My Rally Project
- Thread starter Lopéz
- Start date
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James_N said:Check:
MSN me if i can be of any help
You might be in a couple of weeks!
[email protected] I can't remember if you're in my contact list.
Back from Wales, and thoroughly knackered.
Decided that the first thing to do would be to put a battery on the 205 and see if it would fire - I haven't touched it since May so I wasn't overly confident.
Fair play, it fired and ran smoothly after barely half a second of cranking. Not bad at all!
Aside from soft tyres and a bit of mould on the leather steering wheel it was all well so I locked it up and started on the garage clearance.
Decided first job would be to oust the cage. OMP roll cage in the 205 is a 2 piece affair. The rear half cage with rollhoop, and the front cage which is a windscreen bar and the 2 arms that run down the A-pillar and post.
The rear cage mounts by bolting onto the rear beam bolts, and bolting to 2 large steel plates that are welded to the floor/sill near the seatbelt mounting point. The half joins at the top using 2 sleeves secured with allen head bolts, and at the bottom in the kickwell where it bolts to 2 more of those welded in steel plates.
So, firstly I undid the sleeves, which are supposed to just slip off. Ha! The drivers side came off quickly but the passenger side needed driving off with a hammer and chisel. It eventually relented though and I moved onto the feet.
Next I tackled the lower mounting "feet". I removed the bolts and begun to cut through the thick welds holding the feet to the floor, to free them from the floorpan. I used 2 metal cutting wheels for this and very nearly needed a third! When the welds were cut through I belted the feet with a lump hammer and they slid out.
Next step was to lever the 2 rear beam mounting points off, not easy as you have to force each tube up about 2" when it really doesn't want to go. I eventually decided a crow bar was the tool for the job, but couldn't find one so a pickaxe had to suffice! It was at this point I remembered that 3 of us fitted the cage, so maybe I was being over-ambitious trying to remove it on my own. Nevertheless I carried on and got both rear mounts to come off.
I then levered the front mountings away from the A post and *ping* the whole cage came loose in 2 parts.
Success!
I now need to find a shotblaster in the Midlands who can prepare it for painting because I can't be arsed to rub all that down by hand.
Only hitch was, it doesn't fit in the Mondeo
so I will have to get it home by other methods!
I currently have the roll cage mounts and bolts soaking in some Bilt Hamber Deox to see if it will get rid of the surface corrosion. Pics later.
Decided that the first thing to do would be to put a battery on the 205 and see if it would fire - I haven't touched it since May so I wasn't overly confident.
Fair play, it fired and ran smoothly after barely half a second of cranking. Not bad at all!
Aside from soft tyres and a bit of mould on the leather steering wheel it was all well so I locked it up and started on the garage clearance.
Decided first job would be to oust the cage. OMP roll cage in the 205 is a 2 piece affair. The rear half cage with rollhoop, and the front cage which is a windscreen bar and the 2 arms that run down the A-pillar and post.
The rear cage mounts by bolting onto the rear beam bolts, and bolting to 2 large steel plates that are welded to the floor/sill near the seatbelt mounting point. The half joins at the top using 2 sleeves secured with allen head bolts, and at the bottom in the kickwell where it bolts to 2 more of those welded in steel plates.
So, firstly I undid the sleeves, which are supposed to just slip off. Ha! The drivers side came off quickly but the passenger side needed driving off with a hammer and chisel. It eventually relented though and I moved onto the feet.
Next I tackled the lower mounting "feet". I removed the bolts and begun to cut through the thick welds holding the feet to the floor, to free them from the floorpan. I used 2 metal cutting wheels for this and very nearly needed a third! When the welds were cut through I belted the feet with a lump hammer and they slid out.
Next step was to lever the 2 rear beam mounting points off, not easy as you have to force each tube up about 2" when it really doesn't want to go. I eventually decided a crow bar was the tool for the job, but couldn't find one so a pickaxe had to suffice! It was at this point I remembered that 3 of us fitted the cage, so maybe I was being over-ambitious trying to remove it on my own. Nevertheless I carried on and got both rear mounts to come off.
I then levered the front mountings away from the A post and *ping* the whole cage came loose in 2 parts.
Success!
I now need to find a shotblaster in the Midlands who can prepare it for painting because I can't be arsed to rub all that down by hand.
Only hitch was, it doesn't fit in the Mondeo
so I will have to get it home by other methods!I currently have the roll cage mounts and bolts soaking in some Bilt Hamber Deox to see if it will get rid of the surface corrosion. Pics later.
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Soldato
- Joined
- 18 Oct 2002
- Posts
- 4,457
- Location
- between Blandford Street and Mars
Lopez, I'll give you a hand if you want, like DRZ, no tow hitch, but a decent sized boot with folding back seats (Saab).
Actually, do you think that roll cage would fit in the back of a (new) A class? I could perhaps borrow the wife's car if it will.
You could end up with a nice "convoy" of small cars lugging your stuff back from Wales
Actually, do you think that roll cage would fit in the back of a (new) A class? I could perhaps borrow the wife's car if it will.
You could end up with a nice "convoy" of small cars lugging your stuff back from Wales
Associate
- Joined
- 9 Jun 2004
- Posts
- 1,813
- Location
- UK
urgh! I say replace all of the water pipes now. That innocent looking bent one sticking out is a right sod when the engine's mounted
Associate
- Joined
- 9 Jun 2004
- Posts
- 1,813
- Location
- UK
Ahh reet
I had a lovely time last summer with my hoses. Replaced a leaky one, the next one along sprung a leak. Repeat until I've spent 100 quid on rubber tubes and made it nice and leak free. Then my water pump exploded.
I love my 205.
I had a lovely time last summer with my hoses. Replaced a leaky one, the next one along sprung a leak. Repeat until I've spent 100 quid on rubber tubes and made it nice and leak free. Then my water pump exploded.
I love my 205.
Soldato
- Joined
- 4 Jan 2004
- Posts
- 20,802
- Location
- ¯\_(ツ)_/¯
I used copper tube to fix my leaky water pipe.
Looking good... Looks like you got a good one as the rear beam is still holding up.
Looking good... Looks like you got a good one as the rear beam is still holding up.
While I have this engine out I will change the water pump and cambelt. Worth doing every 50k on the 205 GTI.jonarob said:Ahh reet
I had a lovely time last summer with my hoses. Replaced a leaky one, the next one along sprung a leak. Repeat until I've spent 100 quid on rubber tubes and made it nice and leak free. Then my water pump exploded.
I love my 205.
Back to Wales one last time to get the cars ready for moving. Woman really has run out of patience now and I have been officially evicted!
First things first, the red 205. Been parked for some time now, so I didn't know how this would go. Turned the ignition half a turn and it burst into life. Result! Didn't even need to charge the battery.
So I drove it out of the garden to free the brakes off, at this point it had 3 flat tyres and brambles growing through the doors etc which was quickly sorted. Took it for a highly illegal test drive up and down the road and it still goes just fine, everything works as it should.
So with the red car out of the way it was time to extract the black car. This thing has not been outside since 2002 I think!
HEAVE-HO Mr Volvo! Note Drift-Spec front wheel on aforementioned Silver Dream Machine. The left rear wheel of the 205 had siezed and was dragging instead of rolling and I was having to tow at an angle because of the garden wall.....
Like a rotten tooth - extracted. Under the cold light of day the condition of the shell was surprising - better than I remembered, anyway.
That red oxide primer has been on there years and the rust hasn't come through which is pretty impressive. The rust patch above the primer is pretty nasty though.
I managed to pull it out a bit further than this, then drove the Volvo into the garage and pushed the 205 right up to the edge of the garden, which drew some bemused looks from the local halfwits.
The roll cage was already out, so with the really hard work already done, I jacked the car up and salvaged what I could. The bottom balljoint nuts had both rusted and rounded so I couldn't save the hubs or wishbones which was annoying, but I managed to get the front struts off. I didn't bother with the calipers because 1.6 calipers are crap.
Then, working dangerously with the car supported on a single trolley jack, in torrential driving wind and rain, I slid under the car and went to undo the rear axle mounts, only to find that they had rotted and broken in half and didn't need undoing anyway. Common 205 failing pint and cheap to fix luckily! The other beam mounts were already undone from taking the cage out, so if I snipped the handbrake cables and brake pipes the axle should drop down, right?
Wrong. I'd forgotton the GTI has a hefty metal bracket that loops round the forward torsion bar and bolts to the body. No way was the bolt coming off so back under the car for a good 15 solid minutes angle grinder action. Access was terrible and I ended up cutting through the exhaust too just to get to it.
Anyway, with that final clamp cut, down came the axle with a thud.
Success! 1 bare shell. The doors are knackered and not worth saving, I'd have liked to keep the tailgate but I just don't have the space captain.
Alas poor 205, I knew it well. I crammed all the spares (and the cage) into the red 205 and reversed it into the garage where it is waiting to be collected soon and brought to the Midlands.
Watch this space (again!)
First things first, the red 205. Been parked for some time now, so I didn't know how this would go. Turned the ignition half a turn and it burst into life. Result! Didn't even need to charge the battery.
So I drove it out of the garden to free the brakes off, at this point it had 3 flat tyres and brambles growing through the doors etc which was quickly sorted. Took it for a highly illegal test drive up and down the road and it still goes just fine, everything works as it should.
So with the red car out of the way it was time to extract the black car. This thing has not been outside since 2002 I think!
HEAVE-HO Mr Volvo! Note Drift-Spec front wheel on aforementioned Silver Dream Machine. The left rear wheel of the 205 had siezed and was dragging instead of rolling and I was having to tow at an angle because of the garden wall.....
Like a rotten tooth - extracted. Under the cold light of day the condition of the shell was surprising - better than I remembered, anyway.
That red oxide primer has been on there years and the rust hasn't come through which is pretty impressive. The rust patch above the primer is pretty nasty though.
I managed to pull it out a bit further than this, then drove the Volvo into the garage and pushed the 205 right up to the edge of the garden, which drew some bemused looks from the local halfwits.
The roll cage was already out, so with the really hard work already done, I jacked the car up and salvaged what I could. The bottom balljoint nuts had both rusted and rounded so I couldn't save the hubs or wishbones which was annoying, but I managed to get the front struts off. I didn't bother with the calipers because 1.6 calipers are crap.
Then, working dangerously with the car supported on a single trolley jack, in torrential driving wind and rain, I slid under the car and went to undo the rear axle mounts, only to find that they had rotted and broken in half and didn't need undoing anyway. Common 205 failing pint and cheap to fix luckily! The other beam mounts were already undone from taking the cage out, so if I snipped the handbrake cables and brake pipes the axle should drop down, right?
Wrong. I'd forgotton the GTI has a hefty metal bracket that loops round the forward torsion bar and bolts to the body. No way was the bolt coming off so back under the car for a good 15 solid minutes angle grinder action. Access was terrible and I ended up cutting through the exhaust too just to get to it.
Anyway, with that final clamp cut, down came the axle with a thud.
Success! 1 bare shell. The doors are knackered and not worth saving, I'd have liked to keep the tailgate but I just don't have the space captain.
Alas poor 205, I knew it well. I crammed all the spares (and the cage) into the red 205 and reversed it into the garage where it is waiting to be collected soon and brought to the Midlands.
Watch this space (again!)
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