205 Sport Van, Supercharged GTI6

[allye]

The underside took a long time but worth it!

IC fits very nicely that way up, even better cuts pipe work in half and even better than that is it means the complete pipes and IC setup will move with the engine and not getting tugged around by the engine movement.

[silverzx]

Damnnnnnn this gonna be rapid!!!

[Paul_13]

What rad is that bud?

[allye]

Its a radtec shortened one, bend me over prices but hey ho!

[Paul_13]

Baker BM one basically?

[allye]

It where they used to get them from but after talking to BBM they are changing suppliers so couldn't supply me one quickly as they are made to order. They delivered this one within about 2 weeks so I was happy with that, stunning bit of engineering!

[allye]

As mentioned above a deer decided take the front off the A3, so that took up two of my valuable days off! Also been helping a friend get his 90 on the road. Galvernised everything, heated windscreen/mirrors, disco 300tdi and axels, etc etc etc, it's one of the very earliest ones, first year of the 90 I think.



Any way, 205.got some nice hose clamps to use instead of jubilees.



Changed my seats to some 405 ones with material and more bolster instead of the leather.



Finished all the welding from the torn hand brake mounts and seat rails.



Mounted my PAS reservoir. Not seen another rotrex 205 with PAS?



Sorted the leak I described in the other thread.



Dropped the heater box off and started the sound proofing on the fire wall.



Removed the matrix to find what looks like a fairly new Valeo unit, bonus, also took the motor apart cleaned and greased.

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Got my oil coolers mounted, 4 littlest brackets off the head light panel and scuttle on 4 bobbins, hopefully no cracks.





And finally cleaned the floor up of any surface rust and primed, doubt I'll be painting it.

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Pictures of said Audi, got off pretty lightly for 60mph to be fair.

[insomaniac45]

This van is EPIC.... keep up the great work keep the updates coming.

[allye]

Alrighty, busy summer over, back on the van. I'd half got the wiring squared away just needed the 205 side of the brown multi plug needed (not something the diesel ever had) They are all mated up now and spent hours getting rid of wires and putting in loads of new wire on the earths. I've also gone through the entire and use a contact cleaner and little files for cleaning connectors.




Exhaust, another big job ticked off. Please note this is 2' maniflow and only temporary until a 2.5 is found or made! Standard GTI6 down pipe and a nice maniflow 205 system made from mild steel. It came with huge canon which was removed and replace with a downswept tail pipe, discreet is the key.





After fannying around modifying the front end that needed a quick tart up.



Smoke tested the intercooler, its actually a forge item which is a billy bonus.



Finally ordered up the fitting and hydraulic hose for the oil cooler.



and how its looking now, picking up slam panel and inlet manifold from powder coaters next week, supercharger oil ordered, turning key next week!!!

[Eeyore]

exciting times! good luck!

[Matt-Rallye]

Lots of attention to detail! hope all goes smoothly with first start!

[allye]

Thank you chaps! Been a long time coming and I can assure you it'll be arse twitching rather than exciting, not that I do t have confidence in myself...

[allye]

Winning today, will do more of a update later but I finally got the oil cooler sorted and sealed, first run up to temp, fans kicked in, heat in the cabin, all gravy.

[allye]

Well today I drove a 205 for the first time in years, all the way up the track and back again!

Clutch is nice and light, brakes are sharp and high, hand brake has been adjusted, gearbox isn't whining which is a win for me personally, only trundled along in 1st and 2nd but they felt good and noticeable slightly longer than my other 205's which is what I wanted. No leaks, no knocks or bangs, gear levers adjusted and feels great.

One happy chap! Just needs a complete interior/dash, all exterior lights, proper wheels and bumpers/valances!

[allye]

Hold on tight for this exciting update.

Recommissioned the wiper system, fairly seized so stripped and greased.



Replaced every bulb and plugged all the lights back in and they all work, which for anyone who has put a project together back after couple years is a huge win.



Cleaned rear light clusters.



Told you it was exciting, just all MOT type things. Think I'll MOT it with a sparse interior and run for a while to sort any issues then set about the inside which is a project in itself.

[allye]

I’ll update this soon I promise! Had a summer of fun in it last year. No break downs just lots of fun and perhaps one blat to 150 with a RS5.