When Joe originally purchased his Peugeot 205, he thought the rust was exclusive to one area. After a bit more inspection, it turns out this is one rusty Peugeot 205. Time to get it fixed.

Purchasing a £400, 202,000 mile Peugeot 205 diesel was always going to present issues. Joe, however, didn’t envisage quite how many issues his now aptly dubbed rusty Peugeot 205 was going to present. What started off as an attempt at removing the jack quickly moved into a gaping hole being created above the front driver’s side wheel arch.

After a tad more prodding, that hole quickly became a crater. Now while we have prided ourselves on this being a DIY restoration, in order for our health and safety conscious colleagues to allow us on our cheap car road trip, some professional welding was needed.

It was only when a mechanic cut out the rust to form a square did it become apparent just how much rust was present, with a clear hole to the wheel being on show. From here, a new flange is needed, which is mocked up using carboard first, before cutting a mild steel sheet and welding it into place. Next up, more cardboard is used as a template to cut another piece of mild steel sheet to weld it onto the flange and securely onto the car to cover the hole.

With the welds complete, it’s then treated to seem sealer before being painted yellow to match the body as well as the bottom side being undersealed to protect it from future rust.

Next up was the interior, and in particular, the stereo. Joe recently added an aerial base but was missing the actual aerial. That was then hooked up to an adaptor for the universal ISO connection before being mated to a second hand Pioneer head unit that is more in keeping with the back-to-basics vibe surrounding the rusty Peugeot 205.

Joe also tackles some of the smaller, tidying up jobs on the car to bring it up to a standard adequate enough for our upcoming road trip. You won’t want to miss that. Don’t forget to subscribe to our YouTube channel!