dava.
Member
Registered: 2nd Nov 05
Location: Falkirk
User status: Offline
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my mate who owns his own garage decidedto make a build thread of his 205 track car build on our local forum, i know some of you guys on here are into 205's and the sort so thought id post it up -
the story from the start
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 standard 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 adjustable all round.
cosworth 2wd intercooler modified and fitted to the 205 .
End caps cut off and rotated 90 degrees
Factory !! 
ran a few track days this year on that spec
Next up a fancied a bit more power having owned a few high powered 205s (super charged mi,umpteen turbos) in the past i wanted to 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 with a little 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 it came backlike this .
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 
*i will keep adding to this as my mate adds to the one on my local forum* 
[Edited on 10-11-2008 by dava.]
[Edited on 10-11-2008 by dava.]
[Edited on 16-11-2008 by dava.]
[Edited on 23-11-2008 by dava.]
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[Edited on 30-09-2009 by dava.]
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stubbsy05
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Registered: 23rd Oct 02
User status: Offline
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Awesome! I so want a 1.9 GTI next year for some track days and a weekend toy!
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dava.
Member
Registered: 2nd Nov 05
Location: Falkirk
User status: Offline
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should have more updates soon this only takes us up to a few months back, still got all the work and plans that he is working on just now
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Graham88
Member
Registered: 16th Apr 07
Location: South East Kent Drives: E46 M3
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That's cool
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AK
Member
Registered: 5th Jul 00
Location: Aberdeen City
User status: Offline
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Can you post that project here (if you want).... few 205 fanatics on the site... 1 building a 1.6 supercharged one just now.
http://www.trackscotland.co.uk/forums/viewforum.php?f=10
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dava.
Member
Registered: 2nd Nov 05
Location: Falkirk
User status: Offline
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now on to the good part
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
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
now completely completely striped ready for the engine bay to be seem welded and strengthened
This section will showin brief 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 :wink:
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
full thread can be found here aswell - http://www.falkirkcruise.net/forum/viewtopic.php?f=7&t=31960&start=15
[Edited on 10-11-2008 by dava.]
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dava.
Member
Registered: 2nd Nov 05
Location: Falkirk
User status: Offline
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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.
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dava.
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Registered: 2nd Nov 05
Location: Falkirk
User status: Offline
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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
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S77 CKL
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Registered: 16th Aug 08
Location: North-East
User status: Offline
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Not bad power for the 2litre 8valve.
I had a 1.9 gti and home brewed turbo'd it, was runing cosworth injectors and intercooler like above and different managment, was a awesome tool, really loved being thrashed and hoyed around, 205's rock for track cars i think, good build.
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jr
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Registered: 20th May 02
Location: Kent
User status: Offline
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great projct, keep us updated
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dava.
Member
Registered: 2nd Nov 05
Location: Falkirk
User status: Offline
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will be coming out bigger and better, think most folks begin to take an intreast when he gets on to the engine stuff, still got door bars to weld i place as well as few wee niggly bits on the cage, fiber glass doors, boot etc to be preped and sparyed while the full car gets sprayed,
good to see folks replying and taking an intreast on a corsa site
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mattyross
Member
Registered: 22nd Dec 05
Location: lincolnshire Drives: 1997 C12NZ
User status: Offline
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i do like this. i confess to disliking french cars, but the 205 is a remarkable car.
excellent project, function over form. keeping a watchful eye on this.
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Nick-S
Member
Registered: 3rd Mar 04
Location: Leigh. Drives: RS Megane 230 F1 Team R26
User status: Offline
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this is 
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dava.
Member
Registered: 2nd Nov 05
Location: Falkirk
User status: Offline
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as are these, wee sneeky peek for yous untill the engine work starts -
dp- engeneering "welders nightmare"
T4
[Edited on 29-11-2008 by dava.]
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mattyross
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Registered: 22nd Dec 05
Location: lincolnshire Drives: 1997 C12NZ
User status: Offline
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sadla_xe
Member
Registered: 1st Feb 08
Location: Tamworth,west midz Drives: Corsa sport
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a lad i know has one of these
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dava.
Member
Registered: 2nd Nov 05
Location: Falkirk
User status: Offline
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been a while since an update due to the garage being very busy both bodyshop and mechanical side of things leaving no spare time for my own build,
so heres an update upto today
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
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dava.
Member
Registered: 2nd Nov 05
Location: Falkirk
User status: Offline
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worked out that the extra weight added by building the cage like this will then be lost again with the addion of fibreglass doors,boot and bonnet
more updates coming soon
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sand-eel
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Registered: 15th Mar 07
Location: carluke/braidwood--IRNBRULAND
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dava.
Member
Registered: 2nd Nov 05
Location: Falkirk
User status: Offline
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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 8)
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
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Graham88
Member
Registered: 16th Apr 07
Location: South East Kent Drives: E46 M3
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That's a rather big Turbo
Should be good!
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205tom
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Registered: 1st Mar 06
Location: leigh nr wigan
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gti-6 engine?
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Ryan
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Registered: 23rd Jun 08
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dava.
Member
Registered: 2nd Nov 05
Location: Falkirk
User status: Offline
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quote:
Originally posted by 205tom
gti-6 engine?
gti-6 engine has been used as the test engine yes, but the full engine will be a gti-6 head with a low compression bottom end in a xu10 block
[Edited on 16-12-2008 by dava.]
[Edited on 09-01-2009 by dava.]
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dava.
Member
Registered: 2nd Nov 05
Location: Falkirk
User status: Offline
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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 its 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 .
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