Ive been wanting to start a project thread on my mates car for a while now so here it is...

Some of you will follow and of read my 205 2.1 16v rallye track car thread which is here http://www.306gti6.com/forum/showthread.php?id=125344

and this 205 GTI build is becoming a pretty awesome build too and certainly worthy of a build thread

Around 4 years ago we went up to the midlands somewhere and came home with a really tidy 1991 graphite grey 205 Mi16 which had a few choice mods and what you would class as a tidy weekend/fun car.
At this point it wasn't really the idea to rip it apart and make it a track car but after a few choice mods the first track day soon came and went and Craig had the bug!

The lovely example of a fast road 205 MI16 soon had coil overs, Tran X plate diff, Safety devices roll cage, bucket seats and a few more mods.
It stayed in the fashion for a while and Craig started to get plenty of track days under his belt which was mainly Castle Combe or we both did a few airfield days.

The MI16 engine was the swapped to a GTi6 engine. Now for all those MI16 lovers out there I can say as a track car and running back to back MI16 and Gti6 engines the GTi6 engine is so much better in all aspects

This was all a couple of years back and I don't have any pictures to hand but from here onwards I do....

The spec at this point was a properly fitted GTi6 engine, 309 running gear, Gaz coilovers, safety devices cage, Tran X diff, 2.25 Torque technique exhaust, bucket seats etc etc and already it was giving my 205 a run for its money out on track!!

night before a trackday at Combe...
half way swapped from the 1.9 wheels with road tyres to the Speedlines with R888's



in the pits


Then the build really started to happen....
The car headed to Colin Satchell's workshop and had rear coilovers, front subframe and all his running gear plus a Satchshift.
Pics dont really do justice


Flash makes the underside look bad but here is the rear coilovers


and while the car was there somehow a set of Jenveys, Dta and a sandy loom was added then we took it down to Saltash and Sandy mapped the car at circa 180hp.



After collecting the car we were both itching to get out on another trackday so a local Combe on was booked up. It was going to be an interesting day, my 205 has nearly 50hp more but Craigs 205 was really well developed and the thought was his corner speed would be higher and manage to overcome the power issue down the straights.

It was a damp trackday and after a couple of easy slow shakedown laps on craigs car he started to build confidence and get used to the different driving style the car required with the new suspension.
We were correct the car had so much grip in the corners even in the damp. So much so after a couple of laps Craig was being towed back the the pits on a rope behind the recovery truck
He said it just stopped.... turns out the bottom end seized solid due to oil starvation and that was all before 10am.

A Peugeot sport france baffled sump kit and a Accusump system were soon purchased and a £200 replacement GTi6 engine was soon chucked in the car after a cambelt kit was fitted.

Back up and running at French car show 2013 at Combe with the GTi6 stand


A couple more trackdays came and went, and the cheap engine wasn't as good as the previous one and a few other annoying issues started to make the car a bit unreliable. Craig wanted to strip the car down and build it up properly to what he wanted as for the last 4 years things have kept on getting added and the whole car needed a bit of love underneath.

We came across a engine that was build 5 years ago with solid lifters, cams, Wossner pistons, steel rods, balanced crank which had never been fitted and just dry stored. After a few conversations we soon had it in the back of my work truck and headed to Pug Racing for Miles to give it a strip, check and assemble but also to added the Pugsport sump, Billet flywheel and crank pulley along with a paddle clutch.
That meant without the engine to worry about we could get cracking on the car....

old Gti6 engine came out






looks a bit sorry for itself


Works Maniflow exhaust manifold and a full 2.5 Maniflow system were purchased



Gti6 calipers weren't going to cut the mustard, Now binned in favour of Hi Spec 4 pots


we found a fair bit of surface rust when the bumper came off. Craig set to work on de rusting and painting while I started getting rid of crap that wasn't required... (gti6 engine loom, ecu etc etc)

With Oulton park trackday now only 2 weeks away and myself and craig booked on we don't have much time and the lack of light now in the evenings meant we were struggling to get to work on it. We took the decision Monday to trailer it over to my work and keep it in a storage container and in the evenings move it across to the workshop.

last night we dragged it from the container and into the workshop





Back looks awesome!


front end going back together


exhaust system fitted. Just need an engine to bolt it upto



Starting to look like a car again!


near on midnight last night and the point we gave up.



Were hoping to get the nod from Miles this afternoon and collect the engine. We can then get it fitted and potentially running this evening! another late one coming up I feel....

ill keep the updated coming when they happen

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230 hp 2.1 16v XU 205 rallye on jenveys Project thread here
309 3dr K20 Type R

Looking good mate. Maybe 1day I will get out on track with you lot in the 205

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Its out just waiting on engine builder to pull his finger out and get over his man flue so he can crack on with my bottom end

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Always the same when you rely on other people, always takes ages. Still a hell of a lot i need to sort for mine yet, full interior, dash and chassis looms what no one seems to have!
What front suspension is he running on this? and any pics of how the rear coilovers are mounted?

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Nice hi specs lol.

Silly question how much room do you have in a stripped 205, thinking way to the future but would love another car mid-end of next year and would love a 205 but at 6ft4 I'm guessing it'll be tight lol

Yeah it'll be track only so stripped as much as pos like my rallye was. It's only a hope at the min but be nice to start with something even lighter than the rallye was so 205 seems a logical step but will have to see how it pans out

Nice to see several pics of me taking an executive role

Finally off the axle stands haha should be epic at Oulton!

Lookin forward to seeing this at Oulton!

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Team Running Engine again!
Team Negative Camber!
My Budget track engine build thread!
Now appearing at a Trackday near you!!

I'm Just shy of 6'6' and there's a chap with a V6 205 who is taller than me! They are fine. When I had buckets in my 205 Rallye they were real low and I had shed loads of room.

Interestingly I find I have less leg room in my 309 than 205's, I'm going to shift the drivers seat back!

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205 Van SC'd GTI6 - because why not
309 Goodwood V6 - sold
205 Rallye GTI6 - Bent

EFA

Awesome project, can't wait to see this and yours in a couple of weeks.

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Goldie the track car.

Full day on it today.

Exhaust all fitted and finished, all coolant plumbed on, throttle bodies and inlet fitted, Engine all wired up, filled with oil, gearbox filled with oil, hi specs bolted on.
All the lights work as I stripped the loom right down to what was required and it even cranks over now!
Need to sort the fuel supply out still then try and start!

Will add pics when I get on the computer and mapping is booked in for Thursday at Launceston
With sandy

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230 hp 2.1 16v XU 205 rallye on jenveys Project thread here
309 3dr K20 Type R

The car had all the 205 wiring loom, then the GTi6 engine loom and ecu plus when the throttle bodies got fitted the standalone ecu and wiring were fitted.

I stripped the whole gti6 engine loom down and left a couple of wires. The alternator, starter wire, oil pressure and ive still got to sort the fuel pump wiring out which is fairly simple.

pictures from the weekend and Thursday night

Engine got collected and awaiting the gearbox to be fitted on


engine in, underneath all bolted up and I crack on with wiring the engine up


I finished clamping up the exhaust manifold and bolted the rest of the exhaust system on.


throttle bodies re fitted and still wiring up


Craig took care of the brakes...


coolant plumbed up, wheels bolted back on and looks complete!


engine bay picture


it cranks over, full of fluids etc. Craigs popping over to merlins as we need a few bits for the fuel lines and we should be in a position to try and start it this evening.
The DTA is mapped for a standard Gti6 engine on throttle bodies. This engine now has forged pistons, solid liters and cams. It may fire it may not!
Mapping is booked for this Thursday, Its not the end of the world if it doesn't start before mapping but it would be much nicer to get it running so everything can be checked and tested. Nothing worse than getting it to the rollers and having an unfixable problem while on the rollers.

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230 hp 2.1 16v XU 205 rallye on jenveys Project thread here
309 3dr K20 Type R