rapidcossie

One of my good friends cars that I thought some on here might like.














Ok going to do a build thread on my 205 we are in the middle of building for the beginning of next year.

Alot of folk will have seen it this year anyway but i have recently stripped it down to a bare shell to undergo alot of work due to the engine that will be going in it this time .

Going to start off when i first got it to the stage it is at now this will be a on going thread for the next few months as it gets built from start to finish and all in house.

A pic of the car first of all just a pretty std 1.9 gti .



then i converted it to a 2.0 8v turbo for the track.



at this time it was stripped out , a set of bucket seats and a safety devices multi point weld in cage



engine pretty much std except bigger exhaust and 14psi boost from the t25 turbo this putting out around 190 atf .

brakes were gti-6 285mm on the front and std 1.9 on the rear .

suspension was koni adj all round.

cosworth 2wd intercooler modified and fitted to the 205 .

End caps cut off and rotated 90 degrees



Factory !!

rapidcossie

Next up a fancied a bit more power having owned a few high powered 205s in the past a wanted a play around with the engine alittle .

Biggest problem with the 2.0 8v engine is there has'nt been alot of them tuned in the past so we had to pretty much just make a spec up as we went alittle trial and error but was fun



sent my old turbo away to aet turbos to see what spec i could get made up for the std manifold and to my surprise they said could upgrade to a hybrid T3 (biggest i had heard of on a std manifold was a T28) so i gave them the go ahead and a week later .

old turbo against the new one






next up was an uprated cam shaft this car from CATCAMS a nice stage 3 cam





now with the bigger turbo and cam i knew i had to go for a stand alone management so i bought KMS management , to go with this i got my hands on a set of cosworth green 803 injectors at this stage the engine looked like this



after a bit off mapping with the new engine the inlet temp were alittle high so we went for a bigger intercooler this time i opted for a evo one





now at this stage i need to be able to get the power down so we went for a quaife diff and a set of toyo 888's cut slick tyres





so now able to get the power down we now had to be able to stop so decided to upgrade for the gti-6 brakes to a set of hi spec 4 pots and still able to keep the 15" wheels



That was the car for a while and at that spec we managed to get 230 / 240 bhp at the fly a nice figure and defo good power increase



and not every day runs smoothly , burst water pipe

rapidcossie

Plans were made for the car to get stripped again this time for the proper build and a nice 2.0 16v turbo engine (same as t16 but better spec'd) and a good few body mods inc seem welding , new cage and light weight panels now hoping for roughly 750kg and 350 bhp.

So car goes in looking like this



to this in no time , engine stripped out





now right back to a bare shell with everything off

rapidcossie

of course being stuck on one of the lifts is no good so was moved into its possition for the time being and for work to commence .

so as it is in the weld and prep area

rapidcossie

This section will show how the engine bay has been seem welded and strengthened.

reason for this work is basically a 205 was never designed for hard track use and certainly not for high powered engines as this picture will show the strut top after a bit of hard cornering .

see how its started to dome.



so this is where the strength needs to be added

area gets prep'ed



now plates get tacked into position



everything gets checked making sure there 100% and then fully seem welded into position



now while preping the engine bay to seem weld i found a couple of rust patches so decided to cut them out and plate them up properly



section cut out and ready for a plate to be made and welded in place



now its not like you can just go out and buy in a section to replace it , so a section has to made up now for this all that was required was a bit of sheet metal , plasma cutter , square and a hammer





now a rough size is cut a shape can then be made to fit



now must be trial fitted



and when happy with the fit tack welded into place and then seem welded




and the rest of the engine bay seem welded

rapidcossie

we'll engine bay pretty much complete except the cage work which will follow , i moved on to seam welding the inside of the car .

For this to be done correct and the cage to be 100% spot on i had to strip the dash completely out and then had to dress up every seam on the car again to be able to start the welding pretty much the same procedure as the engine bay .

inside untouched except seats removed



dash starting to be removed




completely stripped




getting prep'd




then seam welded





so now car completely seam welded its now time to move on to the new front cage to be made for this we are using 38mm cds tube and getting bent with out HUTH pipe bender.

reason for the new front cage is i was wanting it a bit tighter to the A piller and also wanting it to go straight on to the strut tops and cross braced at both doors and behind the seats.

first part of the cage in place





now a perfect fit to the A piller alot happier so now added the first part of the cage to go onto the strut tops.

rapidcossie

Another part of the cage complete but ran out of pipe so will have to get more ordered tomorrow to get the cage finished off .





and the strut tops completely braced





then seam welded the subframe , now ready to be powdercoated

rapidcossie

was back on the cage again trying to get it finished off , now pretty much 90% complete just a few we bits left to go on .

centre bars to support behind the seats





then both doors crossed





then the final side supports triangulated







next up am going to build up a trial engine to fit it in and make sure everything is fitting before it heads into the bodyshop to get prep'd and painted before the proper rebuild

rapidcossie

well managed to make up a test engine today to try out positions for various parts and to make sure of clearance issues which i thought could be a problem , but after its in and everything tested its pretty much perfect to say the least

a few teasing pics (now this will make me get the finger out)









and a pic to show the room to get in from the cage

rapidcossie

Managed to get the last pieces for the cage in place and thats now all the welding and cage done , next up is the car will be getting fully prep'd for painting this week and will hopefully be painted before the week is out depending on other work . Thought it would have been quiet first few weeks in jan but is not and we are actually fully booked so will just have to find time to squeeze my own in or ill end up running well behind.

strangthing plates welded to A pillers and roof






roof also braced



and the last piece was to brace the cage onto the rear suspension points





the rear beam now fixes up through the floor and the cage to stop any flex this will go nicely with the group A beam we are building for it .

rapidcossie

well today seen me in to start the preping the car , nothing to drastic needing done but few dents etc normal stuff for a car 20 years old





all filled and ready to prime





rest of the car stripped ready to start the paint work now all off the wiring loom , steering column and clutch and throttle cable oh and peddle box and servo

now this is total naked

clarke5700

kool never realy liked pugs but fair play

rapidcossie

and on that note a was back in today to start the painting so had to give a few of the boys a shout as the team are still off till monday , so cheers guys

first off moved the car into the booth and panel wiped it all




then on to the etch primer




then started the high build primer

onit




then full car primed






now ready to paint woohoo

rapidcossie

and for another little update ,

today seen the car go into paint , big ups to toffi nice job for first day back dont say a aint nice to ya

and on that note always bet on black






pictures really dont do it justice imo coz this really s to die for

fraser9764

iTrader: (3)

Proper piece of kit!
Thats what i call a cage!!!!!

rapidcossie

yeah he really went to town on the cage!

All this stuff done in house except the engine mapping.

bigchez

Wicked!

boothy

iTrader: (14)

fuckin hell you havw been busy

Kezmo

nice work

Twins

iTrader: (18)

Great work there,well done

gus

iTrader: (1)

excellent stuff

Slevin Kelevra

is dave racing this one??

should be fun on the hill!

SteveW

iTrader: (2)

awesome work, well done. Thats gonna be great fun

nellrodd

I love 205's i had one a long time ago and it was bags of fun!! THis looks like a real beauty mate, top job so far, look forward to the next updates!!

Fastas

very nice kool project

rstdave

iTrader: (3)

Blimey, that's bin done proper!! A serious amount of work gone into that already, will be awesome when finished!

CraigoScott

iTrader: (1)

very very cool project!

one thing is confusing me, why hasnt he welded in some seat rails? as it seems that he is still using the standard mounts for his buckets? the standard ones are not the strongest!

rapidcossie

Dont htink he has ever hada problem with the standard ones so he hasnt felt the need to alter them.

its_a_ford_thing

that is a awesome cage mate

rapidcossie

Yeah this is his own car/company demo and he has plans to enter it in the Scottish saloons this year

Homer.

Looking good, keep us updated

fraser9764

iTrader: (3)

they were the mounts in our first one when we bought it, the nut had basically been pulled up through the steel.
we repaired this one by welding flat bar over the top, but the new one we made WRC type mounts
seems madness tbh to do all that work and risk the seats falling out
other than that, Top Notch!!!

fezzajsy

iTrader: (9)

very very nice

rapidcossie

Just put your question to the builder of the car and I got this reply.

"the seat rails are strengthend and not using the std fixings we made our own"

J1mbo

iTrader: (1)

thats quality !!

SteveH

Loving it Euan

CraigoScott

iTrader: (1)

good good

top build, get some more pics up!

rapidcossie

ill keep updating as we go.
should be everyday now

CRAIG HAYTER

looks a proper toolreally good work

Slevin Kelevra