simes
Part of things
Posts: 734
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As a long time lurker I feel I should post up some pictures and a brief spec of my car.
1990 205GTI - owned for 7.5 years.
Started modding her after about 3 years, things happened slowly over the next few.
Eibach lowering springs (25mm) Bilstein front suspension Group N Top mounts Rebuilt rear beam - torsion bars adjusted to match lowered front. Group N mounts Skip Brown Road speed dampers.
XU9JA4 (Mi16) lump removed from 405mi16x4 only 57k miles old then. Dismantled and rebuilt with new mains and a pair of 262 cams. Custom loom made so all engine electronics relocated into car. Bosch Motronic 1.3 management Maniflow 4-2-1 with Magnex centre and rear silencers Mi16 gearbox - stripped and rebuilt (new bearings)
206GTI180 front brakes Replaced rubber hoses with braided Replaced all steel pipes with new copper ones.
Replaced Non-PAS rack for PAS rack with all assistance removed - makes for a quicker rack.
I seemed to have stopped for now - routine maintenance jobs seem to get in the way.
Still makes me laugh each time I drive her.
All the Rolling roads I've been on I seem to get around 172bhp - so pleased about that. Especially as she weighs on around 900kg.
EDIT: 2016 now - will try and rehost the old photos - pre dslr!
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Last Edit: Mar 11, 2016 20:49:40 GMT by simes
Simes
205Mi16 - 262 cams, Jenvey Throttle Bodies, Emerald managment blah blah...... E91 320D MSport Honda NC30 Vespa 300GTS
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Looking great! I'd love a mint GTi as a road car but insurance would be an effing nightmare.
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1997 TVR Chimaera 2009 Westfield Megabusa
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Speedle
Posted a lot
Need a Country Rock band in the Hampshire Area? https://www.facebook.com/DirtRoadDiaryUK
Posts: 2,221
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cor thats loveley mate! my mates got a 205 gti i bet he wished his 205 looked that minty fresh!
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Padz
Part of things
Personal Plates ftw
Posts: 394
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I (heart) that !
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"I'd rather lie in a bath of my own excrement than own a Vectra " - 2002gimp 25/1/07 "Anal Alert would be an absolutely superb name for piles cream " - Hirst 28/1/08 1991 - Peugeot 205 GTI 1996 - Rover Mini Cooper
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luckygti
Posted a lot
I need to try harder!
Posts: 4,912
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Nov 10, 2007 20:26:01 GMT
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That is very nice indeed. Think I'll be using this for my inspiration!!
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simes
Part of things
Posts: 734
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Mar 11, 2016 19:25:50 GMT
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Holy thread resurrection. Thought I had better update this, you know it's been a long time since one updated, as I've had 3 different jobs, bought and moved house, got married and got a couple of kids! I'm copying this over slowly from another forum..... So on Jan 25th 2009, someone decided to use my car as a brake. March 2009. Another 205 was offered to me at a fair price, it hadn't moved for 18 dry stored months and I was finally able to buy back the salvage of G692EPC. I was initially looking for a Sorrento or Laser green but I was contacted and offered this car, I found the new car like this A quick check over of the normal rust spots was all I needed - this car was in good condition and only a totally standard 85k miles old. There were a couple of little issues but to be honest I wasn't too bothered as those bits were going to be removed. It hadn't started in over a year so we removed the plugs, stuck in a battery and cranked her over. Well that all worked nicely. Put the plugs in tried again and she fired within about 2 seconds. Success - so my plan of driving it back as opposed to trailer was looking good. I returned a week later and drove it back the 20 odd miles or so to my house. I'd not driven an 8v for about 4 years so it was quite amusing (spelt:stalling). Got quite a few looks as I'd not cleaned the car at all and it was really covered in a lot of cement dust. One thing I did come to identify was that the brakes were not all that hot. Perhaps I was used to my old HDI calipers or the rear brakes weren't working. The MOT I had booked it in for that day comfirmed that the rear brakes were not really doing much - I suspect the compensators needed changing. Anyway safely home and no MOT - well I was hoping to get the car ready to chip over to France the following week. My plan initially was to fix her up and drive the 8v around for a bit of fun. But then I realised I should just get on with the reshell. So, I took the next few day of work and started..... I hired in a crane for the week and started by removing the 8v engine from H961 So into my garage for a week of spanner wielding - my girlfriend had also gone away so I was able to get on with quite a bit of car work. I actually found something of use in the Haynes manual too....get some old 4mm gauge steel rod and make a pair of U-shaped brackets to keep the bonnet propped up. Amazing in 9 years of ownership I never new this existed!! I decided to strip the ancilleries from the 8v block just so I could get it out easily. Inlet & exhaust manifolds were off along with the starter and alternator. Driveshafts and mounts all came off pretty easily - scarily a few nuts and bolts were a little too easy to undo. Bye bye 8v Next installment to follow.....
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Last Edit: Mar 11, 2016 20:28:46 GMT by simes
Simes
205Mi16 - 262 cams, Jenvey Throttle Bodies, Emerald managment blah blah...... E91 320D MSport Honda NC30 Vespa 300GTS
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simes
Part of things
Posts: 734
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Mar 11, 2016 20:09:00 GMT
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The engine and gearbox came out as one after I'd removed the battery tray which came out a lot easier than expected. I'm now left with this... The loom is still in there, I in my haste hacksawed this up and removed it. I then set about degreasing the engine bay. Spent a couple of hours in there and really should have spent longer, knowing what I know now I wished I'd taken the m/c and servo out. I also noticed that over the years the battery had leaked and stripped a lot of the paint off the inner wing. I had to strip this all back and I primed it with red oxide. I'm going to have to revisit this area in the winter, I simply don't have thr time to wait for paint to dry! Whilst that lot was going on I set about removing the alarm from H961. This was a terrible drain on the battery and I was going to replace it with a Toad Ai606. Well this alarm could have been factory fitted. The Ignition amp was near to the cam cover and the integration of it into the rest of the car was very very good. It took me a while to get this out. End of day 2. Next day began with stripping G692 ready to remove the Mi lump. I wanted to do this with minimum disturbance to the engine and ancilleries, my plan was to try and remove as little as possible. I had to remove the exhaust, radiator and a few other coolant pipes and with the drive shafts disconnected and gear rods too all I had to do was disconnect the electronics. G692 had originally been converted to Mi16 power by Miles, for me, back in 2004. The loom was one of Miles so all it involved was disconnecting the two multiplugs from under the dash, disconnecting the ECU and feeding it all through the bulkhead. Believe it or not, it all fitted nicely through the hole in the bulkhead, ready to be hoisted out. Well not that easy really, the XU9JA came out using a sling and I had plently of clearance all around. However this had everything attached to it and to boot the Maniflow manifold had come away from the block nicely but unfortunately welded itself together so was in the way a touch. I had to pop out and get a 'load balance' bar - it allowed me to lift the engine out but also to be able to tilt it and clear all the bodywork. Almost the best £30 odd quid spent so far. Note coolant pipes still attached. Whilst the engine was out I decided it would be a good idea to change the cambelt. I did think about the tensioners and water pump but to be honest, they are genuine parts and were changed only 30k ago when the lump was stripped and rebuilt. I saw that it's advisible to use the 'special dowels' to lock the cam pulleys in place prior to changing the belt which obviously I didn't have. I toyed with the idea of using a substitute (spelt:old drill bit) but a quick phone call later I had managed to get a friend machine up the correct dowels as described in the Haynes. Sweet! I had removed the alternator at this point as the 8v engine had come with a new one....more on this. Ready now to go in to H961, I replaced cam side engine mount, removed the battery tray and got the engine in
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Last Edit: Mar 11, 2016 20:10:52 GMT by simes
Simes
205Mi16 - 262 cams, Jenvey Throttle Bodies, Emerald managment blah blah...... E91 320D MSport Honda NC30 Vespa 300GTS
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simes
Part of things
Posts: 734
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Mar 11, 2016 20:12:40 GMT
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So engine in and loom all plugged up, new oils and coolant - went to fire her up and what happened? Well the starter motor stayed on all the time and it didn't fire up. After a little swearing and thinking (it is late on day 6 of 6 consecutive days working 9am - 7pm) I figured there was something wrong! My old car was a phase 1.5 and this is a 2. Peugeot changed switched live and permanent over - I just had to switch these over which was pretty simple. Hey presto she fired up albeit very loudly as I'd got not much exhaust connected. smile.gif Back to work now so most of my time has vanished but I've connected the driveshafts, gear link rods, new clutch and throttle cable and the car moves under its own power. Sadly the master cylinder has failed - not a problem as I'm swapping my old one over. For some reason I decided to start installing the Toad Alarm - I've identified most of the wires required and hope to get this in over the weekend. I'm also hoping to get hold of an adaptor pipe to join these two things up. I've sold my old Magnex - it was getting a bit too loud for me so I've gone for a nice stealth standard rear section. Jobs this coming weekend. Swap beam over Swap front suspension over Make brakes work Make the alarm work Prep for the MOT Not much then - I'm also doing up our house and training for a Triathlon! then loads more.....
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Simes
205Mi16 - 262 cams, Jenvey Throttle Bodies, Emerald managment blah blah...... E91 320D MSport Honda NC30 Vespa 300GTS
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simes
Part of things
Posts: 734
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Mar 11, 2016 20:15:24 GMT
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So Saturday starts with removing the beam from the old car and leaving the shell resting on some old tyres. I did make up a large dolly for this to sit and roll around on, but realised that the castor wheels only can take 75kg each, so I'll need to get hold of some more Beam came off pretty easily and then I forgot how heavy they are! . It was rebuilt about 30,000miles ago and I know the shafts were replaced. It has been lowered, has rebuilt calipers (bleed nipples not seized, I twiddle them every couple of months and has Skip Brown dampers. Beam also came off H961 pretty easily, this was rebuilt 3000miles ago and is completely standard (for sale soon) however the brake lines will need replacing back to the compensators. Not a problem as I've got new bits to replace with, just boring as I'll have to remove the fuel tank. Refitting my old beam was a pain as I was doing it on my own. Heavy and awkward to even jack into position on my own. After some swearing I managed to get it up there and tightened and torqued correctly. Yippee. Some hours later I removed the complete subframe from G692, that was enough work for the day! Bilstein Streetline dampers Eibach springs HDI brakes I remember when I bought all these parts new. I toyed with the idea of cleaning them all up but I'll do that at another time - probably in the winter. All I want to do is drive the car. A couple hours later and I've swapped over the struts and brakes. I've kept H961's hub carriers and driveshafts for the time being to avoid too much mix and matching. Should any driveline issues/vibrations occur I can track them down easier. # No longer looks like a 4x4. Need to put in new brake lines as they had decayed (brass nuts rounded off!)
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Simes
205Mi16 - 262 cams, Jenvey Throttle Bodies, Emerald managment blah blah...... E91 320D MSport Honda NC30 Vespa 300GTS
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simes
Part of things
Posts: 734
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Mar 11, 2016 20:16:38 GMT
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Update: Yesterday was spent connecting the brakes. Unfortunately most of the unions were hard rusted and I think a compensator had failed. I ended up replacing the brake lines from the compensator back to the rear calipers. Had to remove the fuel tank which was then I found that one of the brake lines had been replaced before and the old pipe was still there as evidence. Had to replace the front nearside line also as it had decided to get too friendly with the flexi hose. All my flexi - hoses were braided so I've reused those so connected everything up and called it a day. Forgot to add also fitted a new master cylinder. Today I refilled the system with fluid, bleed it and tweaked the handbrake. That was enough! Got a couple of days off work this week so I'm aiming to swap carpet and seats, finish the alarm, connect the exhaust up and make the lights work! and then Couple of days off work - today and tomorrow. Spent most of today trying to align the bonnet striker - still doesn't want to f***ing shut. No photo's too angry!
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Last Edit: Mar 11, 2016 20:17:15 GMT by simes
Simes
205Mi16 - 262 cams, Jenvey Throttle Bodies, Emerald managment blah blah...... E91 320D MSport Honda NC30 Vespa 300GTS
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simes
Part of things
Posts: 734
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Mar 11, 2016 20:19:43 GMT
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So where were we - oh yes trying to shut the bonnet down! well it just wasn't working so I went and did some thing else...namely remove all the interior from car and then refit my old bright red carpet. Very bright - and now one of our bedrooms looks like this and the hallway like this Back to the bonnet though and I think I've identified the problem. On this car from what I remember the bonnet was always a bit difficult to shut. I'd only ever shut it once befere removing the slam panel and then everything else. This was the problem i1357.photobucket.com/albums/q753/simes205/H961%20build/26_600x400.jpgCould it be striking the radiator? It got a bit bent in the accident I played around with it seeing if anyting was catching - best thing to do was remove it....but.. After measuring up the striker on this and my old bonnet it seems this one was set 5mm shorter. Trying to adjust it was not going to happen as it had welded itself tight I had to think of another plan. other bonnet Mmmm a bonnet swap! That's fixed the issue now which is great. Glad I took two days off work to sort that - what a complete waste of holiday!!! Anyway radiator, fan, lights, windscreen washer bottle etc and all front harmess electrics connected and ready to go, also swapped my old 'new' front indicators over. Away this weekend in France, so no garage time - although I suspect i'll be helping my dad bleed the brakes on his 1953 Austin Somerset
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Simes
205Mi16 - 262 cams, Jenvey Throttle Bodies, Emerald managment blah blah...... E91 320D MSport Honda NC30 Vespa 300GTS
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simes
Part of things
Posts: 734
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Mar 11, 2016 20:21:51 GMT
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So what's new...... When I refitted the brakes I noticed the M/C was a bit dodgy. My replacement from the write off was only 10,000miles old so that's now on. I sold my old exhaust (possibly a bit too early!) so I've been unable to run the car for longer than about 1 minute. I had Miles get a section made up to join the maniflow and standard exhaust section together. I'm pleased as it fits like a glove (my measurements and sketch were accurate) By using these two items I've now managed to seal it all up. Since I did all this around 3 weeks ago - I've been out on my test track and got it running nicely. Lots of stamping on the brakes cleaned up the 6 months build of rust so they stop well now. I had a bad idle and general missfire which was due to a couple of HT leads working loose. The AFM also needed plugging a little better. I should have an update for you later today - Alarm fit, dashboards nearly all back in and just some tweaks for MOT.
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Last Edit: Mar 11, 2016 20:22:17 GMT by simes
Simes
205Mi16 - 262 cams, Jenvey Throttle Bodies, Emerald managment blah blah...... E91 320D MSport Honda NC30 Vespa 300GTS
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simes
Part of things
Posts: 734
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Mar 11, 2016 20:23:03 GMT
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July 2009 Quick update: MOT'd, passed Sad day though as G962 went to the scrapyard.
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Last Edit: Mar 11, 2016 20:24:01 GMT by simes
Simes
205Mi16 - 262 cams, Jenvey Throttle Bodies, Emerald managment blah blah...... E91 320D MSport Honda NC30 Vespa 300GTS
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simes
Part of things
Posts: 734
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Mar 11, 2016 20:27:51 GMT
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July 2009. I drove the car down to Goodwood for the FOS, for it's first run / shakedown. Something fell off on the M23, not that significant. When leaving Goodwood later that day the drive belt was squealing. Turned out the nut for the tensioner on the alternator had fallen off.
6 days later we drove the car, fully loaded with camping gear over to France down to Biarritz and over the Pyrenees to Spain. 2500 trouble free miles, except for one dodgy earth on the headlamp which was sorted immediately. If I remember rightly the amp for the sub died on the 600 miles journey back up to Normandy to see my folks.
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Simes
205Mi16 - 262 cams, Jenvey Throttle Bodies, Emerald managment blah blah...... E91 320D MSport Honda NC30 Vespa 300GTS
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simes
Part of things
Posts: 734
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Mar 11, 2016 20:30:13 GMT
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Jan 2010. After the reshell, well in fact after the engine was originally rebuilt by Miles back in 2004 we were always aware that it needed 'mapping' to make use of the slightly wilder cams....it has only taken me 5 years to do this! With the cold weather setting in and the fact that I don't have the time to tinker on the car at the moment and after a quick chat with Miles it seemed the best idea was to take it back down to his workshop for some more work. Car now back from Miles where 'she's' received the following work: Removed: 3-row loom, AFM, Mi16 inlet manifold, ECU, dizzy cap, ignition amp etc etc. Installed: New loom and importantly new plugs etc Emerald ECU GTI-6 inlet manifold Air Filter Coil pack etc. Work is exemplary as usual. Car was then trailered to a garage local to Miles who then carried out the mapping. Well, I must say the power delivery is very pleasant and the car feels a lot more 'powerful'. My trip back home along the Autobahn last night was keeping me very amused especially now the way the torque is delivered in a very linear fashion. 3.5k onwards is even more amazing than it used to be, overtaking is no problem. :wub: :lol: I'm sure I'll be back for some TB's at some point.....probably best to get my wedding out of the way.
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Simes
205Mi16 - 262 cams, Jenvey Throttle Bodies, Emerald managment blah blah...... E91 320D MSport Honda NC30 Vespa 300GTS
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simes
Part of things
Posts: 734
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Mar 11, 2016 20:30:46 GMT
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Jan 2010 We got 171bhp & 140lb ft torque which is good, the unit pulls in a much more linear fashion and the power is instantaneous. It's much more responsive over 3krpm and overall I'm very happy with the performance. I've had power readings prior to this work over the last few years on a selection of rolling roads with 174 being recorded so returning to those particular rollers I would expect to see 180bhp. The rollers we used for this are known to read under and this has been confirmed by other standard cars running on there. Also the mapping is not yet finished including cold start and idle. As I rushed the mapping before Christmas we didn't get a chance to sort out the the idle and cold start. So I'm off to Dave Walkers next week to sort those bits out. I'm also going to set the ECU up to hold three maps and be able to switch between them on the fly. I'm thinking: Map 1 - MOT map, idle leaned off to avoid excessive HC's. Also with revs limited to 3000rpm to avoid mechanic thrashing it around the block Map 2 - Leaned off at higher revs for thrifty motorway cruising Map 3 - Sport mode!
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Last Edit: Mar 11, 2016 20:31:58 GMT by simes
Simes
205Mi16 - 262 cams, Jenvey Throttle Bodies, Emerald managment blah blah...... E91 320D MSport Honda NC30 Vespa 300GTS
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simes
Part of things
Posts: 734
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Mar 11, 2016 20:32:46 GMT
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Back from Emerald, not a bad day was had. Mapping finished and we got 185bhp with 145Ibft of torque not bad really although we all know rollers aren't accurate. Still a few concerns with the idle and general driveability what with it having cams and a plenum. Probably going to go for some throttle bodies soon, that will apparently solve the problem!
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Simes
205Mi16 - 262 cams, Jenvey Throttle Bodies, Emerald managment blah blah...... E91 320D MSport Honda NC30 Vespa 300GTS
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simes
Part of things
Posts: 734
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Mar 11, 2016 20:35:35 GMT
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April 2010 Not much to add recently apart from I've finally finished installing/programming the TOAD alarm. You may remember about 10 months ago I did actually install the system but left out the bonnet and also door switches as there was a dodgy earth which was sending false triggers on the door part of the interior light switch. I got a couple of switches from an old 306 my brother had kicking about so that's all sweet. Decided to tackle the rust on the bonnet which I've ignored for about 5 years (bonnet was from last car) Drilled out the rivets to remove the sound proofing - which is now sitting next to the bootlid in my garage that I'm supposed to be using as a replacement for the current one. Sanded down the rust to bare metal and applied fresh paint. The bracket for my coil pack snapped the other day so I had to make up a new one, in a hurry....Like 2 hours before the south meet!! I'll be revisiting that part again soon to make something a bit nicer. Also my camshaft end caps have turned up so I'll get these on soon. Still having a few issues with the map, especially when warm - the idle goes crazy. A bit like an 8v hunting but eventually it goes from 500 - 1500rpm and then stalls. I'll fix this one day - maybe with some TB's. Anyway I'm hoping a polish and wax will fix the problem. EDIT: Transpired the crazy idle was the 2 wire ICV. I later fixed the issue by unplugging it!!
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Last Edit: Mar 11, 2016 20:57:54 GMT by simes
Simes
205Mi16 - 262 cams, Jenvey Throttle Bodies, Emerald managment blah blah...... E91 320D MSport Honda NC30 Vespa 300GTS
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simes
Part of things
Posts: 734
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Mar 11, 2016 20:36:35 GMT
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Again not too much to report on apart from getting a new bit of exhaust made up. The last one didn't have a kink in it which meant the centre box kept hitting the chassis. Now it's much better! Custom made out of Stainless with a Lambda boss welded in too. Over the last 500 miles or so selecting 2nd, 3rd and fourth gears at pace was becoming more difficult, they weren't selecting nicely at all. Realising that my 50,000mile old Group N bottom mount was getting a bit old I purchased a new one from Pug Racing. It arrived very promptly but took me a further 6 weeks to get it fitted to the car, performed in a similar way to how I installed the last one: Remove lower fork. Cut through the rubber and metal of old mount with hacksaw. Knock out the remainder. Clean out shell. Smear the new one with liberal amounts of grease. Apply force with a copper mallet to tease the new one in. All in and no need to remove anything from the car or take to be pressed in. All gears work a treat. What's next....mmmm door pins or throttle bodies.
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Last Edit: Mar 11, 2016 20:58:35 GMT by simes
Simes
205Mi16 - 262 cams, Jenvey Throttle Bodies, Emerald managment blah blah...... E91 320D MSport Honda NC30 Vespa 300GTS
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