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Restoration Peugeot 205 1.9 GTI

Updated: Oct 16, 2021




Brought as a rolling project in 2019 this car proved to be an extremely fun and fast hot hatch for the few months I used it while making some much needed repairs to my ford capri. Finally the time came to take the Peugeot off the road and begin the repair work. This is the work I carried out.

The Peugeot as it was the day I drove into the workshop. Still going strong but definitely seen better days.

First job is a compression test to make sure the engine is as strong as I think it is. All 4 cylinders are pushing 170 psi with little variation between them confirming that it is a strong engine with plenty of life left in it. Obviously at this stage a full service, cam belt and water pump were needed and carried out. Also the sump was removed in order to clean the oil pump pickup. The oil pump drive chain was found to be slightly to loose and therefore shimmed to take up the slack. This is a common fault and 3 different size shims were produced to rectify it.

A quick look underneath with the rear axle and fuel tank removed reveilles the extent of the rust. Top left we have the inner sill section underneath the passenger rear seat. Top right is the same section on the driver side. Bottom pictures the under side of the boot from near and off side.

Next came the interior strip down. Rust had crept into the seat belt mounting points. Not ideal.

Then came the fun part of cutting all the rot out ready for new metal.

New panels made from 18 gauge sheet steel fabricated and welded in place. Seatbelt anchor points now solid as new.

the outer sills prove to be solid but for the last couple of inches. No need to replace the whole thing a quick repair will suffice.


Next up is to tackle a completely rotten boot floor along with the mounting points of the rear axle. Normally a sight like this would make the heart of the average classic car owner sink through the floor.

But not a problem for the K J Classics workshop.

2inch box section steel is used to recreat the structure of the rear end including cross members and the axle mounting points. These are seam welded all the way along the inner rear wing and into the sill at the front end.



Sheet metal panels finishes the rear end. Beads are rolled into the metal for added strength. All panels are made in house using a bead roller.

A coat of flexible stone chip......

And a few coats of paint and the rear end is finished.


Now for the front end. With the wings removed more or the same if revealed (33 years of rust and and poor repairs) .


Finally all the welding on the Peugeot is complete.


With the wings off access to the front suspension and steering is good so now’s the time to get the spanner’s out. Not to much wrong hear with the main engine service already done . A split drive shaft gater, a worn steering track rod, 2 new track rod ends, 2 front drop links, new brake lines front to back, new fuel lines, and all new water hoses complete the mechanical work.


Now to finish the front end. Again with a good coat of stone chip and the paint.


With the welding and mechanical side of the job finished and with the inside and underside painted all thats left is the cosmetics. The exterior paint was tired and needed a freshen up. Fortunately there was no rust on the outer panels. The front wings had been replaced already at some stage of the cars life so all there was to do was remove a few dings and dents.

Painted at last.

Wheels and tyres next. A full referbish and a set of toyo proxes should help it stick to the road.

A few more little jobs like new black trim. New fog lights and a little rewiring hear and there and it’s ready to go back together.















Finished at last. It just shows that even when the problem looks huge, professional help can save that classic car from the scrap heap and breath new life into your cherished classic car.






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