Project 1991 Peugeot 205 GTI 1.9
 

Well after searching for quite a substantial time I came across this little gem a week ago today, Whilst she look pretty clean (to be fair it is for 23 years old) it does need some TLC. But I'am the right guy for this.

so this will be an on going project not to be done asap just as and when as I plan never to sell it like the previous one I let go 4 years ago.

This car will make the odd appearance at shows, but more importantly I hope it turns some heads.

so here goes.

The Cars history from Day one, Owned by 7 people in its life, seems a few but each and every one has documented every part of its life Now to me this means everything, Infact to complete the history I bought the original Sales brochure for £17 :shock:

I have every MOT certificate, I have every tax disc but 1992. and every single receipt for work and services etc and some history a previous owner had documented. More importantly I have the orginal Book Pack that came with the car fully stamped & the original Lion AA Guide.
https://farm4.staticflickr.com/3856/...6513c8a8_c.jpgThe gti by Rostle84, on Flickr

The car has covered a Genuine 95k Approx since new & is backed up by the national Mileage register and HPI
https://farm4.staticflickr.com/3866/...6932e690_c.jpgThe gti by Rostle84, on Flickr

The interior of the car is completely standard And this is how it left the factory apart from the radio has been changed to a pioneer unit, The Mats never came with this car However these are Genuine GTI mats from Peugeot which came with the limited edition 1.9's back in the day., Kindly Given to me on long term loan from My Mother a previous gti owner in 1990.
https://farm4.staticflickr.com/3924/...37e65d12_c.jpgThe gti by Rostle84, on Flickr

https://farm6.staticflickr.com/5562/...f13f600d_c.jpgThe gti by Rostle84, on Flickr

The Paint work is finished In Sorrento Green and complimented with the Original Speedline alloys, this will be getting re painted at some point due to age its suffered a fe knocks in its time plus some bubling in the paint means it needs doing
https://farm6.staticflickr.com/5568/...3ee5d16c_c.jpgThe gti by Rostle84, on Flickr

The engine on the car is completely standard Apart from a couple of blue hoses which wont be staying on the car. 130bhp XU series engine with everything as it left the factory, Missing at present is the Jack.
https://farm4.staticflickr.com/3835/...2bf4163d_c.jpgThe gti by Rostle84, on Flickr

Still has the original speedline alloy spare with Michelin tyre fitted to it, bumper needs new Irons fitted to secure it further & the tail gate badges need refreshed
https://farm6.staticflickr.com/5590/...2bf99dc2_c.jpgThe gti by Rostle84, on Flickr
https://farm4.staticflickr.com/3893/...4b4f36d4_c.jpgThe gti by Rostle84, on Flickr

The Iconic 1.9 badges speak volumes
https://farm4.staticflickr.com/3862/...e4fe513d_c.jpgThe gti by Rostle84, on Flickr
https://farm4.staticflickr.com/3913/...3b7eddf1_c.jpgThe gti by Rostle84, on Flickr

General Body condition overall isn't too bad, some corrosion to deal with but that's easy sorted
https://farm4.staticflickr.com/3916/...9d501631_c.jpgThe gti by Rostle84, on Flickr

https://farm4.staticflickr.com/3854/...0a8c6fbf_c.jpgThe gti by Rostle84, on Flickr

Meets the rest of the fleet of vehicles. Looks well at home
https://farm4.staticflickr.com/3865/...3cb5d310_c.jpgThe gti by Rostle84, on Flickr

https://farm4.staticflickr.com/3905/...62518dbd_c.jpgThe gti by Rostle84, on Flickr
https://farm6.staticflickr.com/5579/...a286e41a_c.jpgThe gti by Rostle84, on Flickr
https://farm4.staticflickr.com/3894/...8df45584_c.jpgThe gti by Rostle84, on Flickr

Be a slow process to get it how I want it.

Nice m8, like classics like these
:thumb:

Fecking awesome!!!!!!! So much want

always a fan of the earlier french hot hatches including the much underated 309 gti

my mate has a 205 with an mi16 lump on throttle bodies..........sounds like hell breaking loose :)

just one LOL from me though..................the up-turned golf club for a gear stick-gotta love it

That brings back great memories Rob. One of my very favourite past cars.

Subscribed

Had a couple of these, and would love another to tuck away.

Love it. :thumb:

Nice Rob, looks like you've picked a great example as a base for an awesome refurb, subbed :thumb:

love it! i had a 309 gti but only because the 205 the guy was selling was only the 1.6 gti. loved the 309 to bits tho and it handled every bit as good as the 205,s did.

Whilst she looks sound enough on top there are Quite a few rust patches to cut out and metal work to replace on it which really is a free repair to me as I used to do allot o fabrication work.

Then Been looking around for replacement parts spooxmotorsport seems favourite at the moment.

I have a fair list just off initial inspection tonight. she just wont pass an mot as it is unfortunately.... Its bloody close but not close enough the tin worm has been helping itself over 23 years.


Peugeot 205 Build checklist.

Weld to nsr boot corner & Outer rears where bumper mounts have gone so need re constructed
Weld nsr and osr under rear seats. remove fuel tank and re route brake pipes correctly & inspect underbody
Weld nsf foot well under carpet & straighten floor and build up floor were has been crushed by incorrect jacking
weld osf foot well under carpet, same again jacked up in the wrong place
Fit new rear bumper & fit new bumper Irons
Replace front bumper with new one with fitting kit
New number plates
refit radio correctly
Fit new exhaust system
fit new clock surround
fit new passenger sun visor.
fit new tailgate badges
fit new mudflaps
Fit new aerial
Re-trim seats
fit new front fog lamps & Front lamp kit & rear lamp kit
Service engine & fit timing belt, replace clutch & hoses inc metal transfer pipe
new wipers and re paint wiper arms
Overhaul Wheels
Fit new spare tyre
Remove dents and paint body & engine bay. plus underseal body after completion of welding.

That's the jobs to be getting on with for now, Looks like the Subaru will be coming out of its cosy garage.. :cry:

The bonus is the rear beam has been rebuilt 6 months ago and runs Goodridge braided lines to the brakes which have also just been replaced & is running new toyo proxy tyres.


It was never going to be perfect at this age which I don't really mind as it's something to do over winter.

Next up is the pictures of the corroded area's and corrective procedure

That's the jobs to be getting on with for now, Looks like the Subaru will be coming out of its cosy garage.. :cry:


And moved into the cosy garage at work more like :) and you will be commuting in one of the cars off the forecourt or Abbys old track car if you and young stan aint killed it yet :)

Be a home build repair, cant be doing with it a work I'd rather no one-else was involved Until it comes to painting it. Still using my sti for commuting in for now. Abby's car is still sat there. Been to oulton park on a full day tracking it and its in once piece still. Last heard they were going to send it to be bust for bits

is it been broke at Stans Rob ??

No looking to sell it to a breaker to do the deed as we don't have the relevant license to break cars for spares

Whats the scrap value weight wise not whats on/in it £150 also rob did you find out off your sis a bit more info regarding the beetle ???

about £150 these days, But they want more than that, its up for £7500 but to be fair when you count the gear that's fitted to it you'd get it back plus a bit more for your troubles. we have had allot of genuine interest in the car but when ever anyone goes out in it they scare themselves they say its far to quick. I was waiting for Ali her fella to ring me and tell me what the score is I know its a rolling shell but that's about it and that its tax exempt. I'll jog his memory

Looking forward to your progress :thumb:

[QUOTE=rob84;11514555 I was waiting for Ali her fella to ring me and tell me what the score is I know its a rolling shell but that's about it and that its tax exempt. I'll jog his memory[/QUOTE]

Cheers rob

Love 205's... Built one with an mi16 in the late 90's 3rd and 4th gear was epic and handled amazing... Looking forward to some updates...

Love it, will always have a soft spot for these, so many good times were had.

I used to have a laser green 1.9 GTi. It was great fun. Far from standard as I used to hill climb and sprint it.

Attachment 58829

Update time
 

It's been a while since I last posted up an update so here goes. With work commitment's etc its been difficult finding the motivation after work to get going with it.

Anyhow the weekend is here the MRS is at work for the weekend so Time to go play in the garage.

This is what I had presented to me once I'd removed the front end of the car. 23 years of use has taken its told or its had a minor bump at some point and a crap repair.

https://farm4.staticflickr.com/3944/...460a321c_c.jpgCutting out the tin worm on project gti by Rostle84, on Flickr

Passenger side headlamp surround pretty much the same.

https://farm3.staticflickr.com/2947/...85aed9ac_c.jpgCutting out the tin worm on project gti by Rostle84, on Flickr

So with both front wings removed and the top section of the headlamp surrounds removed this is what was hiding behind it
https://farm3.staticflickr.com/2948/...f37d95f6_c.jpgCutting out the tin worm on project gti by Rostle84, on Flickr

So I took the plunge and ordered some new panels last week, I had to go down the route of pattern parts for it. I'm pleased I got two new front wings as this is what was lurking under the passenger one

https://farm6.staticflickr.com/5603/...7d63edd6_c.jpgCutting out the tin worm on project gti by Rostle84, on Flickr

The inner wings on both sides were remarkably spotless which was a huge relief

https://farm4.staticflickr.com/3947/...79ea04fa_c.jpgCutting out the tin worm on project gti by Rostle84, on Flickr

As to can see easily on the drivers inner section where the jack sits its literally holed its that rotted through, But never fear that's nothing major and I will crack on with the next bit.

https://farm4.staticflickr.com/3950/...f7063e1f_c.jpgCutting out the tin worm on project gti by Rostle84, on Flickr

Washer bottle and battery removed from the passenger side, Looks better than the drivers but I always say the only way to deal with rust is to cut it out back to good metal and replace.

https://farm4.staticflickr.com/3939/...f6f565da_c.jpgCutting out the tin worm on project gti by Rostle84, on Flickr

First piece on that side cut out, the bottom section I wasn't happy with so cut that out later too.

https://farm6.staticflickr.com/5597/...626b9442_c.jpgCutting out the tin worm on project gti by Rostle84, on Flickr

As above but the corner piece was cut out too as It was starting to rot. the rest is minor surface rust which will mop off with a wire wheel attachment and sort out later.

https://farm4.staticflickr.com/3932/...6de825d7_c.jpgCutting out the tin worm on project gti by Rostle84, on Flickr

as per the otherside, the only way was to cut the whole lot back to good metal

https://farm6.staticflickr.com/5606/...3e9a7d74_c.jpgCutting out the tin worm on project gti by Rostle84, on Flickr

as you'll agree, they sections removed are pretty much buggered, These will be used to make up copys on new zinc coated metal.

https://farm6.staticflickr.com/5612/...8be3375b_c.jpgCutting out the tin worm on project gti by Rostle84, on Flickr


Both sides cut out, photo taken before the section removed on the passenger inner section

https://farm4.staticflickr.com/3932/...f4f4ceaa_c.jpgCutting out the tin worm on project gti by Rostle84, on Flickr

Well heres the old section ready for the scrap vs the new galavnised front section.

https://farm6.staticflickr.com/5609/...5be305e7_c.jpgCutting out the tin worm on project gti by Rostle84, on Flickr

Quick offer up of the new panel, with it being a pattern part and not an original I thought it may be a bit out in places, But its pretty sweet.

https://farm3.staticflickr.com/2950/...cccb1106_c.jpgCutting out the tin worm on project gti by Rostle84, on Flickr



That's all for the moment folks, stay tuned for the next update.

Good work Rob. Bit of pain at the start but it will get better and better as you go forward. Just love these cars so well done for fostering this one mate.

Cheers Mick, It was one of those things stood there thinking where on earth do I start at. I removed both front and rear bumpers etc and at that point looked at the underside of the bonnet and the damage to the wings in places I thought umm I'll just get new panels. As it happens they arnt to expensive either and come already galvanised and painted black which is pretty nifty.

Anyhow after talking to a couple of body repair specialists who did a select few GTI's in the past I was informed were to look for issues & pleased I took there advice on board and set too. & adopted the approach rusty metal will never heal cut it out and replace It will last far longer.

Once I have this one sorted I'm buying a 1.6 version to do the same to and once that's done perhaps a 205 Rallye if I can find one so I have the whole sport range except the T16. :thumb:

Brings back some memories seeing the new front panel, I repaired my old 205 GTI after some old tit pulled out in front of me.

Great little cars.

I'm pleased I have a set of spot weld drills lol. wasn't to bad to get off but with all the rust it was a bit of a task finding them all.

I agree Fantastic little car's, well it will be once I've got it sorted :thumb:

Was thinking the other day when this car was new I was only 7 years old, My mum had a 1.9 in Miami blue limited edition she used to take us to primary school in it. Never thought I'd own another after the red one I sold :lol1:

Well, Time set aside today from my daily duties to start again with the GTI

So I bought a brand new Mig Welder and Big Hobbyweld Tri mix cylinder, no messing around with disposable ones.
Attachment 58830

Attachment 58831

So armed with new sheets of steel My dewalt Grinder and a box of grinding and cutting discs and a few Panel beating tools Kindly Loaned from martin (Cheers Mate) I set too with the repairs to the boot floor section.

Heres what I'm talking about. Rotton and holed, Most common areas, Plus two holes in the center.

https://farm8.staticflickr.com/7487/...90f4dd31_c.jpg20140915_183609 by Rostle84, on Flickr

Only a small Hole but the rust where it joins the rear arch was going to come through at some point so that was cut out too.
https://farm8.staticflickr.com/7509/...48fc8f42_c.jpg20140915_183619 by Rostle84, on Flickr

First piece in the middle of the floor removed and a plate made up, Weld magnets are ace for this no more trying to juggle metal.

https://farm8.staticflickr.com/7536/...67639b28_c.jpg20141108_151503 by Rostle84, on Flickr

https://farm4.staticflickr.com/3942/...74a2f3ca_c.jpg20141108_151511 by Rostle84, on Flickr

https://farm8.staticflickr.com/7507/...d0f7bf12_c.jpg20141108_155658 by Rostle84, on Flickr

First section ground back and primed with Acid etch

https://farm4.staticflickr.com/3953/...eec6708a_c.jpg20141108_181643 by Rostle84, on Flickr

Second section ground back and primed

https://farm8.staticflickr.com/7580/...5f2e4d11_c.jpg20141108_182612 by Rostle84, on Flickr

Corner piece all cut back to solid metal and a dummy plate cut but needing trimmed is offered up
https://farm4.staticflickr.com/3941/...52a8344d_c.jpg20141108_153128 by Rostle84, on Flickr

Welded in and drilled down to the chassis and welded through to give rigidity

https://farm8.staticflickr.com/7569/...4a381f43_c.jpg20141108_155651 by Rostle84, on Flickr

Not bad, slight overlap no huge lumps uniform in size, I think that will suffice.

https://farm4.staticflickr.com/3944/...9c208619_c.jpg20141108_161015 by Rostle84, on Flickr

all ground back and wire brushed, Bit shiney really.

https://farm4.staticflickr.com/3952/...3fefa2d6_c.jpg20141108_185000 by Rostle84, on Flickr

Now etch primed up

https://farm6.staticflickr.com/5605/...c54f3564_c.jpg20141108_185333 by Rostle84, on Flickr

That's one side down, One to go

https://farm6.staticflickr.com/5616/...c3bb7977_c.jpg20141108_185438 by Rostle84, on Flickr

The other side cut out plated ground and primed.

https://farm6.staticflickr.com/5616/...cb795fba_c.jpg20141108_185450 by Rostle84, on Flickr

https://farm6.staticflickr.com/5610/...db20a56b_c.jpg20141108_183633 by Rostle84, on Flickr

That's all for today, Next instalment is Inner wing repair to outter wing plates and bumper mounts.

Jeez I'm reading this and thinking why oh why did I sell mine
I had a 1990 black non sunroof 1.9 with a few upgrades and absolutely no rust I bought for 600 quid a few years ago when I sold my last Wrx
But now I've got an RA needing an engine i went and sold it a few weeks back
Should really have been parked up for another few years indoors as these are gonna be worth a ransom soon
Attachment 58832
That was mine god luck with your project

Front panel fitted and clamped into place ready to be welded on Bonnet fitted and catch setup to front panel. Both front wings fitted. Osf needed manipulated into place to sit right as the forming wasn't quite right plus had been bent a little at some point compared to the nsf. Doesn't look much of an update but I can assure you it took a while to achieve.

https://farm1.staticflickr.com/472/2...058bdc56_c.jpg10614330_10155361569285157_6796788906958143391_n by Rob Ostle, on Flickr


https://farm1.staticflickr.com/493/2...ec3907f0_c.jpg10410251_10155361568930157_5900792382189939412_n by Rob Ostle, on Flickr

https://farm1.staticflickr.com/560/2...2021a487_c.jpg10408763_10155361569880157_4417649481004714394_n by Rob Ostle, on Flickr

https://farm1.staticflickr.com/297/1...68f53bb6_c.jpg11009199_10155361569045157_2012998812337184129_n by Rob Ostle, on Flickr

https://farm1.staticflickr.com/290/1...1e3790b7_c.jpg11054329_10155361570150157_3889296478109985702_n by Rob Ostle, on Flickr




Small progress report today on Project GTI. The fiddly bits that everyone hates doing. Inner wing sections were the sunroof drains run we're literally rotted away to nothing. This means the rear bumper has no corner support (bumper supports to make at a later date). Anyhow cut the inner arches away to good metal with the plasma cutter and the took the shape to a new sheet of steel and cut to the exact shape enabling me to butt weld in the new steel making it sit flush. These bits will never be seen but I like things done right. After welding those in there was the little task of making a new rear tow eye. This was literally hanging on by a wing and a prayer. So cut that off and the supposed support brackets to the rear body. I then set about fabricating a new tow eye using the original pressed loop. Easy enough but took a while to shape etc. once done offered it to the car were it became apparent I needed to add a support for extra strength. I then welded a small section over the top then cut down and welded. 90 Deb section so it would weld onto the chassis rail. Easy enough. Job done. Etch primed and painted. Next update coming soon.

https://farm1.staticflickr.com/327/2...6b280a9c_c.jpg11870728_10156049758745157_6664872463790803824_n by Rob Ostle, on Flickr

https://farm1.staticflickr.com/435/2...08c4e99d_c.jpg11222586_10156049760750157_8025187924315525632_n by Rob Ostle, on Flickr

https://farm1.staticflickr.com/443/2...b6edbcd2_c.jpg11811400_10156049759050157_1695018312504654539_n by Rob Ostle, on Flickr

https://farm1.staticflickr.com/544/2...438ef001_c.jpg11846700_10156049761300157_4194844679160571718_n by Rob Ostle, on Flickr

https://farm1.staticflickr.com/413/2...5a55658b_c.jpg11825724_10156049761615157_2955714174761792284_n by Rob Ostle, on Flickr

https://farm1.staticflickr.com/439/2...3b6aef9e_c.jpg11218924_10156049762075157_6102272465625057003_n by Rob Ostle, on Flickr


https://farm1.staticflickr.com/328/2...9f9b2859_c.jpg11825230_10156049763175157_8591319009955633347_n by Rob Ostle, on Flickr

https://farm4.staticflickr.com/3678/...7d9c0395_c.jpg11811287_10156049763370157_4735896948343472880_n by Rob Ostle, on Flickr

Small Update for tonight, I bought some new tools for the Job at hand. I need to make new sections for the front inner wings as basically they have seen better days so I cut them out back to good metal with no rust on.


New vice and a clarke Metal folder and some panel beating hammers& dollies.





Excuse the state of My garage there are tools lying everywere at the moment.





https://farm6.staticflickr.com/5834/...7e5c4938_c.jpgUntitled by Rob Ostle, on Flickr





Started with cutting the basic shape with the Plasma Cutter and popping it into the folder to get the nice smooth folded edge to weld back onto the wing section, Old one on the right as you can see has seen better days





https://farm1.staticflickr.com/604/2...0e3c1b5b_c.jpgUntitled by Rob Ostle, on Flickr





The next bit was to figure out how to get the curve in the center to match up to that of the front panel.





https://farm6.staticflickr.com/5824/...3499fe4b_c.jpgUntitled by Rob Ostle, on Flickr





Easy enough once I got my head around it. Slight cut in the center with the Plasma cutter then with the use of the Hammers and dollies made the basic shape needed to match the front panel Then welded the center up and edge piece & flattened back





https://farm1.staticflickr.com/680/2...e52f208b_c.jpgUntitled by Rob Ostle, on Flickr





https://farm6.staticflickr.com/5701/...4ebcec50_c.jpgUntitled by Rob Ostle, on Flickr





Job done for tonight, Coated with Galvanised Zinc primer, Ready to weld in.





https://farm6.staticflickr.com/5699/...3ec4d99a_c.jpgUntitled by Rob Ostle, on Flickr

Seats are out and is the floor in the car at the moment, But I wont spoil that surprise just yet its a bloody mess under the carpet. I can see daylight in more areas that I wanted.

I really need to concentrate on one area and finish that first. But I like to vary it a touch.

Also Had a Guy Who is an Aviation Engineer in Cambridge Machine and press fold me a pair of custom rear Inner arch sections for my bumper to Mount onto

http://www.209-design.co.uk/205gti/bumpermounts.jpg

http://www.209-design.co.uk/205gti/bumprefine.jpg