Progress report. Long overdue! 205 gti ++
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Thread: Progress report. Long overdue! 205 gti ++

  1. #1
    1000+ Posts cam85's Avatar
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    Default Progress report. Long overdue! 205 gti ++

    Im slack. Thats it really.

    I started a business and met a girl 2 years ago. Since then its been a bit of a blur. The business sucking most of my time. The 205 the other part and the rest...well, you know who taking up that time!

    Where I left the other thread was about 2012 sometime. I was building a crazy 2.235L J4 motor. Its halfway there, head is done, piston and rods are ready to be orderd ( when I have lots of $$ ) and the throttle bodies will be done at the same time. The 2.3 build was adding up big time. After the head was built I was still looking at well over $8K to get it into the car. Something which I just could not afford with starting a new business. So, I took a turn.


    The Red Rat as its been coined by a couple on here, has had a pretty good overhaul.

    It all started with me finding a J4R motor that had been a bit of a slut really. PeterT built it, Adrian W had it for a while, then it want to Lauree in Melbourne and then I got it. It had never been used but had had a few mods over the hands it had passed so that when it got to me it was almost read to put into the car.


    We got it home. Fitted a GTi6 Inlet and exhaust manifold to it and pondered the next move. Patpug owed a few favours at the time so I commissioned him to modify an Old Haltech Loom ( e6x ) to run the New J4r. The biggest task was getting the Ignitor wiring spot on. There was little info about it but we go there in the end. Big thanks Pat!

    With the motor sitting there and the ECU and wiring almost ready I began work on the car.

    The RedRat was a basket case of wiring looms it seemed. I ended up ripping out all engine bay looms and half a dash loom and started again. A total pain in the arse and a big time sucker. I cant thank Pat enough for his time on this one! Lucky I had a few other looms lying about. We identified what we needed and got most things to work.. ( lucky 205s are an addiction like Heroin to me hence I have bits like this lying about )


    I cleared the engine bay of as much as I could, gave it a wash, removed a few things here and there and began some work! First thing was the fuel lines. These are a pain in the bum when doing a 16v conversion. The inlet piping on the fuel rail is different so replacement is the only answer. Not a bad thing as the 30yr old lines had seen better days. Routing them under the booster and up where to old filter sits. Replace fuel filter, check!

    I was going to be using a BE3 gearbox and had a good condition S3 pedal box lying about to popped that in. The BE3 uses a different clutch cable to the BE1 and the clutch pedal is different. WHile swapping that over we also installed a 23.8mm MC which was needed for the bigger brakes we were planning on using.

    Once that was done I got to work on the Radiator cowling. Taking a fair whack of meat off that helps with clearance of the inlet manifold. THe Aussie delivered 205s have an extra part for the Aircon condenser. Whipping that out quick smart allows plenty of room and less weight! A hacksaw is handy in a situation like this!

    WIth the engine out, I had the subframe welded and painted. Removed the old steering rack and replaced with a Xsara VTS item ( 2.6turns lock to lock ). New wishbones, bushes, droplinks and arb bushes. While all that was apart we made a short shifter, fitted bronze bushes and popped it all back together.

    Fitted a VT top mount and extended the lower fork. Most of the bay was ready for the engine now. It fitted in nicely! Needed a few adjustments on the MC clearence but was pretty good.

    Fitted the gearbox along with driveshafts etc.

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    Wired it all up. Plumbed it all in and turned the key. Never fired. Weird
    Had it towed to have an exhaust fitted so I could get it home and fire it up. Still nothing. Was turning over but ust not catching. Eventually caught yet was running very rough and just not clearing. After many hours ( days actually ) tinkering and a visit from PeterT we put a can of upper cylinder cleaner through it and it fired into life perfectly! Must have been some much somewhere not allowing a valve to shut...never really know

    The car was pretty rough to be honest. The suspension was truly race spec and horrible and the brakes were terrible. I was not expecting brilliance as not 1 things is original on the car. Only the fuel tank and lights I think..

    I had the bilsteins sent to heasman to be assessed and re valved to suite a light poundage spring. Turns out they were stuffed! 1500$ in servicing later and the dampers re-valved to suit the springs I wanted and the rear dampers matched to the torsion bars we were in business. ( rear is 21.5mm bars /148lbs )

    I drove the car for about 6 months and then wanted a change. It was just to much of a hassle and I was not using it on the track.

    The Diff ( Tran x ) was set to uber race spec. Basically any degree of steering input would almost lock the diff. Great if your on the freeway driving straight or on the track but not living in Bondi navigating through tight streets. The gearbox was also to short for the road. Im actually getting old now ( 29 ) and am visiting my dad in Bowral more often than I would have first thought. 2 hours at 4000+ revs in a 205 with no sound proofing was pretty hardcore. I recorded 110DB in the cabin one day. I bought earplugs.. Ive just had the diff settings changed to something more liveable and all fitted to a VTS gearbox. ( should be in this week )

    So about 2 weeks ago I bought 4 new CV boots. I thought. Easy, pull shafts apart and replace boots! Get a phone call as I often do with 205 related stuff. "your shafts are totally rooted". Great. Knowing that 205 shafts are rare as in OZ and the replacement stuff apparently bad quality I had to consider my options. We decided to get some good 306 shafts and chop them up to 205 length! While they were out I wanted to lighten the flywheel, change gearbox and replace the wishbone bushes. The wishbones, much like the replacement 205 driveshafts are shite. The actual bone is ok, its the bushes that wear. Ive travelled under 3000ks and they were totally stuffed. Replaced them with ( OE are now NLA ) Powerflex Black Series ( Thanks Brett from here, great speedy service ) The flywheel was stuffed also so decided to buy a new one. TTV do a light ( 3.2Kgs ) wheel so decided to get that while I was at it. Nice bit of gear. Its light, and so is my wallet from the purchase!

    The Bilsteins I obtained a little while ago were a backyard stitch up. The dampers themselves were fine, it was the way in which the dampers connected to the top mounts. The top mounts were some plate steel with a spherical bearing that the top spindle of the damper went into which was held together by a sleeved nut. A common way to do it. The whole setup was just loose, worn out and did not have enough clearence to enable camber/castor without fouling the underside of the top mount resulting in the whole assembly not being able to freely turn with the steering. The whole setup was suss so decided to tackle this while everything was apart. Lucky I have a guy prepared to take on all my small crappy jobs that need fixing! Ordered new fancy top mounts from BBM and have had some top hats machined to keep the spring off the underside of the top mounts! Yay!

    All this should be back together this week and I cannot wait to have it finally finished! ( mechanically that is ! )


    A big thanks to all involved. Patpug this car owuld not be moving if not for you. Countless phone calls to PeterT and Adrian W. Thanks for all the help.


    Will post a few porn shots when a few parts come back etc this week
    Last edited by cam85; 11th August 2014 at 09:02 PM.
    lozenge, Richard W and patpug like this.
    98 Xantia CT
    94 205 Gti Classic #9
    92 405 Mi16
    87 205 GTi Race Car
    http://www.aussiefrogs.com/forum/res...-race-car.html

  2. #2
    Fellow Frogger!
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    Great work, photos are a must for such expansive works.
    Michael



    1987 Peugeot 205 GTI
    Build Thread:
    http://www.aussiefrogs.com/forum/res...ti6-build.html

  3. #3
    1000+ Posts cam85's Avatar
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    Check out the thread in the sig below. Theres a few pics there. More to follow

    Cam
    98 Xantia CT
    94 205 Gti Classic #9
    92 405 Mi16
    87 205 GTi Race Car
    http://www.aussiefrogs.com/forum/res...-race-car.html

  4. #4
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    Did you still want the be1 gear knob?
    Michael



    1987 Peugeot 205 GTI
    Build Thread:
    http://www.aussiefrogs.com/forum/res...ti6-build.html

  5. #5
    Fellow Frogger! Bluey's Avatar
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    Old setup.
    Progress report. Long overdue! 205 gti ++-cp_old_top_hat_2.jpgProgress report. Long overdue! 205 gti ++-cp_old_top_hat_1.jpg

    New setup. Enough camber now?
    Progress report. Long overdue! 205 gti ++-cp_new_top_hat.jpgProgress report. Long overdue! 205 gti ++-cp_new_top_hat_2.jpg

  6. #6
    1000+ Posts Capago's Avatar
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    Good stuff!

    This is a true representation of our lives:
    Attached Thumbnails Attached Thumbnails Progress report. Long overdue! 205 gti ++-1544466_10154494275515089_1455471095396588033_n.jpg  
    chez00 likes this.
    The wrong oil is better than no oil at all.

  7. #7
    Fellow Frogger! chez00's Avatar
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    Hey Cam, nice work. Just wondering if you can elaborate on the "extra bit" the aussie 205's have for the A/C?
    1988 205 GTi XU10J4
    2001 406 Monaco 5sp V6

  8. #8
    1000+ Posts PeterT's Avatar
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    Quote Originally Posted by Bluey View Post
    New setup. Enough camber now?
    Nice work. I'm going to make some new top hats for my Bilsteins. I'd love to get rid of the tender springs but it seems impossible.

    '92 205 Mi16
    '90 Mi16x4

  9. #9
    Fellow Frogger! patpug's Avatar
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    Ha ha, all fun and games, and it's a pleasure mate. Really interested to see how she goes when you get it all back together.

    Also, somewhere in that story we did a great track day at Wakefield which was awesome fun - super cool that we were both keeping up with wrxs, Clio rs etc. Love these cars!

    And 29 is not too old for hard springs and crappy old French cars - talk to me in 10 years buddy! ;-)
    205 gti-6

    205 track car build in progress http://www.aussiefrogs.com/forum/res...-race-car.html

  10. #10
    1000+ Posts Richard W's Avatar
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    I think you forgot to mention your wider (309?) rear beam and the custom arms for extra camber that you imported from the UK?

    Clearly you are mellowing as you approach the big three oh - taller gearing for more relaxed cruising, softer settings on the LSD, talk of installing power steer... next you'll be putting some soundproofing back in the car!

  11. #11
    1000+ Posts cam85's Avatar
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    Haha, was only looking at that dynamat stuff last night..

    I have a plan. Cant tell anyone as its gonna be a surprise...

    Cam
    98 Xantia CT
    94 205 Gti Classic #9
    92 405 Mi16
    87 205 GTi Race Car
    http://www.aussiefrogs.com/forum/res...-race-car.html

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