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Dec 17, 2015 10:38:55 GMT
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185 60 is the standard size for those wheels, if its hitting the bodywork it sounds like the bumpstops are missing.
you can't swap the beam bearings, never managed to remove any without damaging them, not that i've ever tried as replacements are cheap and I've never pulled a bearing out that I knew the age of so they were destined for the bin regardless.
you can get a rebuild kit very cheap from a polish company on ebay.
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stevietuck
Posted a lot
Never argue with idiots,they drag you down to their level then beat you with their expertise!
Posts: 1,350
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Dec 17, 2015 13:19:43 GMT
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welshpug when I said swap the bearings, I meant for new ones. Your right you never get bearing out undamaged. So I have a new plan... Today I have stripped the old beam down. It came apart so much easier than the other one, not that I have managed to get that apart! Beam spread across garden lol!  p/s shaft...  d/s shaft...  d/s bearing...  There was no sign of any needle bearings in there, no wonder I had neg camber!! So tomorrow I'm going to nail the car back together well enough to move it off next doors drive as he is home on Saturday. Once Iv'e moved the car I will drop the beam off it and try to strip id down, should be easier off the car. Then using the best parts off both beams I will rebuild one good one from the two, using new bearings and shafts ( unless the shafts on the gti beam are ok) I should have just rebuilt the old beam right from the start. The idea of getting the gti beam was it was a straight swap and the car would be back on the road within a few days. HA!!! With the hassle Iv'e had, I never want to touch the dam thing again so a rebuild makes sense. Chances are the gti beam wouldn't have lasted long anyway, god knows how long it had been sitting unused. don't know how long it will take to get parts, so don't know if I can get it done before xmas, but I'm getting used to having no car now, and riding my bike just about everyday is really good for my mental health too. Thanks for looking steve.
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Dec 17, 2015 14:46:58 GMT
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oh dear  new crossmember required there! fingers crossed the other tube is at least usable, the gti ones do tend to fare off much worse as the stiffer bars mean the arms don't move up and down as freely, concentrating the wear. yeah, cycling helps me massively too. |
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stevietuck
Posted a lot
Never argue with idiots,they drag you down to their level then beat you with their expertise!
Posts: 1,350
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Dec 17, 2015 17:37:00 GMT
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welshpug Thats the non gti beam! I had half started to take the bearing out in that pic. I have started to clean it up and had a good look at it now. At first it looked like the outer casing of the bearing was complete, but once out and cleaned I can see a small gouge in the bearing surface on the beam. Its only about 3mm wide by about 15mm long and about 2mm deep, but its right in the middle of where the bearing would sit and there would be a good 5mm of bearing surface either side of it, so hoped it would be ok? What do you think? Once the gti beam is stripped, if its in better condition I can use it, but if not do you think this one will be ok? Cheers steve
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stevietuck
Posted a lot
Never argue with idiots,they drag you down to their level then beat you with their expertise!
Posts: 1,350
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Dec 17, 2015 19:34:28 GMT
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While doris is off the road I may as well try and get this fitted..  along with these... |
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stevietuck
Posted a lot
Never argue with idiots,they drag you down to their level then beat you with their expertise!
Posts: 1,350
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Dec 17, 2015 19:53:44 GMT
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Sorry messed up the above post. What I was trying to say was.... Along with these...  and this...  I have a couple of cans of bumper paint, so will give the front bumper a few coats when I take it off to fit the valance. Got my brother to buy me these for my birthday last month...  They are stainless steel bumper mounting bolts, cheers bro. I'm feeling pretty positive. This can only be a good thing? Cheers steve. |
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stevietuck
Posted a lot
Never argue with idiots,they drag you down to their level then beat you with their expertise!
Posts: 1,350
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Yesterday morn I bodged Doris back together enough to move her off next doors drive. I had managed to get the d/s torsion bar out the other day, so I raised her up enough so the tyre didn't rub. On the p/s the torsion bar is still seized, so I just fitted the spare wheel, which is a 13" steel with 155 tyre so no rubbage that side either  Then I just drove her back to her normal spot outside my house. Its really weird, I live on a cul de sac with ten houses on it, mine is the only one with no drive! There is some drop curb outside my house but not right across. When my front garden fence was falling down with rot, I decided to just take it down so I could pull my car on to the front garden,as its just stone chipped. This is the view from my front window..  You can just about see the drop curb in front of the car. Problem I have is there is too much drop from the pavement to my garden, and the car straddles the pavement with the front wheels in the garden, while the back are still on the road, so the car grounds out. Even if I get the car on the garden ( or should I call it my forecourt lol!) the ground is too soft, so jacks and axle stands sink. I have tried laying ply board under the jack and stands, but it never feels very stable. Also the stone chips are a nightmare if you drop anything, you can't find it. At some point in the future I will concrete the front, but for now my solution is to just pull the front end of the car on to my forecourt leaving the back end on the pavement, so I have a good surface to work on. So that I don't annoy my neighbours too much I think I will leave dropping the other beam off the car until I have ordered the new bearings and shafts. I decided I'm just going to get new shafts, as the chances of the other ones being in good condition are very very small. I will hopefully get the new parts ordered later today, and I plan to finish stripping and cleaning the old beam too. thanks for looking steve. |
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stevietuck
Posted a lot
Never argue with idiots,they drag you down to their level then beat you with their expertise!
Posts: 1,350
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Dec 19, 2015 18:26:21 GMT
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Right gang, back with more news... As I said above, today I wanted to get these...  Out of these...  As you can see I managed it. A good blast on the casing round the splined part with the blow torch, and a couple of good whacks with my trusty big hammer and they were out. It's going to be so much easier to get the trailing arms down to Sandys to press the new shafts in now So far I havn't bothered to clean up much of the beam because untill Iv'e stripped the other beam, I won't know which parts I will use. In an ideal world I will be able to use the gti torsion bars and antiroll bar, but we will see how it goes. I ordered the new bearings and shafts earlier, they are suposed to arrive Tuesday ,so I may drop the beam tomorrow. In a bid to make myself feel better about being without a car, I decided to whip the front bumper off to fit the gti front valence. To be honest, the bumper has seen better days. It has quite a few wee cracks and chips, and one of the bolt holes looks like this...  The other like this...  as you can see the first one is way bigger than its meant to be, and my new fancy bolts fit straight through the hole!!! The new bolts are designed to fit under the red trim that goes on a gti bumper. I don't have the red trim piece so plan to spray the heads with bumper paint. I gave the bumper a quick sand, and I mean quick! then it got three coats of dark grey bumper paint. Here it is packed in to the shed to leave overnight ...  Next I went in to the house and bolted the driving lights on to the valence, like so....  So tomorrow I can bolt the two together and fit it back on the car. I should really wire the lights up while I'm at it, but I will see how I get on. Thanks for looking, steve. Oh and please feel free to comment/slag me off Oh and sorry about the rubbish pics. I cant even blame the camera, its quite good, its the thing holding the camera thats curse word |
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stevietuck
Posted a lot
Never argue with idiots,they drag you down to their level then beat you with their expertise!
Posts: 1,350
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Dec 20, 2015 13:57:35 GMT
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Spot the difference....   I'm really pleased, looks so much better. I wont lie though, they don't work yet. It's quite mild up here today but the wind is freezing, so I left that job for another day. It's not like I can use the car, so lights not working yet is no big deal Cheers steve. |
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Dec 20, 2015 17:22:24 GMT
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looks really good bud! not really a pug man myself, but always had a fondness for the 205.. bookmarked this build, its a good read!
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jonxs
Part of things
Posts: 650 
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Dec 20, 2015 18:22:47 GMT
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Looks much better with the front valance, just need a rear one now  |
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stevietuck
Posted a lot
Never argue with idiots,they drag you down to their level then beat you with their expertise!
Posts: 1,350
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s1105117 and jonxs Cheers guys. I keep looking out the window and smiling pity I cant take her for a drive! Hopefully later today I will drop the other rear beam, so I can strip it down and give it a look over. New bearings and shafts should arrive the morn, but I'm not overly confident about that. cheers steve.
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stevietuck
Posted a lot
Never argue with idiots,they drag you down to their level then beat you with their expertise!
Posts: 1,350
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Well I take it all back, what I said about my parts not arriving today. This lot just turned up...  I still haven't dropped the other beam off the car yet, I was hoping to do it yesterday afternoon, but it was raining, and it still is! Forecast says its going to rain all day and tomorrow. I have now resigned myself to the fact that I probably wont get it done before xmas. The most important thing is to do it properly and that it lasts. I will try to get the new shafts pressed in to the trailing arms tomorrow. I have arranged to borrow works van for a couple of hours to get some shopping, so I will do the shafts while I have it as 2x trailing arms (with old shafts still fitted) and the new shafts will be quite a weight on my bike cheers steve. |
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stevietuck
Posted a lot
Never argue with idiots,they drag you down to their level then beat you with their expertise!
Posts: 1,350
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Dec 22, 2015 16:07:57 GMT
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Well despite what the forecast said, it stopped raining so I nipped out and whipped the beam off Doris. It only took about half an hour as everything was only finger tight from when I put it back together the other day. Pretty much as soon as I was lowering the beam on the jack it started raining again! I packed up the tools and when inside for a cup of tea and a smoke. Twenty mins later the rain stopped again so it was back outside to strip the beam down. Beam number two spread across the garden....  Shaft one...  Shaft two...  I might have even got away with using them, but Iv'e got the new ones so I'l use them. Bearings look like they have just started to break down ...  I've not taken the bearings out yet, thats a job for tomorrow but this cross tube is definitely in better condition than the other one, so I will be using this one. That's all for today folks steve. |
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stevietuck
Posted a lot
Never argue with idiots,they drag you down to their level then beat you with their expertise!
Posts: 1,350
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Dec 23, 2015 17:32:27 GMT
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Right today I went to my mate Sandy's and used his press to remove the old shafts , then pressed the new ones in. Then when I got home I removed the old bearings from the cross tube and stuck the new ones in. Tomorrow I'm going to put the beam back together and if its not pi$$ing down refit it to the car. Could it be that I actually have doris back on the road for xmas? Things went really well today so I'm bound to have problems tomorrow Sorry didn't get any pics, my hands were covered with grease. Cheers steve. |
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stevietuck
Posted a lot
Never argue with idiots,they drag you down to their level then beat you with their expertise!
Posts: 1,350
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Dec 24, 2015 18:04:38 GMT
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Well today I started at 9.30am putting the beam back together. It took me quite a while as I was cleaning everything as i was going, plus I was mixing and matching parts, and I had to keep dodging rain showers. Anyway here's a few pics of stuff... New shafts ....  New bearings, seals and lots of grease...  By about midday I was looking at this....  As you can see I didn't get round to repainting all the scratches, I just wanted it on the car! You can also see in that pic that when I removed the old beam I thought I would be clever and remove the back plate with the handbrake and brake pipe still connected, meaning less work when refitting.Well it didn't work because I couldn't for the life of me workout how I had done it (as is how I had feed the pipes and cables round the beam ) so ended up disconnecting the pipe anyway. I kept having to dodge rain showers, but by about 2pm I had had enough and thought sod it get the waterproofs on, and by 3.30pm just as it was getting dark I had the wheels back on and dropped off the jack. First thoughts were, b0ll0cks, I haven't lowered it enough. I had wanted it somewhere between the too high that it was to start with, and the too low it was with the replacement beam. But ended up with it being about the same as it was to start with. I'm not too bothered because when I fit the gti front struts that I have, I can lower the back to match. I cleaned the splines on the torsion bars with the wire wheel, and the splined sockets with a wire brush, and gave everything a really good greasing, so as long as I don't leave it ages it should all come apart ok. Off with the waterproofs and in to the driving seat, out of the cul de sac down the hill, and b0ll0cks there is still air in the brakes, and the exhaust is rattling about like a bolt in a food mixer! As for the beam its self all is good, so while on the test drive I stopped in at the shop for a four pack of stella lol! Stopped in a carpark for a quick rubbish pic....  See, just like Iv'e not done anything to it at all I will sort the brakes and exhaust over xmas if I feel like it Merry Christmas everyone Thanks for reading Steve. |
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stevietuck
Posted a lot
Never argue with idiots,they drag you down to their level then beat you with their expertise!
Posts: 1,350
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Dec 24, 2015 20:35:36 GMT
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Dec 24, 2015 22:11:02 GMT
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Well done Steve. Great progress. Merry Christmas
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Dec 24, 2015 22:21:46 GMT
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a pug dealer is the best place to get bumpstops, not stocked so will need to be ordered in, about £12 a side iirc.
they come with the cup the bump stop is pushed into and the bolt.
invariably the head of the bolt is rotten/rounded! welding a nut to the remains does wonders.
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simes
Part of things
Posts: 734
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Dec 24, 2015 22:53:47 GMT
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Or grabbing the remainder of the cup with stilsons and hope when turning it takes the bolt with it.
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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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new crossmember required there! fingers crossed the other tube is at least usable, the gti ones do tend to fare off much worse as the stiffer bars mean the arms don't move up and down as freely, concentrating the wear.
