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Thread: Phil's HOS 205 GTI6 budget build.

  1. #26
    PDJ
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    Quote Originally Posted by lowpugV2 View Post
    Just out of interest, what do you have left of the GTi6? Seats? Door cards? Parcel shelf etc... The exhaust?
    I'll be using the exhaust (or as much as possible)
    The guy who bought the wheels via Gumtree has first refusal on the complete doors
    The leather on the front seats are pretty shot and one is Red & grey cloth the other is Alcantara.
    Rear seats are red & grey 1/2 leather and in pretty good shape.
    Parcel tray has been chopped to accommodate speakers.

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  2. #27
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    Latest question is regarding the wiring loom conversion.
    With the sticky on 205 Driver no longer showing any pictures the loom stripping and conversion may be a bit much for me.
    Is there someone locally who can do the loom conversion or would I be best off sending it to Miles in the UK to sort out?
    Ive got the chance of sending it back to the UK with my Dad to save some postage costs.
    Phil's HOS 205 GTI6 budget build.-img_3941.jpg
    Are these the 2 brown plugs from the 205 that are needed.

    Phil's HOS 205 GTI6 budget build.-img_3940.jpg
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  3. #28
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    Yes, those are the plugs.
    9 pin: Instrument cluster gauges & starter
    6 pin: Fuel pump, tacho & ignition +12V

    You may also be better off replacing the 205 power distribution block with a generic distribution block if your 205 wiring is at all bare.

  4. #29
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    Phil's HOS 205 GTI6 budget build.-img_1522373708.180572.jpg
    Phil's HOS 205 GTI6 budget build.-img_1522373720.660160.jpg
    Phil's HOS 205 GTI6 budget build.-img_1522373746.113668.jpg

    A couple of deliveries and a stripped out 306.
    I think Iíve got everything I need from the 306. Just got to arrange to get it taken away now.


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    1000+ Posts PeterT's Avatar
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    A few of those goodies take it beyond a budget build!

    '92 205 Mi16
    '90 Mi16x4

  6. #31
    1000+ Posts Richard W's Avatar
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    So it looks like you've gone the Pug1Off route with the Catcam 106s and their remapped ECU? It will be really interesting to see how it goes. I think the lightened flywheel is a good purchase - very happy with how it makes mine so happy to blip throttle. Are you changing the final drive as well.

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  7. #32
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    Quote Originally Posted by PeterT View Post
    A few of those goodies take it beyond a budget build!
    Its hard to resist when everything is out.
    If the engine is out it's worth doing a service, cam belt, water pump, etc. If the cam belt is off it's probably worth doing the head gasket, if the head is off you may as well stretch to a pair of cams Then you need a remap to suit.
    Same with the flywheel. If it's all out of the car and needs sorting it's worth doing it once doing it well.

    A few years ago I pulled the engine out of my Moke to paint the engine bay and fit a ported head and new cam.
    That turned into full suspension (donuts, hilos, shocks, bushes, adjustable arms and tie rods, refurbished rack, disc brake conversion, new wheels and Tyres.
    Its hard to stay on track once you start pulling things apart.

    I know 99% on here will perfectly understand the "man logic" behind it all.
    Just just don't tell the Mrs
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  8. #33
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    Quote Originally Posted by Richard W View Post
    So it looks like you've gone the Pug1Off route with the Catcam 106s and their remapped ECU? It will be really interesting to see how it goes. I think the lightened flywheel is a good purchase - very happy with how it makes mine so happy to blip throttle. Are you changing the final drive as well.

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    Thats them Richard.

    Actually it's all your fault for suggesting it to me and making me blow the budget.

    Once the 306 is gone I can start pulling down the 205 and hopefully get this project moving on a bit.
    I pulled the cover off the 205 the other day and noticed the Rego ran out in Feb 2012. I basically only drove to home 3 kilometres and parked it for 12 months before I trailered it to the farm where it sat until last year to then get trailered to my house where it's sat for another 12 months.
    The poor thing is overdue some serious love.
    We'll have to do a back to back comparison once I'm on the road too.
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  9. #34
    1000+ Posts Richard W's Avatar
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    I can't wait for the comparison.

    Do you want my Cometic head gasket to bump up the compression a little? You'd need to check valve clearance.

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    Quote Originally Posted by Richard W View Post
    I can't wait for the comparison.

    Do you want my Cometic head gasket to bump up the compression a little? You'd need to check valve clearance.

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    Sounds good. Thanks Richard.

    Regarding the final drive. That'll be staying standard as per the Xsara VTS 5 speed.
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  11. #36
    1000+ Posts Richard W's Avatar
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    Quote Originally Posted by PDJ View Post
    Sounds good. Thanks Richard.

    Regarding the final drive. That'll be staying standard as per the Xsara VTS 5 speed.
    I'd recommend the s2 GTI CWP that I have used. I like the gearing in mine. The J4R likes to rev so lower gearing is good if you can...

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    The VTS box is great as a bolt in option. It is essentially the same as an Mi16/s16 gearbox with a slightly longer 5th gear.

    Has the 4.4 FD with IMO perfect gearing for a road 16v 205. Short enough to have fun and long enough when cruising in the higher gears.

  13. #38
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    The vts box I had ended up being a be4 so be carefull if your going to mix and match internal parts.

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    Does it have the big diff like the S16 box?
    Quote Originally Posted by cam85 View Post
    The VTS box is great as a bolt in option. It is essentially the same as an Mi16/s16 gearbox with a slightly longer 5th gear.

    Has the 4.4 FD with IMO perfect gearing for a road 16v 205. Short enough to have fun and long enough when cruising in the higher gears.

  15. #40
    1000+ Posts cam85's Avatar
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    Sure does. Its a be4r i believe. Has smaller teeth (less noise apparently) on the gears but a bigger diff.

  16. #41
    1000+ Posts Richard W's Avatar
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    Forget my CWP suggestion then!

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    Quote Originally Posted by Richard W View Post
    Forget my CWP suggestion then!

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    A good suggestion for a S3 205 box and s2 diff none the less Rich!

  18. #43
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    I'm not sure what the VTS box is. I picked it up went straigh over to Adrian's for a quafe install.
    I do know however that it's considerably smaller and lighter than the 6 speed as I had them side by side and I lugged then in and out of the Hilux.
    I supprised that GTI6 owners don't change the 6 speed out just to save on the weight. In fact UK Rallye (a lightened GTI6) should have been a GTI5.
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  19. #44
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    Okey Dokey.
    A bit of progression has been made. The engine and box are back together. Gearbox has had the Quafe installed and the engine has had the cams installed, new clutch with lightweight flywheel, new lightweight crank pully, water pump and cam belt and an A/C delete auxiliary belt kit fitted.
    Iím waiting on a modified loom and modified exhaust down pipe from Pug Racing.
    Iíve dropped the front subframe off and stripped it down as Iím going to fit the steering rack from the SI I wrecked some while back.
    Iíve decided not to spray the engine bay as itís creaming up ok. Iíve used some of Aldiís finest metal paint around the top engine mount area and battery tray as there was a bit of bare metal. Great paint as it sets rock hard.
    Pulled the dash out today and removed the engine loom and ecu. The SI dash will be going back in as itís in pretty good shape. The ecu has a Powerchip sticker on it. Do know if itís any good or makes much difference. I may plug it into my running 205 to try it out.
    Found a bit of rust around the front windscreen so the screen will have to come out to sort that.

    Phil's HOS 205 GTI6 budget build.-img_1534667337.122245.jpgPhil's HOS 205 GTI6 budget build.-img_1534667374.842065.jpgPhil's HOS 205 GTI6 budget build.-img_1534667433.653912.jpgPhil's HOS 205 GTI6 budget build.-img_1534667468.029092.jpgPhil's HOS 205 GTI6 budget build.-img_1534667477.850137.jpgPhil's HOS 205 GTI6 budget build.-img_1534667494.558836.jpgPhil's HOS 205 GTI6 budget build.-img_1534667507.064964.jpgPhil's HOS 205 GTI6 budget build.-img_1534667524.507463.jpgPhil's HOS 205 GTI6 budget build.-img_1534667544.000945.jpgPhil's HOS 205 GTI6 budget build.-img_1534667557.675164.jpg


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  20. #45
    1000+ Posts Isis's Avatar
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    Good effort Phil. More importantly, how 'my' mini going? :>
    S3 205 GTI x 4 and getting lower
    1998 S1 Lotus Elise
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  21. #46
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    The mini is safely under the black cover in the pic. The new engine for that is in the middle of the same pic under a white rag


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  22. #47
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    A couple more goodies. Phil's HOS 205 GTI6 budget build.-img_1535107677.765674.jpg


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    Quote Originally Posted by PDJ View Post
    A couple more goodies. Click image for larger version. 

Name:	IMG_1535107677.765674.jpg 
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    Looks like a care package from BakerBM

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    Quote Originally Posted by CEyssens View Post
    Looks like a care package from BakerBM
    Gear linkages from Baker and care package of conversion loom and downpipe from Miles at Pug Racing.


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  25. #50
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    Phil's HOS 205 GTI6 budget build.-img_1535967598.963678.jpg

    A bit of painting done. Had them blasted and primed then a coat of Aldiís finest metal paint. Iíve done a couple of mini subframes in it and itís great stuff. Dries rock hard unlike Hammertone that stays quite soft.
    Picked up some 206 calipers just need some 266mm 307 discs to upgrade the brakes. These will have a nice new 22mm master cylinder from EAI along with some bits that should be here this week.

    Any tips on best place to buy new discs from?


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