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Thread: Richard's 205 GTi6 project

  1. #51
    1000+ Posts Richard W's Avatar
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    After a Christmas hibernation and a long while of slow progress, a few things on my project car are finally starting to come together.

    Huw has almost finished my engine. The motor's been balanced and the crank has had all of the casting marks removed. The photo of the pistons shows the lightest piston on the right and the heaviest on the left which has apparently had a fair bit of material removed to get the weights to match. It's pretty much all back together now. The inlet manifold and a couple of other bits are being bead blasted to make them all pretty and then ready to install. It all looks fantastic. I've just delivered Huw my new lightened flywheel and freshly painted cam covers (red - copying Hicho!). The aim is to collect it all on Thursday ready to install.

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    Richard's 205 GTi6 project-rw_crank_linish.jpgRichard's 205 GTi6 project-rw_piston_balancing.jpgRichard's 205 GTi6 project-partly-assembled-engine.jpg

    The gearbox too is back from Adrian W and ready to go with the 3.94 final drive and the Quaife installed.

    I got the shell back from the paint shop down in Mittagong a while ago but there was still some ripple in the doors - so it's currently back in the shop having the doors re-done. Hopefully that will be back by the end of next week so the shell will be ready for us to install the motor and gearbox next weekend. It will then be brought back to my garage in Sydney to assemble the rest of the car at my leisure!

    The upholstery is proving to be a bit of a challenge. I decided to get the seats fully recovered in black leather with a red top stitch. The guy doing it was adamant that he would be able to get the shaping of the seat base and around the bolsters just right. When I went to collect it a couple of weeks ago, however, I found he'd done a dreadful job. He's blamed poor quality of the foam base for most of the problem. I'm not sure about that, but it seems to me that I'm now a bit stuck - the upholster has pulled the original seat covers apart to make his pattern for the new covers, so if I were to take the seats to someone else now I'd either need a second set of seats for the new upholsterer to pull apart or the new guy would have to start without any proper pattern. So I've ordered brand new foam bases for the seats and I'll give this guy a second go. There will be tears all round if he doesn't do a vastly better job this time!
    Richard's 205 GTi6 project-seat-bases.jpg
    Last edited by Richard W; 13th March 2015 at 11:27 PM.
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  2. #52
    Fellow Frogger! patpug's Avatar
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    Wow this is a comprehensive build Rich. That's the trouble with doing things well... Its hard to know where to stop!!!
    205 gti-6

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

  3. #53
    1000+ Posts BIGRR's Avatar
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    What progress?
    Present fleet:-
    Peugeot 93' 205 Gti 16v
    Peugeot 73' 504 Ti from new
    Peugeot 08' 407 Hdi Coupe from new

    Previous fleet:-
    Peugeot 95' 605 Sv
    Peugeot 92' 205 Gti
    Renault 72' 16TS from new
    Renault 69' 10
    Renault 71' 10s
    Renault 68' 10 from new

    "Be reasonable do it my way!"


  4. #54
    1000+ Posts Richard W's Avatar
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    Hi Robert

    Progress has been slow I'm afraid. It's been a crazy busy year for me at work, we're doing a big building project, and we're setting up a new business for my wife - so my days are full! Any spare time tends to get spent with family rather than the car, so the most I've been able to do is sneak in an afternoon here and there...

    The limited progress since last update:
    - After 3 goes, the seats have been finished and look good
    - I've been slowly sourcing replacements for missing, broken or imperfect parts for the interior and body trims
    - the interior and most of the exterior trims are back together and look pretty good!
    - most of the mechanical parts are there ready to go.

    I just don't see myself getting a good block of time to get into this in the foreseeable future so the plan is that, now that he's finished his work on Pat and Cam's race car, my car is going to go to Huw later this month. Not as satisfying as saying I've done it myself, but better than having the project just stall. We'll see Huw can get it moving for me!

    Richard

  5. #55
    Fellow Frogger! SilverGTi_6's Avatar
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    Great stuff. Love to see a pic of the seats when you get a chance. I'm considering embarking on the same nightmare in the near future!
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  6. #56
    1000+ Posts Richard W's Avatar
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    Here's a shot of one of the front seats. A painful and expensive exercise, but I couldn't find any alternative if you really want your interior to look good...

    Richard's 205 GTi6 project-front-seat-recovered.jpg
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  7. #57
    Fellow Frogger! SilverGTi_6's Avatar
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    Looks great mate. Worth the effort it would seem.
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  8. #58
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    Getting there Rich! Going to be superb when done.

    Also, looking back through your thread, red tappet covers really are the only way to go. You could pretty much have a clapped out shell and red covers would make it concourse!

  9. #59
    1000+ Posts BIGRR's Avatar
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    Thanks for the update.
    Present fleet:-
    Peugeot 93' 205 Gti 16v
    Peugeot 73' 504 Ti from new
    Peugeot 08' 407 Hdi Coupe from new

    Previous fleet:-
    Peugeot 95' 605 Sv
    Peugeot 92' 205 Gti
    Renault 72' 16TS from new
    Renault 69' 10
    Renault 71' 10s
    Renault 68' 10 from new

    "Be reasonable do it my way!"


  10. #60
    1000+ Posts Richard W's Avatar
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    I bought new old stock '1.9' badges for the rear quarter panels on my car but have not been able to find any matching 'GTI' badges, until I found that Le Musee De L'Aventure Peugeot does reproduction badges. The museum doesn't do easy payment like PayPal, and also don't speak great English (and my French is dreadful) but the effort was worth it.

    They arrived today. If you didn't know, you'd never be able to tell them apart from originals. Very happy.
    Richard's 205 GTi6 project-new-badges.jpg

  11. #61
    Fellow Frogger! Grey_Lover's Avatar
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    Looking good . That seat looks stunning

  12. #62
    1000+ Posts schlitzaugen's Avatar
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    Quote Originally Posted by Richard W View Post
    Here's a shot of one of the front seats. A painful and expensive exercise, but I couldn't find any alternative if you really want your interior to look good...
    Looks very nice, but was it leather originally?
    ACHTUNG ALLES LOOKENPEEPERS

    Das computermachine is nicht fur gefingerpoken und mittengrabben. Ist easy schnappen der springenwerk, blowenfusen und poppencorken mit spitssparken. Ist nicht fur gewerken bei das dummkopfen. Das rubbernecken sightseeren keepen hands in das pockets-relaxen und watch das blinkenlights.

  13. #63
    1000+ Posts Richard W's Avatar
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    Quote Originally Posted by schlitzaugen View Post
    Looks very nice, but was it leather originally?
    No - it was originally red half leather. But then, it didn't have a J4RS or big brakes originally either...

    The seats are identical to the leather seats with red top stitch that were available as an option when the car was new.
    SilverGTi_6 and Codman like this.

  14. #64
    1000+ Posts Richard W's Avatar
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    Car and parts patiently waiting for Uncle Huw to collect them in the morning and get things moving again....

    Richard's 205 GTi6 project-waiting-huw.jpg
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  15. #65
    Fellow Frogger! Bluey's Avatar
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    New Bilsteins, Eibachs and freshly painted hubs.


    Fuel rail modified to take Dash fittings. Bigger injectors.



    Inlet manifold bead blasted and clear powdercoated to preserve its appearance.
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  16. #66
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    Very nice .. i like the idea of clear coating the inlet . What type of injectors did you use ?
    206 gti 180
    306 gti 6
    fx holden historic race car

  17. #67
    Fellow Frogger! SilverGTi_6's Avatar
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    That inlet manifold is beautiful.
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    Peugeot 308 GTi
    1966 Volvo 122s
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    Lotus Sport 111, RCZ, 205 GTi, Volvo C30 T5-R, Honda S2000, 206 GTi180, Lotus Elise 111R, 205 GTi 6, Manual 406 coupe, 306 GTi 6, 405 MI16 (twice!), 505 GR

  18. #68
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    That inlet looks suspiciously like mine mate!

    Although mine was sandblasted, then powder coated silver/grey and then clear coated with powder as well!

    Amazing they look almost identical but with different processes.

    Coming along nicely Rich.

  19. #69
    Fellow Frogger! Bluey's Avatar
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    Quote Originally Posted by Grey_Lover View Post
    What type of injectors did you use ?
    Supercharged VT Commodore. 370cc vs 260cc for the standard Gti6 injectors. As long as the standard 205 pump keeps up, which it should, the engine won't run out of fuel on the dyno like Pat's did. Not sure if it was injectors or fuel pump in Pat's case though.

  20. #70
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    I'm interested in how you did the -dash fitting mod to the rail. It looks very neat, I'd love to do that to mine. is it welded or swaged or?
    1988 205 GTi XU10J4
    2001 406 Monaco 5sp V6

  21. #71
    1000+ Posts Richard W's Avatar
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    Quote Originally Posted by Hicho View Post
    That inlet looks suspiciously like mine mate!

    Although mine was sandblasted, then powder coated silver/grey and then clear coated with powder as well!

    Amazing they look almost identical but with different processes.

    Coming along nicely Rich.
    It is possible that I asked Huw to do something similar...
    Last edited by Richard W; 4th November 2015 at 05:30 PM.

  22. #72
    Fellow Frogger! Bluey's Avatar
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    Quote Originally Posted by chez00 View Post
    I'm interested in how you did the -dash fitting mod to the rail. It looks very neat, I'd love to do that to mine. is it welded or swaged or?
    Silver soldered.

    Subframe stitchwelded (TIG).





  23. #73
    1000+ Posts PeterT's Avatar
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    Quote Originally Posted by chez00 View Post
    I'm interested in how you did the -dash fitting mod to the rail. It looks very neat, I'd love to do that to mine. is it welded or swaged or?
    I did Pat's for him, silver soldered.

    '92 205 Mi16
    '90 Mi16x4

  24. #74
    Fellow Frogger! Bluey's Avatar
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    Subframe powdercoated.

  25. #75
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    Huw, obviously the benefits are a stiffer / stronger front end, is this worth the effort? If so I might get mine done, the work is sensational! I am seriously jealous of Richards achievements.
    87 S1 205 GTI / GTI6 powered a project underway
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