My Peugeot 205gti (Dimma) Restoration
Discussion
All repairs now done on the new floor and its almost stripped of all underseal and ready to be fitted to the car I have just got to weld some braces into the shell to support it once floor removed.
I have turned my attention's back to the sunroof conversion as I had to removed the dealer fitted sliding sunroof due to it having bits missing and was silicone shut so guess it leaked.
I managed to get a complete roof from a scrap 205 with all the vacuum sunroof parts needed. First up was to remove all bits from roof so it only left me with a roof skin which is now the template.
Now I know people will say it would have been easier to fit a new roof but I believe this is easier and on another note if other people wanted to carry out this the no paint would need doing.
the two sunroofs
I the place the roofskin over my roof and secured into place with a bolt through the Ariel hole.
Next up is to drill the holes these are a 12mm hole so to make sure these are drill in the correct position I got my dad to make a drill guide that will fit into the 12mm hole with a 5mm pilot hole through it then I will run a 12mm hole saw through the roof as this will give very little burring.
Once all the holes are drilled I will fit some bolts through the roof skins before I jigsaw the hole larger then I will glue the support bars once the new rivnuts have been fitted I believe this can be done to any aftermarket sunroof fitted sunroof as long as the hole is in the right place.
My dad has been working on the car rotating stand with the front almost complete and the rear one getting there progress will be very slow now as I going offshore for 3 weeks with work.
I have turned my attention's back to the sunroof conversion as I had to removed the dealer fitted sliding sunroof due to it having bits missing and was silicone shut so guess it leaked.
I managed to get a complete roof from a scrap 205 with all the vacuum sunroof parts needed. First up was to remove all bits from roof so it only left me with a roof skin which is now the template.
Now I know people will say it would have been easier to fit a new roof but I believe this is easier and on another note if other people wanted to carry out this the no paint would need doing.
the two sunroofs
I the place the roofskin over my roof and secured into place with a bolt through the Ariel hole.
Next up is to drill the holes these are a 12mm hole so to make sure these are drill in the correct position I got my dad to make a drill guide that will fit into the 12mm hole with a 5mm pilot hole through it then I will run a 12mm hole saw through the roof as this will give very little burring.
Once all the holes are drilled I will fit some bolts through the roof skins before I jigsaw the hole larger then I will glue the support bars once the new rivnuts have been fitted I believe this can be done to any aftermarket sunroof fitted sunroof as long as the hole is in the right place.
My dad has been working on the car rotating stand with the front almost complete and the rear one getting there progress will be very slow now as I going offshore for 3 weeks with work.
Next up was to get really brave and cut the hole for the sunroof bigger before I started the cut I fitted some MDF under the roof skin to reduce the vibration when cutting.
Then cutting started
There where a couple of holes in the roof skin from the old sunroof these where welded up and had some filler skimmed over.
I then cleaned up the support beams and removed all the old rivnuts new rivnuts will be fitted later today if my dad brings the tool with him then they can be fitted to the car.
Well that's the hole cut and edges cleaned up had a trial fit of the sunroof I believe its a success.
Then cutting started
There where a couple of holes in the roof skin from the old sunroof these where welded up and had some filler skimmed over.
I then cleaned up the support beams and removed all the old rivnuts new rivnuts will be fitted later today if my dad brings the tool with him then they can be fitted to the car.
Well that's the hole cut and edges cleaned up had a trial fit of the sunroof I believe its a success.
Yep got the car from Scotland there are no updates at the moment due to work gone mad and it looks like I will be offshore till early September. I'm itching to get on with it I had set a target of getting all welding done by end of this year sadly I'm starting to feel this target is slipping away.
I have all the parts for the repairs just no time at the moment but next job will be the floor repairs then sills and rear arches and bumper brackets then boot floor repairs.
I have all the parts for the repairs just no time at the moment but next job will be the floor repairs then sills and rear arches and bumper brackets then boot floor repairs.
Finally back from working offshore and been told im working from office for next few weeks which means I can do some more on the car I have done a little over the weekend including removing the fuel tank and the floor under the tank is surprising in good condition so thumbs up there. I have also removed the exhaust hand brake cables and gear link arms all in prep for when car goes on spit which im hoping for next weekend if all goes ok then I can brace car up an remove the old floor.
Whilst cleaning parts inside the car I thought I would sort out the old screw holes from where the dimma showcage was fitted what I thought was a few holes turned into a big mess when I hit with the wire.wheel and was left with no option but to cut out and weld a plate in.
I spent today removing the rear beam and subframe and getting the car up on the spit, my spit is made up of two engine stands that I got for £50 and my dad made the frames to fit to the car so a cheap frame.
Rear not looking too bad but will clean back to bare metal to see what its really like.
I have made the beams that will be welded in for when i remove the floor just got to get the door braces made then cand remove floor.
Also I placed my new bonnet on and bolted wing on to side that has been cut about and it allready looks a good fit so really happy
Whilst cleaning parts inside the car I thought I would sort out the old screw holes from where the dimma showcage was fitted what I thought was a few holes turned into a big mess when I hit with the wire.wheel and was left with no option but to cut out and weld a plate in.
I spent today removing the rear beam and subframe and getting the car up on the spit, my spit is made up of two engine stands that I got for £50 and my dad made the frames to fit to the car so a cheap frame.
Rear not looking too bad but will clean back to bare metal to see what its really like.
I have made the beams that will be welded in for when i remove the floor just got to get the door braces made then cand remove floor.
Also I placed my new bonnet on and bolted wing on to side that has been cut about and it allready looks a good fit so really happy
Finally I have managed to get on with some work on the car, The car is now on its spit which is making it so easy to carry out the work on the underside. I have started to clean up one chassis rail this needs to have some of the dents pulled out but no big issue and you can see from the strenghting plates are badly damaged lucky my replacements are in better condition.
I then made a start on cleaning up the rear under the seats all not looking to bad at the moment found small amount of rust under the rear seat will pop over scrapyard and cut piece out i need to carry out the repair also found a hole in the support arm for the rear suspension this has been cut out and plate fitted and welded up just need to carry out repairs to other side when I turn car over other way.
I have also cleaned a fair bit into the boot floor just dont have any pictures yet but aim is to finish cleaning underside carry out repairs to under seat section and boot floor and what ever else i find then remove front floor and fit new so plenty to keep me busy this year if im ever at home.
I then made a start on cleaning up the rear under the seats all not looking to bad at the moment found small amount of rust under the rear seat will pop over scrapyard and cut piece out i need to carry out the repair also found a hole in the support arm for the rear suspension this has been cut out and plate fitted and welded up just need to carry out repairs to other side when I turn car over other way.
I have also cleaned a fair bit into the boot floor just dont have any pictures yet but aim is to finish cleaning underside carry out repairs to under seat section and boot floor and what ever else i find then remove front floor and fit new so plenty to keep me busy this year if im ever at home.
Another small update
I have been carring on with cleaning up the underside allmost finished the rear of the car and am getting near to turning car over the other way so I can get to the parts I cannot reach, So far no more major rust found and what has been found has been cleaned up just got to treat still have a couple of patches on the boot floor to weld and one under rear seat but nothing to major once this is done I can focus on the new floor and get the underside in primer and sealed up then can apply the stonechip then just leaves the rear arches to do then fingers crossed that will be all the welding finished, Stripping underseal I wouldnt wish on anyone its a killer of a job.
I have been carring on with cleaning up the underside allmost finished the rear of the car and am getting near to turning car over the other way so I can get to the parts I cannot reach, So far no more major rust found and what has been found has been cleaned up just got to treat still have a couple of patches on the boot floor to weld and one under rear seat but nothing to major once this is done I can focus on the new floor and get the underside in primer and sealed up then can apply the stonechip then just leaves the rear arches to do then fingers crossed that will be all the welding finished, Stripping underseal I wouldnt wish on anyone its a killer of a job.
Worst part of boot is around the spare wheel support but its just a matter of cutting out and using a part from my spare boot floor I also decieded to treat any small rust I found then I have just coated in etch primer for moment to stop any surface rust but its looking better allready.
Worst part of boot is around the spare wheel support but its just a matter of cutting out and using a part from my spare boot floor I also decieded to treat any small rust I found then I have just coated in etch primer for moment to stop any surface rust but its looking better allready.
Worst part of boot is around the spare wheel support but its just a matter of cutting out and using a part from my spare boot floor I also decieded to treat any small rust I found then I have just coated in etch primer for moment to stop any surface rust but its looking better allready.
I have cut out the spare wheel support part of the floor and welded in a new part I have made a start on dressing the welds up with a grinder just need to finish with my belt sander and finer discs for a flush finish.
I have cut out the spare wheel support part of the floor and welded in a new part I have made a start on dressing the welds up with a grinder just need to finish with my belt sander and finer discs for a flush finish.
I have been carrying out repairs to the boot floor and making good progress have one more patch to do on the floor but need to turn car over on stand first.
Progress on this has almost ground to a halt due to being busy at work then been taken ill and signed off work so not be able to do much to the car as I would have liked so I have used the time to do some smaller jobs like sorting parts for powdercoating and plating and vapour blasting so have boxes everywhere now. I have also use the time to get the tyres removed from the split rims so these can be sent to dimma for refurb and yet this showed up a major problem with one of the front wheels as its had a new outer rim in its time and looks to have had the wrong one fitted.
front wheels
Bottom front wheel is one with wrong outer rim fitted you can see the difference
I have also used the time for some retail therapy and ordered some new coilovers,wishbones,wheel bearings,track rod ends,tie rods,anti roll bar links,steering gators,anti roll bar bushes,suspension top bearings,rear bump stops I also got a refurbed rear beam, First load of parts turned up yesterday was like a early Christmas.
I'm going in for a operation at the end of month then I'm hoping to be able to get the shell finished so it can be sent away for kit to be fitted and paint
Progress on this has almost ground to a halt due to being busy at work then been taken ill and signed off work so not be able to do much to the car as I would have liked so I have used the time to do some smaller jobs like sorting parts for powdercoating and plating and vapour blasting so have boxes everywhere now. I have also use the time to get the tyres removed from the split rims so these can be sent to dimma for refurb and yet this showed up a major problem with one of the front wheels as its had a new outer rim in its time and looks to have had the wrong one fitted.
front wheels
Bottom front wheel is one with wrong outer rim fitted you can see the difference
I have also used the time for some retail therapy and ordered some new coilovers,wishbones,wheel bearings,track rod ends,tie rods,anti roll bar links,steering gators,anti roll bar bushes,suspension top bearings,rear bump stops I also got a refurbed rear beam, First load of parts turned up yesterday was like a early Christmas.
I'm going in for a operation at the end of month then I'm hoping to be able to get the shell finished so it can be sent away for kit to be fitted and paint
I have managed to clean up one wheel arch and get in primer as you can see the outer arch and bumper support bracket still need replacing but this will be getting done by bodyshop when they refit kit next up is to rotate car other way so I can do other rear arch then will remove sills and then floor and fit new floor and sills then it will not be far off going to bodyshop hopefully in the new year.
I have made a start on getting ready for the removal of the floor and I have removed the lower part of the sills but kept top part on to keep strength I have also braced the car across the doors and chassis ready for when floor removed, Inner sills looking ok so far and I have removed one strengthening plate from drivers side going to drill spot welds on bulk head and fuel tank area then hoping to turn car over end of week then can remove strengthening plate and lower sill from passenger side then floor wont be far away from being cut out once I recover from my operation on Monday.
Still have the dents to remove from the chassis legs but will do once floor removed
I have also dropped parts off to be powdercoated.
Still have the dents to remove from the chassis legs but will do once floor removed
I have also dropped parts off to be powdercoated.
I have finally got car turned over the other way and have had a constructive day removing underseal(worse job in the world) managed to get a front arch and the rear arch cleaned and in etch primer this rear arch had suffered more with rot as you can see not much left of the bumper bracket but I have a new on to fit.
Jobs tomorrow if all go well are to remove rest of underseal from the underside then remove front strengthening plate and part of sill ready for floor removal and if I get time may weld last patch onto bootfloor.
Jobs tomorrow if all go well are to remove rest of underseal from the underside then remove front strengthening plate and part of sill ready for floor removal and if I get time may weld last patch onto bootfloor.
Got a call today from the powdercoaters to tell me my parts were ready so popped in car and went and picked it all up really happy with how it all turned out also got them to blast some bits before they go off to platers next week when I got home there was a parcel with my gaz coilovers in so a good day in all. I have also dropped the steering rack that I stripped and the anti roll bar brackets at the vapour blaster today should have them back next week then can start putting subframe back together and steering rack.
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