ingot another.

[bashbarnard]

wahoo another 205 hdi!!!

[Poodle]

Lovely! Glad you decided on putting a proper engine in.

That does look very rust free, going for a full strip and seal to keep it that way?

[aaron_one]

This looks good, be good to see the hdi engine in there soon!

[allye]

Not going to fully strip the underside as the majority of it is very good, I'll use a fairly mild wire brush attachment to take the surface rust back to metal and treat, the entire underside will be treated to some epoxy mastic.

[allye]

Had three days at the garage so got a bit done to the van, inbetween a transit clutch, susuki clutch, astra radiator and other bits I had some time to get the arches and engine bay sorted and readish for paint and underseal, only a couple small bits of rust to sort. Pretty decent for a 21 year old I reckon!


Lightly wire wheeled, will go over it a little more before painting, no going to bare metal there is no need,  more of a tidy up.

Normal rust spots.

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Removed the loom all labelled up ready to mate to the HDI loom.

Finally managed to get this out in one go, anyone ever got the foam out in one piece though!?

[allye]

Got me a 206 2.0 hdi eco gearbox! The correct longer than a HDI box one. WIN!

[Stef205]

Can your buddy Stef put bigger bars in this one for towing etc when he has your axle?

[allye]

I will fit a tow bar, but for a 400kg trailer tent so no! Customers always right?

[Stef205]

oh your customer now? remind me to invoice you for the rest

[bashbarnard]

206 hdi eco box. Always wanted one. No idea where to get one though!!

[allye]

Just came across it on ebay last nigt, only one on there. 20DM21 is the correct gearbox for them to clear up any confusion that I've read onlone. Shares the same code as some 307 110 HDI gearboxes except those are cable shift.

[bashbarnard]

Ok fair enough always good information to know. get it fitted

[allye]

Im going to stick the final drive in my hdi box, ive done a hydraulic clutch conversion on my Goodwood but dont want to do it again!

[allye]

Got the bulk of the body work done! Was my aim before leaving for winter so it wouldn't rot any further. First think was to get it inside, bolted the beam on with 2 bolts and placed the front on a towing dolly, one person pushing around.



The drivers seat mount had split, I know common on 205's but the first time I'd come across it. Got that welded back up.



Let my friend weld that as it's slightly important! I did all the rest though.



Couple of the patches made up, half seam welded and some plug welds.





Primed behind the front panel patches to try and stop it rotting any further.

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Then the utterly horrible job of cleaning up the underside, a day of wire wheeling destroys your arms! I'm not going back to bare metal just a thorough clean up, protect where needed and paint. I've undersealed using the gun, when I'm back I'm going to brush on some epoxy mastic to finish it off. Used Jenolite rust eater all over too, much prefer it to kurust.

It's in very condition under the 20years of self rust protection and grime. What I started with.



Wire wheeled, I used a fairly mild wire wheel and a knotted one on more stubborn/rusty areas.









Zinc primed bare metal areas, then under sealed.







As said I will go over with white epoxy mastic in the spring. Thats how its left, bolted the beam back on and wheeled it outside once it was dry and wont be touched until March! Then I have all of March and April to finish it.

[205dtub]

Very thorough, did the same with mine. Definitely waxoyl afterwards, best stuff you can use!
Solid work so far I'll be following this one!

[allye]

Not a fan of waxoil personally. I'll go over with epoxy mastic which is the shit!

[Stef205]

waxoil has water in it! why trap water between panels

[allye]

Changed my mind again, this setup is now going in, much better noise.

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Too add, this conversion is partly for silly speeds, but mainly to piss of stef by using a rotrex!

[Stef205]

wont piss stef off as he spent half as much for the same/more power and better sound! stef is smiling ear to ear

[zx_volcane]

hah, wonder what engine will actually end up in this by the time you've finished :p

can't argue with a supercharged 16v though

[Magenta Sunset]

if hadn't needed to buy one in a hurry, i'd ask you if that caravan was for sale

[welshpug]

still no match for a set of trumpets

[allye]

hah, wonder what engine will actually end up in this by the time you've finished :p

can't argue with a supercharged 16v though

100% this one! Heart ruling over head for sure, although saying that the setup in the 306 really isn't bad on fuel at all when cruising.

if hadn't needed to buy one in a hurry, i'd ask you if that caravan was for sale

I think it actually is for sale! 

still no match for a set of trumpets

Indeed not, however I was pleasantly surprised how good it sounds and hasn't killed that distinctive GTI6 noise.

[Stef205]

still no match for a set of trumpets

boost is king always will be, im sorry but youll need to bend over then pay 8-9k for the same power with bodies at the same time reving the tits off it all the time.

[Piggy]

still no match for a set of trumpets

Said no man with boost ever