Custom Peugeot 205 'mega bulge' bonnet

[gretsch-drummer]

Hi all, thought I'd show what I've been working on for the past few weeks. The story is a mate with a Mi16 205 has had trouble with being able to shut his bonnet properly with his big filters on the front of the twin webers. So I tasked myself in making a bulged bonnet out of fibreglass. Like the automatic bonnet with the bulge at the rear and tapers down my plan is to take the bulge right to the front to allow the extra room for the filters.

Scrap bonnet and a few sheets of hardboard to create the bulge section:

20180222_110927 by Andy Wilcock, on Flickr

20180303_191801 by Andy Wilcock, on Flickr

Then lots of filling and sanding and filling and sanding:

2018-04-23_05-44-13 by Andy Wilcock, on Flickr

2018-04-23_05-22-05 by Andy Wilcock, on Flickr

20180418_142326 by Andy Wilcock, on Flickr

20180418_201339 by Andy Wilcock, on Flickr

20180418_201324 by Andy Wilcock, on Flickr

2k filler primer:

2018-04-23_05-27-17 by Andy Wilcock, on Flickr

After fettling a few imperfections is was onto the 2k direct gloss:

20180423_162756 by Andy Wilcock, on Flickr

20180423_162915 by Andy Wilcock, on Flickr

20180423_163911 by Andy Wilcock, on Flickr

Now I'll let it cure for a couple weeks then start the fibreglassing procedure. Will probably weigh ~5kg instead of the ~15kg this plug currently is.

Cheers!

Edited by gretsch-drummer on Monday 23 April 18:01

[Penelope Stopit]

Thanks for the post, this is very clever work and I like clever

[gcpeters]

couldn't they have just bought the 205 auto bonnet that already has a bulge in from the factory?

great work though!

[gretsch-drummer]

The auto bonnet bulge tapers down to the original height half way down the bonnet and still foul on the filters. With this bulge going all the way to the front it gives the extra 10-12mm clearance where needed.