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Restorations, Rebuilds & Projects. Restoring her to Concourse? Just getting her running again? Or got a mad project? This is your room.

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Old 08-02-2009, 11:36 AM   #1
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Default My 205 diesel.

Thought i would put a thread up here, as i am bored and thought you lot might like to see it, i haven't got it anymore as i couldn't be bothered with running it, but here's the build of i did

Decided a needed a cheap runabout when i bought my cossie, and found this fairly local on ebay, nice and cheap.




1.8 dturbo, picked it up and was fairly pleased with it, went ok, handled well, but look at the ride height!

After a good clean

At this point we noticed the headgasket was gone, but took no further action, yet.

Bought a set of 1.9 wheels off my mate very cheap...


and refurbed them







Looking even higher!
Then it went to have the headgasket done, this is where things got a bit mad!
My mate had a 309 gti with a Dturbo in, and had loads of bits lying around, he is also a dab hand at tuning/working on them...........
i found this lying around and started making it fit




Also lowered it, using a set of springs i had lying around, and a set of Gaz adjustables, again, very cheap off my mate



Then it came back out like this.....






That was basically the 1.8 with a new head gasket and the intercooler, about 18 psi of boost and loads of fuel, untill the KKK piece of crap turbo cried enough, so we fitted a Garret T2 off a Xantia, running 14 psi of boost and running badly, it made 104 bhp and 178 ft ib of torque (standard is 78 bhp!)

Then, after a load of abuse, finally while doing a 12 car rally, the engine gave up, blew the head gasket on all 4 cylinders and cooked itsself at the same time!

I was going to scrap it at that point, but my mates went and fetched it and took it to their house, and started work on it, top lads!
So i hunted a new engine out, finally finding a 1.9 Dturbo out of a 306 for a bargain price, After alot of fannying around, we finally got it in (it was not a sdtraight swap, as we had hoped!)
Has to run electric power steering off a 106, and modify loads of stuff for it to go in.....




Also found why my brakes had gone a bit dodgy on that fatefull 12 car




Got it back on the road, and after sorting out a few teething problems, it was going great!
Pulled very well, handled superbly and would embaress a 1.9 gti happily!

Stayed like that for ages, running 22psi of boost now, never had it rolling roaded but it was ALOT quicker than when it was at 104 bhp.







Vid on the rollers


and 2 random vids

http://www.youtube.com/watch?v=fMsBHwxoVKw

http://www.youtube.com/watch?v=_d2-95eQq0I

Then, again, it blew the headgasket, and i decided enough was enough and swapped it for my escort van with a mate, who is now redoing it with a steel headgasket, modified inlet, piper cam and other goodies, it will be back bigger and better!

Feel free to comment/take the piss!
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M.A.D 500 spec engine, GT30, Autronic, 1000cc injectors, ST Inlet, airtec 70mm cooler, AP's, 18" revolutions, RWD converted

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Old 08-02-2009, 11:59 AM   #2
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Old 08-02-2009, 12:10 PM   #3
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lol good sleeper man,take it you just had enough of it?
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Old 08-02-2009, 12:13 PM   #4
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yeah, was costing more to run than the bloody cossie!
Was nailing a pair of wishbone bushes and ball joints every month!
Not cheap when wishbones are £75 a corner! lol
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Old 08-02-2009, 12:18 PM   #5
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lol still must have suprised a few people

be good to see when your mate fixes it.
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Old 08-02-2009, 12:35 PM   #6
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Yeah, it shocked a few things!
Was no good top end though, ran out of 'box at 118 (on a private runway, of course)
Yeah, i will defo get some more pics/vids when its back on the road
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Old 08-02-2009, 07:42 PM   #7
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my mate has had a few of these........
I dont know much about them, but he told me, he is now building a 205 van that he found in a barn. the shell is stone mint 77k.

he just put the 306 d turbo engine in and its got the best turbo on(T2??) he's fitting a front mount intercooler. he was on with swapping all the front subframe, for a dturbo one, cos the old 18d is no good for fitting big brakes?.

when its built i'll take some pics, cos if its anything like any of his old one's it will be mint.
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Old 08-02-2009, 07:47 PM   #8
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Great daily driver project
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Old 08-02-2009, 08:56 PM   #9
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Quote:
Originally Posted by cossiegreg1 View Post
my mate has had a few of these........
I dont know much about them, but he told me, he is now building a 205 van that he found in a barn. the shell is stone mint 77k.

he just put the 306 d turbo engine in and its got the best turbo on(T2??) he's fitting a front mount intercooler. he was on with swapping all the front subframe, for a dturbo one, cos the old 18d is no good for fitting big brakes?.

when its built i'll take some pics, cos if its anything like any of his old one's it will be mint.
Yeah, the Dturbo's run the same subframe as a gti, so they benefit from being able to change all the bits over, they also run gti wishbones, instead of the poverty spec bottom arms found on all the other model's!

I would love a 205 Van!

Cheers for the comments
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Old 12-10-2009, 06:05 PM   #10
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love it, 130+ is possible on the bosch pump and t2 turbo
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Old 12-10-2009, 08:53 PM   #11
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Rum little car Dan!!!!!!

Didn't realise you had done so much work to it.

Saw the smoke screen a few times round town!!!!!
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Old 13-10-2009, 05:40 AM   #12
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Reason your blowing head gaksets is running too much diesel judging by that video on the rollers.

My Skoda pickup is running a 1.6 VW block and 1.9 head, with the KKK K24 Turbo, wastegate completely blocked off and I am controlling boost by diesel. Basically you want a little smoke as it comes on boost which clears to a light haze after that. You are causing huge EGT's with that much un-burned diesel and blowing your gasket.

I run 21psi on the larger K24 and never had any problems. Diesel's are great for daily driving.
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Old 13-10-2009, 07:16 AM   #13
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Quote:
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Rum little car Dan!!!!!!

Didn't realise you had done so much work to it.

Saw the smoke screen a few times round town!!!!!
yeah, spent a bit too much on it really!
I do miss it though, god it was fun!
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Old 13-10-2009, 01:23 PM   #14
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Quote:
Originally Posted by Barry_GTi View Post
Reason your blowing head gaksets is running too much diesel judging by that video on the rollers.

My Skoda pickup is running a 1.6 VW block and 1.9 head, with the KKK K24 Turbo, wastegate completely blocked off and I am controlling boost by diesel. Basically you want a little smoke as it comes on boost which clears to a light haze after that. You are causing huge EGT's with that much un-burned diesel and blowing your gasket.

I run 21psi on the larger K24 and never had any problems. Diesel's are great for daily driving.

On the xud diesels with the lucas or bosch pumps, you need to adjust the fueling a certain amount to even effect the boost levels, you can adjust the max fuel and the boost compensator to get the boost up to 18-19 psi with out touching the actuator (t2 turbo) and thats the max you can do it before you have to raise the boost even more to get rid of the smoke,you can also adjust the fueling but thats more smoke.. My 306 was immensly smokey. The headgaskets on the xud engines always go near the drivers engine mount.Always the downside to them

now Vag older derv's, ( i had one of these too, a z1 engined mk3)

i had nothing but problems The turbo (kkk) was nackered, alot worse than any of my turbos in the past, anyway it was running, and of course the bosch pumps are different on the vags to the pug's, so i tuned it, later on the crank broke, so i had to break it
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Old 13-10-2009, 05:12 PM   #15
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Quote:
Originally Posted by Barry_GTi View Post
Reason your blowing head gaksets is running too much diesel judging by that video on the rollers.

My Skoda pickup is running a 1.6 VW block and 1.9 head, with the KKK K24 Turbo, wastegate completely blocked off and I am controlling boost by diesel. Basically you want a little smoke as it comes on boost which clears to a light haze after that. You are causing huge EGT's with that much un-burned diesel and blowing your gasket.

I run 21psi on the larger K24 and never had any problems. Diesel's are great for daily driving.
it was smoing a huge amount on the rolling road vid, but thats mainly to it underboosting, used to stop smoking when it hit ful boost properly.
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Old 17-10-2009, 06:40 AM   #16
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awesome mate td diesels are great fun and very underrated
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Old 17-10-2009, 06:40 AM
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