Project 6' (Ph1 Cossack)

[gretsch-drummer]

Thought I'd post my project up here for you lot to have a gander at. It's been keeping me busy'ish in the last month:

A good couple of month back a 6' popped up on ebay 5 minutes away from me. Luck would have it it was a Ph1 cossack with 105k on the clock. Went to have a look and bought it a few days later. Been driving it since.......poooooooower.

It's going to be a long term project to get it back to standard as much as possible. The main downer on the car is it has had a break in attempt at some point where the pass' door was bent down but its been pulled back and the result is just a bit of wind noise, no water leaks or anything.

The mechanic who I bought it off changed the heater matrix, new rad and changed cambelt and water pump so she's a good un'. In the paper work it's had receipts of head gasket, mintex brakes all round just a couple year ago and bilstein dampers and new springs and a load of sensors from peugeot...beauty.

The rub strips were all colour coded which I'm in the process of satin blacking them, just the front bumper to do now.







Door damage but I've touched it up:


The underneath isn't in bad nick either. Just a little scabby. (brake lines aren't leaking, I'd just WD'd the comp just to keep it healthy)



Plans:
1. Get spare door painted
2. Get dent in boot pulled out
3. Rebuild rear beam (it creaks on long left handers but no camber....)
4. Underseal underneath
5. Paint wheels silver


I'm SORN'ing the car start of December in sis's garage over winter for about 6+ months so this gives me loads of time to get everything sorted.


CHEERS!

Right, not that much has been happening over the past month (stupid busy work) but I've been repairing the front bumper during the week etc.

There was a crack under the fog light so drilled and fibreglassed the rear and will epoxy the front. Also were a few scrapes on the bottom lip as well, all DA'd and fillered. Almost ready to be sent to paint:







This is where the car currently lives (I'm in debt forever to my sister for taking over her garage.)



Enough room to get past each side. Tried taking rear beam off the other day for it's rebuild but 1 of the unions under boot floor wasn't playing ball.

Also managed to get hold of a couple GTI badges. Only need one more and then 3 of the '6' badges.



Managed to get the beam off with the use of 2 jacks last week then spent the evening in the shed:



The only f**k up was shearing a bleed nipple. So will try drill and tap it.

Hopefully getting it all painted up at the weekend then find someone to press the new shafts in for me.

Job jobbed.

Well I had a tin of yellow and red hammerite in the shed so just decided to busy with the brush, also black'ed the mounting arms:



And made a nice purchase from Larkspeed:


Will be off to find a garage to press the arm shafts in then crack on getting it mostly rebuilt.

Just need to find a O/F caliper and load compensator spring unit bit.

Just fitted new handbrake cables and went armed with a wire brush and drill attachment to the boot floor before whacking a coat of Bilt Hamber 80 on:



Another coat on some areas then I've got 2 tins of red oxide primer to brush on tmorrow if I have time.

And this is where I'm at as of tonight.

ENJOOOOOOY

[sam]

Looks good chap going to keep an eye on this!

[Craigus]

Very nice mate! probably my favourite colour too!

[Tom]

WIN! What a project, this will be awesome. Keep it clean on top and clean underneath and it will be worth loads in a few years!

[Midnightclub]

Nice

[Grant]

Nice progress. As said, I will be watching this space!

Beam looks spot on! Loving the attention to detail

[Carlos182]

Now theres a name I haven't seen in ages!
Looks like a good place to start anyway!

[mcvite]

Really nice looking job to detail workmanship you are carrying out there mate,well done!!!
Keep the good work up

[Piggy]

Shweeeet.
Just jumped up to my top 306
...love it

[Matt]

Good work mate.
Still got the bianca?

[L.J]

Love this colour, enjoy

[gretsch-drummer]

Good work mate.
Still got the bianca?

Sure do...


Cheers lads, 'should' be getting shafts pressed in this week by a mechanic I got chatting to the other day. Then can crack on getting it built up. Might send calipers in for a refurbish with some company or just find somewhere to do an exchange or something.

[Niall]

Do the calliper refurb your self mate. Its really not difficult at all as long as you are incredibly careful to make sure the seals are in place properly and not damaged.
Car looks great and nice progress so far. Keep up the good work

[ozonehostile]

Urghmagaaaad I'm so jealous.

Cossack ph1 gti6 is like my perfect Peugeot haha

[gretsch-drummer]

Well Niall I gave it a go...... and I've managed to make a great set of brakes from the 2 sets I had (bought a 6' beam off Sam today which amazingly didn't have sheared bleed nipples etc).

Removed the pistons from the calipers to see which 2 were the best internally:


And picked the best pistons to use, mmmmmm smooooooth:


hmmmmmm fuuuuuucked:


I was able to reuse the piston seals as they looked brand new. Rebuilt the calipers using some brake fluid as lube, repacked the handbrake mechanism with grease and now I have a fully functioning set of rear calipers:


Also managed to salvage this load comp' spring unit from the beam I got off Sam aswell:


All in all........a very good and productive day.

[Jesskendall123]

Nice colour

[gretsch-drummer]

My arm aches now:



A good coat of red oxide primer. Will let it dry over a week or so then see if I can mix a bit of black and silver hammerite to make a metallic grey.

[THE_Liam]

This looks absolutely epic mate! We'll have to drop an XUD in the bianca now so you have a nice economical daily veg burner

[gretsch-drummer]

Diesel???? NEVAAAAAARRR (well probably soon when I'm bored with this french stuff)

Just been to fit brakes on beam, bought some new bleed nipples off ebay but they are a bit longer but seem to tighten alright (might just give in and pay peugeot the £13 for 2). Need to order ARB seals tmorrow and make up new flexi to caliper lines:



Got week off so will be matte blacking the boot floor tmorrow and sealing it with Bilt Hamber UB (looks bloody good stuff)

PEACE!!!!

[Craigus]

Looking good! This is going to be so clean!

[Tom]

God that beam looks sexy!

[ozonehostile]

I am so in love with this car haha.


You're doing everything I would want to

[gretsch-drummer]

Ha, cheers fellas. Will see how far I take the whole project before letting someone else get use of it.

Made and fitted the caliper brake lines and ordered the ARB seals which will be here on Weds. Just been up to the car and satin blacked the underneath ready for the Bilt Hamber stuff:



Hopefully (struggle to) get the beam fitted at the weekend and have it back on some wheels. Just have front bumper, wheels, door and just a couple interior bits to sort and I'm pretty much done with it.

[Pugmarshall]

Andy! Love the work mate, spot on as always!

[ozonehostile]

If you ever decide to sell , let me know Yeah ;-)

[gretsch-drummer]

Cheers Luke. And will do Ozone. You can have first refusal.

Undersealing/waxing DONE:

[gretsch-drummer]

Rattle canned a couple wheels this evening (still needing to get my hands on some proper basecoat and 2k stuff)

Will be flatting top lacquer coat and putting 1 last coat on tmorrow:



(don't know where that bottom edge line has come from, must be a reflection)

Another thing crossed off the list.

[gretsch-drummer]

Productive weekend. 4 coats of lacquer so will let it cure for a week then flat and polish them:





Also managed to get the bumper crack somewhere near:

[stuwee]

A fellow cossack owner?!?

Looking good mate.

[gretsch-drummer]

Managed to rope the ol' man in to giving us a hand:



Edit: just went over for an hour and fitted the brakes etc so after I bleed them and fit exhaust, it's ready for its wheels. Will be buying 6 months tax and a months insurance so I can give it a good run for a while.