205 GTI V6 Project, bigger and better.
Discussion
Hi all,
Thought I would show you all some photos of what I have been slaving over for the past few days...
I built myself a 205 V6 back in april but havn't really used it over the summer but have made the decision (for a few reasons) to re-shell the engine into my other 205 and at the same time uprate the suspension, brakes and sort all the little problems I had in the old shell.
Cleaned up the bay, put in some new brake lines (my first attempt at brake lines, hence why they don't look very neat!)
The two shed's side by side...
The engine is in its new home...
One of the problems I had was the radiator I used was too big and I couldn't fit the grille on, it looked a bit crap. So this time I have decided to see if I can stick with the 205 radiator, it should give adequate cooling as the the larger one I had overcooled it when in motion (it overheated in traffic but that was due to one tiny fan!).
Plenty of room for a rad :O
Rather close to the front exhaust manifold, there is very little engine movement though so I am hoping this will be ok.
It sit's low enough that the grille will fit in place.
Bottom of the rad just poking out!
I managed to use some spare rubber pipe to make up the required hoses, extra lengths were needed as the 205 radiator has an inlet/outlet each end rather then both on the N/S like the old radiator.
Its a tight fit but managed to make it work. (photo take from O'S wheel arch facing forwards)
Another 'problem' I had was that I had to run bonnet pins because the slam panel was not up to the job of supporting the bonnet, it has to be cut out to let the engine fit thus losing a lot of its strength.
So I got thinking and found an old gear rod that looked the right length and strength.
Cut the ends off.
Welded it in place, hey presto! It feels strong enough but I have yet to try shutting the bonnet, will be interesting to see if the bonnet still lifts at over 100.
I also started it up today, the first time it has been run in a few months and it started first time and idled nicely.
I will be finishing it off over the next few days, will hopefully make a couple of track days in october.
I have some Brembo 4 pot brakes to go on the front and some 206 CC 'Nimrod' wheels to go over them. I also have some new suspension on the way, Bilstein grp A tarmac coilovers with 240lb springs and adjustable top mounts, 21mm rear torsion bars and AST rear dampers.
I will update as more progress is made
Thought I would show you all some photos of what I have been slaving over for the past few days...
I built myself a 205 V6 back in april but havn't really used it over the summer but have made the decision (for a few reasons) to re-shell the engine into my other 205 and at the same time uprate the suspension, brakes and sort all the little problems I had in the old shell.
Cleaned up the bay, put in some new brake lines (my first attempt at brake lines, hence why they don't look very neat!)
The two shed's side by side...
The engine is in its new home...
One of the problems I had was the radiator I used was too big and I couldn't fit the grille on, it looked a bit crap. So this time I have decided to see if I can stick with the 205 radiator, it should give adequate cooling as the the larger one I had overcooled it when in motion (it overheated in traffic but that was due to one tiny fan!).
Plenty of room for a rad :O
Rather close to the front exhaust manifold, there is very little engine movement though so I am hoping this will be ok.
It sit's low enough that the grille will fit in place.
Bottom of the rad just poking out!
I managed to use some spare rubber pipe to make up the required hoses, extra lengths were needed as the 205 radiator has an inlet/outlet each end rather then both on the N/S like the old radiator.
Its a tight fit but managed to make it work. (photo take from O'S wheel arch facing forwards)
Another 'problem' I had was that I had to run bonnet pins because the slam panel was not up to the job of supporting the bonnet, it has to be cut out to let the engine fit thus losing a lot of its strength.
So I got thinking and found an old gear rod that looked the right length and strength.
Cut the ends off.
Welded it in place, hey presto! It feels strong enough but I have yet to try shutting the bonnet, will be interesting to see if the bonnet still lifts at over 100.
I also started it up today, the first time it has been run in a few months and it started first time and idled nicely.
I will be finishing it off over the next few days, will hopefully make a couple of track days in october.
I have some Brembo 4 pot brakes to go on the front and some 206 CC 'Nimrod' wheels to go over them. I also have some new suspension on the way, Bilstein grp A tarmac coilovers with 240lb springs and adjustable top mounts, 21mm rear torsion bars and AST rear dampers.
I will update as more progress is made
Love 205's.
k about do you! thats proper 'man-in-shed' work there. Very impressive, its easy to drop a crated/supplied engine in, all those little niggles you miss out on though! Good work with the hoses too buddy. Keep us updated!Thanks
It's not as tight as it looks in the pics, theres only realy a couple of bits that are tight, having seen your C2 up close I would say it fits nicer in the 205 but I expect the C2 has a lot more clearance down below near the subframe.
I filled up the coolant today with the new Rad setup and ran it almost up to temp, the pipe join just off the lower rad take off has burst though as its 2 bits of rubber pipe held together with a plastic sleeve and when the water heated up the plastic sleeve went soft and slid out from the hose clip. I will have to find an equivalent metal joiner to replace it with, maybe a 32mm copper straight union.
I have a feeling I will end up having to use some harder springs, but not sure how well the front and back will match so need to try it out and then make adjustments. It's quite unknown territory!
I keep starting it up just to stand round the back and listen to it burble, I forgot how good it sounds
It's not as tight as it looks in the pics, theres only realy a couple of bits that are tight, having seen your C2 up close I would say it fits nicer in the 205 but I expect the C2 has a lot more clearance down below near the subframe.
I filled up the coolant today with the new Rad setup and ran it almost up to temp, the pipe join just off the lower rad take off has burst though as its 2 bits of rubber pipe held together with a plastic sleeve and when the water heated up the plastic sleeve went soft and slid out from the hose clip. I will have to find an equivalent metal joiner to replace it with, maybe a 32mm copper straight union.
I have a feeling I will end up having to use some harder springs, but not sure how well the front and back will match so need to try it out and then make adjustments. It's quite unknown territory!
I keep starting it up just to stand round the back and listen to it burble, I forgot how good it sounds
Which engine are you using the 12v or the 24v?Made some more progress over the past few days/weeks...
Just about got all the cooling sorted, the pipes are done and the engine has been run upto temp with no problems. Just waiting on some 10" slimline fans for the rad then it's all done.
Managed to get the bonnet to close using the normal bonnet catch, no need for bonnet pins = more like a sleeper
I have also fitted the better front suspensio
n, Grp A Bilstein coilovers with 240lb 9" springs (I may well need to upgrade the springs, but trial and error is how I will tackle it). Also fitted the compbrake solid adjustable top mounts, they were a bit of a pain to fit as I had to oval out the 3 mounting holes to get them lined up right. I have fitted them so the top of the strut is as far back and as far in as possible, I may find that I have too much camber though as I am running 309 wishbones too.
Also fitted some brake pipes from Miles ready for the Brembo's after I get the 288mm disc's tomorrow.
Just about got all the cooling sorted, the pipes are done and the engine has been run upto temp with no problems. Just waiting on some 10" slimline fans for the rad then it's all done.
Managed to get the bonnet to close using the normal bonnet catch, no need for bonnet pins = more like a sleeper
I have also fitted the better front suspensio
n, Grp A Bilstein coilovers with 240lb 9" springs (I may well need to upgrade the springs, but trial and error is how I will tackle it). Also fitted the compbrake solid adjustable top mounts, they were a bit of a pain to fit as I had to oval out the 3 mounting holes to get them lined up right. I have fitted them so the top of the strut is as far back and as far in as possible, I may find that I have too much camber though as I am running 309 wishbones too.
Also fitted some brake pipes from Miles
ready for the Brembo's after I get the 288mm disc's tomorrow.
Yummmmmmmm
Well lots more progress has been made
All the large jobs are finished, it is now running fine, driving fine, taxed, insured and fully driveable!Some of the smaller jobs to be done in the short term are,
Get the tracking sorted,
Find out why the dash bulbs don't work and make them work!
Get Mei to wire in my Rev counter,
Change the seats over to the full leathers,
Put the 21mm torsion bars in the rear beam,
So quite a lot to be getting on with
Something else I have decided to tackle is the Sound deadening, not ripping it out to save weight but infact adding more to improve comfort.
I have got quite used to driving the focus now which is obviously very sound proofed inside and have decided I don't like the way my 205 rattles and bangs over every bump quite so much! I'm not going to go mad but just want to eliminate a little more of the road noise.
I set to work removing the old, damp sound deadening from the boot and replacing it with some that I had lying around.
Here some of the boot underlay that I have replaced. I will get some exterior shots of it now its finished tomorrow as i'm out all day today!
Old stuff
Whipped out and given a clean,
New stuff in place,
Extended to underneathe the rear seats for added deadening. I would have put it all the way under but my roll wasn't long enough.
Get the tracking sorted - Check!
Find out why the dash bulbs don't work and make them work! - Check! Turns out that there are two 5 pin earth plugs that plug in on the LHS of the steering column, only one was plugged in. Then I had to bypass a broken track on the PCB to stop the fuel and oil pressure gauges reading full all the time!
I sorted the dash bulbs out then went for a little drive, put some fuel in then went to gloucester and got the tracking sorted at ProTyre, it was toe-ing in quite a bit (although it looked like it was toe-ing out!) but its now set to dead straight. The steering wheel is (nearly) straight too and it doesnt pull from side to side even under hard acceleration so is a joy to drive
Their machine showed the camber too which is 1.5 degrees negative, a couple of hundredths fluctuation between the two sides.
Anyway, Pics as promised!
It is still riding quite high but that is fine for now, I will lower it down about 20-30mm soon but not just yet.
It is an absolute joy to drive, I have no driveshaft problems, no temperature problems and no electrical problems so I'm well chuffed!
If we get a dry day soon then I will get some 0-60 videos up for everyone
Olber: It still handles really well even with the slight extra weight up front (works out about 40kgs extra - compared to a turbo or GTI6 conversion). It's probably not quite as nimble to drive but you don't lose any of the fun factor because of that, it is so much more fun to drive then my standard 205's although is a bit hair raising at times!
Been driving this about for the past week or so, used up my first tank of fuel covering about 290 miles which works out at about 30mpg (15p/mile) so I am very pleased with that I did plenty of harsh accelerating too, not like I was being frugal!
Should have some more progress over the next week or so, planning to get the rear suspension fitted before Christmas and some more done to de-rattle and smarten up the inside.
At the moment I am refurbing the leather seats I have in my other 205 to put into this one, not sure whether to put the grey carpet in to match the seats or leave the green carpet in to match the car? What do you guys reckon?
Been driving this about for the past week or so, used up my first tank of fuel covering about 290 miles which works out at about 30mpg (15p/mile) so I am very pleased with that
I did plenty of harsh accelerating too, not like I was being frugal!Should have some more progress over the next week or so, planning to get the rear suspension fitted before Christmas and some more done to de-rattle and smarten up the inside.
At the moment I am refurbing the leather seats I have in my other 205 to put into this one, not sure whether to put the grey carpet in to match the seats or leave the green carpet in to match the car? What do you guys reckon?
Goliath205 said:
Olber: It still handles really well even with the slight extra weight up front (works out about 40kgs extra - compared to a turbo or GTI6 conversion). It's probably not quite as nimble to drive but you don't lose any of the fun factor because of that, it is so much more fun to drive then my standard 205's although is a bit hair raising at times!
Been driving this about for the past week or so, used up my first tank of fuel covering about 290 miles which works out at about 30mpg (15p/mile) so I am very pleased with that I did plenty of harsh accelerating too, not like I was being frugal!
Should have some more progress over the next week or so, planning to get the rear suspension fitted before Christmas and some more done to de-rattle and smarten up the inside.
At the moment I am refurbing the leather seats I have in my other 205 to put into this one, not sure whether to put the grey carpet in to match the seats or leave the green carpet in to match the car? What do you guys reckon?
290 miles without rear suspension?? Imprssive! Been driving this about for the past week or so, used up my first tank of fuel covering about 290 miles which works out at about 30mpg (15p/mile) so I am very pleased with that
I did plenty of harsh accelerating too, not like I was being frugal!Should have some more progress over the next week or so, planning to get the rear suspension fitted before Christmas and some more done to de-rattle and smarten up the inside.
At the moment I am refurbing the leather seats I have in my other 205 to put into this one, not sure whether to put the grey carpet in to match the seats or leave the green carpet in to match the car? What do you guys reckon?
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