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mat_the_cat

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  1. Like
    mat_the_cat got a reaction from Coprolalia in 205 GTi - repairs underway   
    Not sure how long this knob will last, so that link may be useful.
    I brushed past the front number plate the other day and one end fell off, so I had a closer look and the fibreglass was a bit crumbly around the screw holes. I could have just drilled (yet) another hole, but instead used a couple of these.
    Once I had dug out my square 8mm drill bit they popped straight in.


    Nice easy job; they expand like a rawlplug so should be more robust than screwing straight into the bumper.

    I popped underneath to make a start on the next job which is replacing the handbrake cables and fuel hoses. Look at the rust bulge!


    Looking at the top though, it's clear someone has been here before me as that doesn't look factory.

    One of the hoses looks like someone (for some reason) has just drilled the top of the tank insert and poked in the hose! The resulting kink hasn't done the hose much good.

    It seems firmly attached however, so will have to remove the tank outlet and see what's going on.
    For now I just busied myself replacing missing trim clips and a couple of rivets which stiffened up the rear valance.

  2. Like
    mat_the_cat got a reaction from Coprolalia in 205 GTi - repairs underway   
    I've had a go at the rear calipers, and unfortunately one is beyond repair. The bleed screw has seemingly been hammered into the body, and after a good while welding things to that and the remains of the flexi, they both came free (yay!) but the threads were non-existent (boo). I drilled out and re-tapped larger, but it turned out the body was cracked



    The better one of the two is pictured above, and that was savable. I dunked the steel part of the body in Deox C, along with various other brackets. 

    It took several days to remove all the rust!

    Before a coat of galvanising primer.

    I've never rebuilt a caliper with integral handbrake mechanism before, so had to make up a tool from an old socket to compress everything to reassemble.

    The last part was fitting a new piston, which is where things went less well. It was the wrong size, and too small to seal in the bore. Double checking sizes and the 205 uses a 30mm piston, however the 206 uses a 32mm piston which looks to be what we have. I'd already bought another 205 caliper to replace the cracked one, but wouldn't match the one I was repairing.
    Still, I thought I may as well finish the repair and see if I can sell to recoup the costs of the kit. New piston going in:

    And the finished job.

    Surely worth £30 to someone?
  3. Like
    mat_the_cat got a reaction from MJK 24 in 205 GTi - repairs underway   
    I've had a go at the rear calipers, and unfortunately one is beyond repair. The bleed screw has seemingly been hammered into the body, and after a good while welding things to that and the remains of the flexi, they both came free (yay!) but the threads were non-existent (boo). I drilled out and re-tapped larger, but it turned out the body was cracked



    The better one of the two is pictured above, and that was savable. I dunked the steel part of the body in Deox C, along with various other brackets. 

    It took several days to remove all the rust!

    Before a coat of galvanising primer.

    I've never rebuilt a caliper with integral handbrake mechanism before, so had to make up a tool from an old socket to compress everything to reassemble.

    The last part was fitting a new piston, which is where things went less well. It was the wrong size, and too small to seal in the bore. Double checking sizes and the 205 uses a 30mm piston, however the 206 uses a 32mm piston which looks to be what we have. I'd already bought another 205 caliper to replace the cracked one, but wouldn't match the one I was repairing.
    Still, I thought I may as well finish the repair and see if I can sell to recoup the costs of the kit. New piston going in:

    And the finished job.

    Surely worth £30 to someone?
  4. Like
    mat_the_cat got a reaction from neil1971 in 205 GTi - repairs underway   
    I've had a go at the rear calipers, and unfortunately one is beyond repair. The bleed screw has seemingly been hammered into the body, and after a good while welding things to that and the remains of the flexi, they both came free (yay!) but the threads were non-existent (boo). I drilled out and re-tapped larger, but it turned out the body was cracked



    The better one of the two is pictured above, and that was savable. I dunked the steel part of the body in Deox C, along with various other brackets. 

    It took several days to remove all the rust!

    Before a coat of galvanising primer.

    I've never rebuilt a caliper with integral handbrake mechanism before, so had to make up a tool from an old socket to compress everything to reassemble.

    The last part was fitting a new piston, which is where things went less well. It was the wrong size, and too small to seal in the bore. Double checking sizes and the 205 uses a 30mm piston, however the 206 uses a 32mm piston which looks to be what we have. I'd already bought another 205 caliper to replace the cracked one, but wouldn't match the one I was repairing.
    Still, I thought I may as well finish the repair and see if I can sell to recoup the costs of the kit. New piston going in:

    And the finished job.

    Surely worth £30 to someone?
  5. Like
    mat_the_cat got a reaction from Sunny Jim in 205 GTi - repairs underway   
    I've had a go at the rear calipers, and unfortunately one is beyond repair. The bleed screw has seemingly been hammered into the body, and after a good while welding things to that and the remains of the flexi, they both came free (yay!) but the threads were non-existent (boo). I drilled out and re-tapped larger, but it turned out the body was cracked



    The better one of the two is pictured above, and that was savable. I dunked the steel part of the body in Deox C, along with various other brackets. 

    It took several days to remove all the rust!

    Before a coat of galvanising primer.

    I've never rebuilt a caliper with integral handbrake mechanism before, so had to make up a tool from an old socket to compress everything to reassemble.

    The last part was fitting a new piston, which is where things went less well. It was the wrong size, and too small to seal in the bore. Double checking sizes and the 205 uses a 30mm piston, however the 206 uses a 32mm piston which looks to be what we have. I'd already bought another 205 caliper to replace the cracked one, but wouldn't match the one I was repairing.
    Still, I thought I may as well finish the repair and see if I can sell to recoup the costs of the kit. New piston going in:

    And the finished job.

    Surely worth £30 to someone?
  6. Like
    mat_the_cat got a reaction from Back_For_More in 205 GTi - repairs underway   
    I've had a go at the rear calipers, and unfortunately one is beyond repair. The bleed screw has seemingly been hammered into the body, and after a good while welding things to that and the remains of the flexi, they both came free (yay!) but the threads were non-existent (boo). I drilled out and re-tapped larger, but it turned out the body was cracked



    The better one of the two is pictured above, and that was savable. I dunked the steel part of the body in Deox C, along with various other brackets. 

    It took several days to remove all the rust!

    Before a coat of galvanising primer.

    I've never rebuilt a caliper with integral handbrake mechanism before, so had to make up a tool from an old socket to compress everything to reassemble.

    The last part was fitting a new piston, which is where things went less well. It was the wrong size, and too small to seal in the bore. Double checking sizes and the 205 uses a 30mm piston, however the 206 uses a 32mm piston which looks to be what we have. I'd already bought another 205 caliper to replace the cracked one, but wouldn't match the one I was repairing.
    Still, I thought I may as well finish the repair and see if I can sell to recoup the costs of the kit. New piston going in:

    And the finished job.

    Surely worth £30 to someone?
  7. Thanks
    mat_the_cat reacted to Popsicle in 205 GTi - repairs underway   
    Really enjoying the updates and the love that you're putting in to this 👍.
  8. Like
    mat_the_cat got a reaction from Cluffy in 205 GTi - repairs underway   
    I've had a go at the rear calipers, and unfortunately one is beyond repair. The bleed screw has seemingly been hammered into the body, and after a good while welding things to that and the remains of the flexi, they both came free (yay!) but the threads were non-existent (boo). I drilled out and re-tapped larger, but it turned out the body was cracked



    The better one of the two is pictured above, and that was savable. I dunked the steel part of the body in Deox C, along with various other brackets. 

    It took several days to remove all the rust!

    Before a coat of galvanising primer.

    I've never rebuilt a caliper with integral handbrake mechanism before, so had to make up a tool from an old socket to compress everything to reassemble.

    The last part was fitting a new piston, which is where things went less well. It was the wrong size, and too small to seal in the bore. Double checking sizes and the 205 uses a 30mm piston, however the 206 uses a 32mm piston which looks to be what we have. I'd already bought another 205 caliper to replace the cracked one, but wouldn't match the one I was repairing.
    Still, I thought I may as well finish the repair and see if I can sell to recoup the costs of the kit. New piston going in:

    And the finished job.

    Surely worth £30 to someone?
  9. Like
    mat_the_cat got a reaction from Coprolalia in 205 GTi - repairs underway   
    Fuel pipes are now replaced, and I've had to replicate the pipe sticking straight up out of the tank, as for some reason  it's been modified to clamp to the pipe inside the tank. I plan to fit a right angle coupling at the top however.


    There's a few bodges I'm finding on this, such as the battery clamp being a thin piece of bent metal, a penny washer and a UNF bolt in an M6 hole.

    It was so flimsy the battery was flopping about all over the place! Now replaced with the proper clamp.

    Next was the handbrake cables, should be a nice easy job until I noticed a drip from one of the rear drums.

    Wait a minute...drums on a 1.9? Well yes, when she bought it the owner pointed out it was originally a 1.6, but they'd been gradually replacing all the bits to turn it into a 1.9. They'd bought the correct rear beam for it, complete with brake calipers although it looked like it'd been sitting at the bottom of the sea. So the plan was always to rebuild that at leisure, and swap it over at the same time as changing the front struts to restore the correct ride height.


    So with the rear end, I'm just going to to the bare minimum to make it functional, and swap the whole thing over in the summer. I have to admit I sometimes reuse the staked nuts if the the groove falls in a different spot on the nut. But I think this one has been reused one too many times! Especially when I levered it away and it just crumbled off.

    Both new handbrake cables are now on, and I'm just waiting for a new cylinder...under £10 delivered so not a big problem.

    While I was there I coated everything with Lanoguard, to keep moisture away. Really impressed with the overall condition, despite the bodges!


  10. Like
    mat_the_cat got a reaction from HillmanImp in 205 GTi - repairs underway   
    Not sure how long this knob will last, so that link may be useful.
    I brushed past the front number plate the other day and one end fell off, so I had a closer look and the fibreglass was a bit crumbly around the screw holes. I could have just drilled (yet) another hole, but instead used a couple of these.
    Once I had dug out my square 8mm drill bit they popped straight in.


    Nice easy job; they expand like a rawlplug so should be more robust than screwing straight into the bumper.

    I popped underneath to make a start on the next job which is replacing the handbrake cables and fuel hoses. Look at the rust bulge!


    Looking at the top though, it's clear someone has been here before me as that doesn't look factory.

    One of the hoses looks like someone (for some reason) has just drilled the top of the tank insert and poked in the hose! The resulting kink hasn't done the hose much good.

    It seems firmly attached however, so will have to remove the tank outlet and see what's going on.
    For now I just busied myself replacing missing trim clips and a couple of rivets which stiffened up the rear valance.

  11. Like
    mat_the_cat got a reaction from Sunny Jim in Festival of the Unexceptional first-timer   
    That was the year of the Hyundai Stellar! Completely by chance an unplanned, I spotted another on the end of a row when I arrived so parked next to it. Then @RayMK did the same!

  12. Like
    mat_the_cat got a reaction from LightBulbFun in Festival of the Unexceptional first-timer   
    That was the year of the Hyundai Stellar! Completely by chance an unplanned, I spotted another on the end of a row when I arrived so parked next to it. Then @RayMK did the same!

  13. Like
    mat_the_cat got a reaction from SEATMad in Festival of the Unexceptional first-timer   
    That was the year of the Hyundai Stellar! Completely by chance an unplanned, I spotted another on the end of a row when I arrived so parked next to it. Then @RayMK did the same!

  14. Thanks
    mat_the_cat got a reaction from Rust Collector in Daily DeLorean project (now with Jeep Wrangler "spared no expense")   
    Especially in this weather I tend to stick gearbox oil in front of a heater for 10 minutes or so, makes pouring it so much easier.
  15. Like
    mat_the_cat got a reaction from HillmanImp in 205 GTi - repairs underway   
    Fuel pipes are now replaced, and I've had to replicate the pipe sticking straight up out of the tank, as for some reason  it's been modified to clamp to the pipe inside the tank. I plan to fit a right angle coupling at the top however.


    There's a few bodges I'm finding on this, such as the battery clamp being a thin piece of bent metal, a penny washer and a UNF bolt in an M6 hole.

    It was so flimsy the battery was flopping about all over the place! Now replaced with the proper clamp.

    Next was the handbrake cables, should be a nice easy job until I noticed a drip from one of the rear drums.

    Wait a minute...drums on a 1.9? Well yes, when she bought it the owner pointed out it was originally a 1.6, but they'd been gradually replacing all the bits to turn it into a 1.9. They'd bought the correct rear beam for it, complete with brake calipers although it looked like it'd been sitting at the bottom of the sea. So the plan was always to rebuild that at leisure, and swap it over at the same time as changing the front struts to restore the correct ride height.


    So with the rear end, I'm just going to to the bare minimum to make it functional, and swap the whole thing over in the summer. I have to admit I sometimes reuse the staked nuts if the the groove falls in a different spot on the nut. But I think this one has been reused one too many times! Especially when I levered it away and it just crumbled off.

    Both new handbrake cables are now on, and I'm just waiting for a new cylinder...under £10 delivered so not a big problem.

    While I was there I coated everything with Lanoguard, to keep moisture away. Really impressed with the overall condition, despite the bodges!


  16. Like
    mat_the_cat got a reaction from Aston Martin in Festival of the Unexceptional first-timer   
    That was the year of the Hyundai Stellar! Completely by chance an unplanned, I spotted another on the end of a row when I arrived so parked next to it. Then @RayMK did the same!

  17. Like
    mat_the_cat got a reaction from AnnoyingPentium in Festival of the Unexceptional first-timer   
    That was the year of the Hyundai Stellar! Completely by chance an unplanned, I spotted another on the end of a row when I arrived so parked next to it. Then @RayMK did the same!

  18. Like
    mat_the_cat got a reaction from Nullzwei in Festival of the Unexceptional first-timer   
    That was the year of the Hyundai Stellar! Completely by chance an unplanned, I spotted another on the end of a row when I arrived so parked next to it. Then @RayMK did the same!

  19. Like
    mat_the_cat got a reaction from BorniteIdentity in Festival of the Unexceptional first-timer   
    That was the year of the Hyundai Stellar! Completely by chance an unplanned, I spotted another on the end of a row when I arrived so parked next to it. Then @RayMK did the same!

  20. Like
    mat_the_cat got a reaction from Lacquer Peel in Festival of the Unexceptional first-timer   
    That was the year of the Hyundai Stellar! Completely by chance an unplanned, I spotted another on the end of a row when I arrived so parked next to it. Then @RayMK did the same!

  21. Like
    mat_the_cat reacted to RayMK in Festival of the Unexceptional first-timer   
    E591BRM was mine.  It passed through three other forum members after I relinquished ownership later that year.  It has not resurfaced for a few years now so its rusty bits will probably make it beyond saving if it is not owned by an enthusiast who can keep up with the welding.  I enjoyed my 7 years with it but the engine in my previous Stellar (D401MTM) was much nicer during its 101K miles with me. 
  22. Agree
    mat_the_cat reacted to Dick Longbridge in Festival of the Unexceptional first-timer   
    I bet you were chuffed to bits!
    Which one is @RayMKs Stellar? I didn't realise there was another on the forum. 
    That must be a fair % of the UKs roadworthy Stellars parked there, surely?! 
  23. Like
    mat_the_cat got a reaction from Asimo in Festival of the Unexceptional first-timer   
    That was the year of the Hyundai Stellar! Completely by chance an unplanned, I spotted another on the end of a row when I arrived so parked next to it. Then @RayMK did the same!

  24. Haha
    mat_the_cat reacted to quicksilver in Festival of the Unexceptional first-timer   
    That was a memorable moment when you arrived behind that TR7. Everyone thought the V8 burble was coming from that, then it drove away and they could still hear it. Cue much confusion.
  25. Like
    mat_the_cat got a reaction from wuvvum in Festival of the Unexceptional first-timer   
    That was the year of the Hyundai Stellar! Completely by chance an unplanned, I spotted another on the end of a row when I arrived so parked next to it. Then @RayMK did the same!

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