As some of you may know I bought an ex pugplus minter (that's the only time I will refer to PP or call it a minter) in April off jamesmall

He had it for 2 weeks and had overheating issues as the fans didnt kick in! so parked it up while he tried to resolve the problem with the previous owner, nothing was resolved
I bought it as a suspected HG failure as there was a lot of mayo in the radiator

Anyway, I got it to my unit and flushed the system and it seemed fine, not much oil seemed to be getting in the oil (what was left could have been stuck in there) I swapped the heat exchanger as these have been known to break down internally.

I then took it to the northwest rolling road day where it made a very healthy 178bhp. However, when I got back to the unit the radiator had a very familiar mayo in it!

So I took it off the road and decided to strip it and change any parts that needed it and clear up all the rust that it had (lots and lots of the stuff most of the boot floor was rusty as were the chassis legs in the engine bay, when I say rusty I mean no paint at all!!

Over the next couple of days I will keep adding to the thread I will also come back and add photos as and when I can

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Cherry rallye - DOB Thursday 29/04/1999
Team Rallye - the leaner, meaner, better looking sister of the GTI6

The best engine in the world is the vagina, it takes any size piston, its self lubricating, starts with 1 finger, and every 4 weeks does its own oil change. It's just a pity the management system is so fecking temperamental. 

Afaik they didn't put a lot of underseal on them to keep the weight down
I removed all the rust, Krusted it, then anti rust primered, then cherry red hammerite, then a nice thick coating of wax oil! Added about 10kg to the overall weight but I'll have a poo before I go for a drive

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Cherry rallye - DOB Thursday 29/04/1999
Team Rallye - the leaner, meaner, better looking sister of the GTI6

The best engine in the world is the vagina, it takes any size piston, its self lubricating, starts with 1 finger, and every 4 weeks does its own oil change. It's just a pity the management system is so fecking temperamental. 

So once it was out I decided to clean the bay up a bit.
Both chassis legs were rusty beyond belief, so a good dose of sanding disk, wirebrush etc, the Krust, anti rust primer and a nice coat of cherry red hammerite later and it was looking much better

I then set about the rear, boot floor, inner wings above the tank etc.
So first off was the beam, the brake lines came out of the compensator with no problems. I also noticed why the beam looked lower on one side,

the passenger side arb plate was swinging freely, the bolt that locks it on place was missing. It was threaded and will need tapping to fix it.
Then it was a case of just unclipping the brake likes to lower the tank. That wasnt the case both main lines were badly corroded and snapped like they were matches!

So once the tank was off I had to replace the whole of both lengths of brake line from the bulkhead back
The underside of the boot floor was a shocker :O I've never seen so much rust, so out came the sander, wirebrush etc and te same process as the chassis legs was applied

While I was doing this I had the apprentice at the unit next door blasting and painting as many parts as he could during his breaks as little earners on the side for him (getting him to do me some wheels tenner a wheel ain't bad and he is quite good)
this is how it looks now


I also had to decide what to do about the engine, do I buy an unproven engine, buy a whole car or fix the engine with A new block.
I chose option 2, I found an 86k phase 2 car with FSH cambelt done etc for £650 still had 4 months mot and 5 months tax so drove it round while the rallye was off the road. Once it was ready for the engine I would break it and chuck the engine in

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Cherry rallye - DOB Thursday 29/04/1999
Team Rallye - the leaner, meaner, better looking sister of the GTI6

The best engine in the world is the vagina, it takes any size piston, its self lubricating, starts with 1 finger, and every 4 weeks does its own oil change. It's just a pity the management system is so fecking temperamental. 

As I have broken about 10 '6's in the last few months I had lots of spare parts to sort out it's many issues
The parts I've replaced so far are

Front bumper - bought off birk (top bloke and very fair)
Both wings - mainly due to the screws through them and the passenger side being a pattern wing due to it previously having a near side impact
The radiator - I damaged it wheel it was in storage
The bonnet - very very rusty
The engine - due to cracked block, did cambelt, tensioner, idler and water pump with a gates 136 tooth belt, also did the inlet/exhaust manifold gaskets and crankshaft oil seal, I received a lot of help from marksorrento205. I can't praise te lad enough! He may look like Jesus but he certainly knows his stuff
The front brake disks - it has Xsi 266mm disks and 283 mm pads
The wishbones - P bushes were knackered as were the ball joints
The TREs - one was knackered so replaced both

really knackered
The drop links - why not
OS drive shaft - it was split and sprayed grease everywhere
Engine top mount - was in 2 pieces
Fan coiling from a none air con phase 1 - due fans not working at all!!
Right hand oil breather on head - had been split when the head was last off
The metal pass cooling pipe that runs behind the bumper - damaged during front end impact
Put a front splitter on - didn't have one
Slam panel - lots of bolts snapped off
Interior - was gti6
Rear quarter windows - were limo black
both front arch liners - were missing broken
Rear beam - arb was not working due to the threaded bolt hole, so used a very good phase 3 item
Front calipers - looked like the car had been swimming in the sea
Rear calipers - just as a precaution
Bulkhead to rear calipers brake lines - very corroded, almost dangerously
NS rear light - was cracked
Parcel shelf - was a phase 1 item
Replaced the rear wiper motor - wasnt plugged in, when I did plug it in it nearly set the car on fire
Peeled the limo tint off the boot glass

Would you have paid £2200 for a car with this many problems???

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Cherry rallye - DOB Thursday 29/04/1999
Team Rallye - the leaner, meaner, better looking sister of the GTI6

The best engine in the world is the vagina, it takes any size piston, its self lubricating, starts with 1 finger, and every 4 weeks does its own oil change. It's just a pity the management system is so fecking temperamental. 

Mint

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Get used to seeing the yellow one !!!
Team 330™
Team "no front end or engine"
Team "LIMITED EDITION" I live for the 306 sticker
Team 0-60 in 6.44 & standing qtr in 14.808 @ 94.55mph all with std engine
203bhp Corolla T-Sport daily driver stealthier than Kwai Chang Caine

After I had sorted the rust it was just case of starting to bolt parts back on.
First was the beam, initially I was going to do away with the compensator on the beam, only because the beam I had was a phase 3. But after taking to my local pug parts desk I found that I would need to swap the abs unit for a later one.
So I removed the seized compensator and gave it a good old soaking and worked it till unseized. The only problem I then found was I didn't make a note of the pipe routing.
Luckily I had the phase 2 outside to check the routing

The tank went back very easily, helped by the fact the tank hanging bars had been cleaned and painted.

This is when I turned my attention to the engine, I sorted out a few days where I could be without a car and started to buy the service parts.

I decided that I would keep the rallye for myself, so decided I would sell my laser green 205 gti6. I love this car but it's nit practical.

A mate told me he was interested in it, so I arranged for a test drive. He loved it, but said it wasn't practical enough. That's when he asked about the silver phase 2 that I was going to break.
He offered a good price so I accepted. I would now have to find an engine. After a 2 minute search on here I found 2 available. Ashs rebuilt rallye engine and Andy798s 86k engine. Unfortunately as is my luck ash had taken a deposit on his that morning so a quick call to Andy and I was on my way to widnes to collect it.

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Cherry rallye - DOB Thursday 29/04/1999
Team Rallye - the leaner, meaner, better looking sister of the GTI6

The best engine in the world is the vagina, it takes any size piston, its self lubricating, starts with 1 finger, and every 4 weeks does its own oil change. It's just a pity the management system is so fecking temperamental. 

Huge amount of work here. Makes me wonder why mine is taking so long when it goes already.

Let's see some pics.

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Cherry Rallye SOLD

whats wrong with this picture?

does this help

how about this?

thats correct, xsi 266mm brake disks on 283 calipers and pads

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Cherry rallye - DOB Thursday 29/04/1999
Team Rallye - the leaner, meaner, better looking sister of the GTI6

The best engine in the world is the vagina, it takes any size piston, its self lubricating, starts with 1 finger, and every 4 weeks does its own oil change. It's just a pity the management system is so fecking temperamental. 

Nice....

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Ph1 Cossack 6

You sir either live for the 6 or have a mental retardation to still be repairing this!

p.s do you do finance for the 205?

Holy carumba! Some unhealthy bodges you're uncovering there.

Good luck with the rest of the car.

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1999 Astor Grey GTi-6 OEM+ (now gone...)
2004 Aegean Blue 206 GTi 180 (also gone...)
2006 Skoda Fabia vRS in Sprint Yellow

But pugplus doesn't work for some partioning firm and breaks cars for a hobby does he?

Swap for a slightly loose 9 year old clit-o?

205 would be a perfect weekend toy but having no garage to store it means it would rust away before my very eyes