Red16

excellent read this thread, just read it all again from the start

black wheels look really good by the way

Phil

iTrader: (1)

Well, I did my first trackday in the Pug on Saturday at Bedford, and had an awesome time! The day was run by Bookatrack and was open pitlane, meaning I did almost 200 track miles

I did the sighting laps on the Eagle F1s with the intention of putting in a few sessions on them, but I quickly decided they wern't up to the job and put the slicks on straight away! A small (read huge) error with the tyre pressures lead to an early spin when lifting off to avoid another spun car. A quick phone call to Marco and he told me what pressures to run and the handling improved no end. The slicks really were awesome and made a massive difference to the car.

Handling overall was a bit of a learning curve as I hadn't really pushed the car at all until this trackday, and only done a couple of hundred miles in the car full stop before now! It proved to be predictable, with minimal body roll, bags of grip and no evidence of the lift off oversteer that I was constantly warned about.



Here is the car in the pits, it almost looks in good condition from that photo

The morning sessions were spent going fairly steady, taking it easy on the engine and learning the car/track. I set the video camera up on my third session out and started to get much quicker. Unfortunately on my fifth session I must have hit the zoom button end ended up with half an hour of my best laps undescipherable. I was a bit gutted as I was hugely faster in the afternoon, but here is a lap from one of the sessions that a I did record:



The car was going well with the only issues being oil temperature at 3/4 on the guage after a lap and a half each session, which in itself wasn't a big worry, but with high oil temperatures the oil pressure was dropping to around 1/3 he way up the guage when the engine was revving, and very low at idle. Still, I didn't let this didn't stop me, but this put an end to my day with 10 minutes of track time left until the circuit closed.









It would appear that one of the rear pads fell out under braking from 80+mph into a 3rd gear corner, I heard a huge bang and saw what I thought was the brake caliper fly out the back! After closed inspection the disc had shattered, both pads fell out and so it was a recovery truck ride home!

All in all the car was great, the facilities at Bedford were great as always, and the weather was perfect!



The slicks also got a good wearing in too!

Roll on the next track day I say

m.d.

gotta love it mate, you were givin that scoob a dam good chase too mate,

rs nutta

some nice driving there

Phil

iTrader: (1)

Thanks guys, I had great fun

Phil

iTrader: (1)

Well, I finally got round to inspecting the damage from the incident at Bedford. It seems that a small shim that fits between the pads and brake carrier fell out, leaving the pads to fall out and cause the problem above.

I begun the stripdown hoping I would just have to change the disc/pads, but no such luck



The remains of the old disc.



I noticed the caliper was a bit worse for wear!



As were the massive 19mm pins that the caliper mounts with

Then I got to the hub..



I'm sure they are supposed to be parralel

So I begun stripping parts off a spare axle



Stub axle removed





The part I need left to soak in WD40 after snapping an alley key trying to remove it. Todays job is hopefully to get it finished

richard_syko

Keep it up mate, nice project

Rab

Nice one mate!

I have the 1.6 fitted on mine, which make one hell of a difference. Top speed is now 106mph though

And 70mph is 4300 rpm in 5th, so motorway driving is NOT economical Great car though. MInes no where near as tidy as yours, but it was cheap I don't suppose you have a spare exhaust manifold kicking about that'd you'd sell? Mine's cracked

NUTS RuS

iTrader: (35)

Sorted yet Phil ?

I had that happen twice on my old rallycar Pug, both times on the offside rear

I drilled and loosly lock wired the pads in place and it never happened again

Phil

iTrader: (1)

NUTS RuS


Yes I fixed it ages ago, forgot to update the thread though I lockwired the slider thingy into place that holds the pads in and it was fine. Thanks to Mike R for a good deal on some new pads

I took it on track last weekend at Bruntingthorphe (where I blew my old 2wd Saph up in style a couple of years ago ) I had a good day on track, but I dont think I would do another airfield trackday, the surface is rubbish and the safety is even more rubbish! (Track surrounded by trees with no barriers etc)

Here are a couple of pics of the 205 on track:





The car behaved perfectly and I had a good day Although it does seem quite down on power (I couldn't catch up with a standard 1.6 with full trim on the straights!) so it may be time for a RR session or an Mi16 conversion soon!

I've had to cancel the next trackday I had planned for Cadwell later this month as i've got to go to the US with work

205T16

Go for the Mi conversion.

Are those pics from FCS?

Phil

iTrader: (1)

205T16


Yes they were from FCS

No major updates as of yet, I spent some time yesterday trying to sort a hot starting problem. (I took the inlet manifold off to get at the starter and filled all the cylinders with water at the same time, as well as ripping the gasket which no one has in stock )

I cleaned up all the connections and earths and the soleniod wire also, it seems better now Today I am heatwrapping the exhaust under the fuel tank (the floor pan gets so hot it burns your fingers if you touch it and there is no heatshield for the plastic tank ) then doing a quick oil change as it is booked in at Mikeanics rolling road on Tuesday for a much needed checkup (mega hot exhaust, running lean and down on power must mean something is up somewhere)

Then I am on track at Oulton on Saturday (birthday present from the girlfriend )

Phil

iTrader: (1)

I went for my first ever track day at Oulton Park last weekend (an open pit day with Bookatrack) And i have to say, what a fantastic circuit! Probably my favourite so far!

I took the car for a rolling road setup at Mikeanics before the event, where power went from 109bhp to 121bhp and it held onto the power for 750rpm more, making a big difference on track!

Here is the car ready to go:



The day was absolutely boiling hot and the 205 not having aircon didn't help I started off slowly, having never driven the circuit before and slowly built up some speed. The other cars and drivers on track were altogether a bit quicker than me with a Ferrari 360 challenge race car, various Radicals and Caterham R500 Superlights on track at the same time! With this in mind I spent most of the morning with the indicators on letting faster cars through!

After lunch I stuck the video camera in and sped up a bit, getting some smooth laps in but not pushing the car much at all. As is always the case, I videos a couple of sesisons, the tape runs out and I then go and put a blinding session in Here is an in car video of a lap of Oulton http://video.google.co.uk/videoplay?docid=...366178967967653

And here are a few pics thanks to a friend who popped up for a look







Hopfully by the next trackday I will have some coilovers fitted (as it is still on completely standard suspension) and maybe a new engine!

All in all, another good trackday in the 205

pee vee

Wicked project mate!

just got a 205 for track use myself!!

can you tell me.

you know what cam is good to upgrade to in 1900 8v??

also, where do you get all your parts from!?

got my first track day on 21st cant wait!

Phil

iTrader: (1)

pee vee

I'm not sure on the cam, the std cam is pretty lairy but I guess a Kent or Piper cam! The best place for parts and advice is the forum on www.205gtidrivers.com have a search on there as absolutely everything has been covered at some point

Phil

iTrader: (1)

Small (but expensive ) update!

Out with the old:



And in with the new:





A few cuts, one or two bruises and lots of swearing later...





Thats Bilstein tarmac dampers and tarmac springs with eccentric top mounts

Just need to fit the rest now

P.S. spot the manure all over the inner arches I somehow managed to get there at Oulton (and no I didn't spin off at all )

r-s-turbo

nice!!!! always loved 205 gtis. my bro used to have a 1.9 might not b the fastest car on the road but handling and power delivery is top!

Si B

iTrader: (59)

Hi Phil,

Only just started reading your post but very impressed with the speed you work when you did get home

I have the same CACK in the back of one of my 205s - what did you use to get it out? Some of it peels off, the rest is SO sticky.

I'm only on page 1, will read the next 3 as soon as I get back from working on one of the Pugs.

Cheers
Si

Phil

iTrader: (1)

SiB

I used a screwdriver and a blowtorch There's not much red paint left on my boot floor anymore but to be honest I don't really care! If I was doing it again I would wear some gardening gloves or something as the foil part will slice your fingers to bits!

Charlie Chalk

iTrader: (1)

Looks good phil

Rossco

Cracking little toy and a great read, keep the updates comming

Eddie RST

Reminds me of my mates old 1.9 it had 45's cam lightened and balanced motor,1.6 gearbox he managed about 120 mph but the gearing was spot on for track and sprint and a nightmare on the motorway, also fully stripped with yoko a048r tyres, bilstien fixed platform group a's! 205's are awesome

Si B

iTrader: (59)

Tips noted! Both Pugs are having full strips and resprays so knackered paint isn't so much of a problem!

Thanks mucka, will be out attacking my car with some flames shortly!

Si

NUTS RuS

iTrader: (35)

Any more trips to Oulton planned Phil ?

I'll bring the again

Spiky

iTrader: (1)

well i just read that thread all in one go


sell me ya car, as i have to do probably 90% of what you have

Phil

iTrader: (1)

Spiky

Good luck creating yours, I hope you don't mind throwing all budgets out of the window Mine was supposed to be a cheap track car whilst I finish the Mk1, its turned into an expensive track shed with no money left for the mk1

NUTS RuS

I was actually planning to start work on the Pug again this weekend, might get some done tomorrow. I need to fit the rear tarmac billys, overhaul the rear beam in general - bearings etc (although its in very good nick it is still recommended apparently) and lower the rear end as well.

Also I think I need a new cam as my top end was getting rather knocky on the way home from Oulton... Is it possible to get oil surge in the head?

pee vee

Seems like its going along well then mate!!


mine now has the uprated engine mounts,
solid rear beam mounts,
uprated top mounts
big brakes and decent tyres..


yeah budgets of any kind seem to go out the window with these sorts of things!! i want some cobra imolas for mine....


and a gti-6 engine lol

Phil

iTrader: (1)

I have fitted the tarmac rear billies, todays mission is to lower the back end a bit

Phil

iTrader: (1)

Whilst lowering the rear end, I noticed that one of the arms was a little stiff, and seeing as I had been toying with the idea anyway I decided a full rebuild of the rear beam was in order.

I whipped the beam off the car and lined it up with the original beam that I have been using for spares for a while the top beam is from a standard 205 1.9 GTi, the bottom beam is a standard 1.9 309 GTi beam:



The 309 beam looks in really good condition externally, but thats not a good way to judge the condition of the itnernal bearings!

With the trailing arm and shaft removed you can see the outer bearings on the off side:



You can see these bearings are just about ok, although it looks like the seal was on its way out as there is some rust forming and a definite lack of grease on the bearings.

The other side was a different story:



You can see the relatively normal looking bearings on the right, the bearings from the nearside of the beam showed that the trailing arm was pretty much seized. These bearings obviously hadn't been working for a while. This could be why my 205 was lifting the inside real wheel so much round the bends on track!

The next job was to inspect the trailing arm shafts to see if they were in good enough condition to re-use:



You can see the surface for the inner bearings is relatively clean still as this is more shielded from the grime ingress.



Although you can see material deposited from the bearings on the seized arm.

The outer bearing surfaces on the trailing arm shafts see all the rust and corrosion usually.



This is the shaft with the good bearings, the surface has been polished from normal wear and tear but there are no signs of corrosion or pitting so a good machine polish should have this one back in good condition.

The other side was a different story:



You can clearly see the arm had been seized for a while and the corrosion is quite bad. This shaft is ready for the bin as even with a good clean and polish it would ruin the new bearings in no time at all.

So here are the results of yesterdays work:





I'd better get ordering some new parts from Peugeot!

Phil

iTrader: (1)

Well I have made some good progress on the beam this week!

I ordered the parts I needed from Peugeot:



I cleaned up the arms using an angle grinder with wire brush attachment - took about 30 seconds!


(Before and after comparison)

I then started removing the old bearings from the cross tube using various long screwdrivers and crowbars etc until I slipped with the hammer so had to call it a day:



A couple of days later I picked up the trailing arms, had one of my decent spare shafts pressed in to replace the knackered one and both shafts spun 180 degrees as the bearings only wear out half the shaft:



Fitted new collars:



New seals to the Anti-roll bar ends:



And pressed the new bearings into the cross tube with new seals:



Rear beam all ready for re-assembly:





(Insert about 3 hours of pain an misery from the front torsion bar splines and hole in the trailing arm not mating correctly and flattening all the splines)

I then made a dummy shock from a stick of wood and set it to 305mm between bolt centers to get the ride height level for each side. And hey presto:



Ready to be fitted tomorrow!

Lambchop

iTrader: (1)

Thats not an unfinished mk1 esc cossie in the background is it?

You taking this to the ring in easter? If so i want a ride

Spiky

iTrader: (1)

nice beam., you know for another 309 beam?

Phil

iTrader: (1)

I have fitted the beam today and plumbed all the brakes back in etc so the car is now complete again I have mastered a method for fitting the rear axle back on with hardly any effort using 3 trolley jacks (it weighs a ton and if you wrestle it into place you strip the threads on the bolts that hold it up).

I will get some pics of the new ride height when I get it out of the garage.

Lambchop
No Ring trip for me - i'll be in India on Business for Easter
That is indeed my Mk1 still unfinished As soon as the 205 is done I will get started on the Mk1

Spiky
They crop up quite often on 205 GTI Drivers and eBay, there was a newly rebuilt on one there recently going cheap - might still be there? Mine cost about Ł150 and was in supposedley good condition On the outside maybe

Lambchop

iTrader: (1)

Thats a shame

Catch up with you another time mate

Phil

iTrader: (1)

I know I started this bloody project as a Ring-mobile and havn't even taken it there yet

To be honest i'd probably take the Audi now anyway as the 205 would only break down I will do my best to make the September ring trip this year