This plan outlines the conversion of a Peugeot 205 road car into a state-level Road/Rally competitor, broken down into five main stages and many achievable, small tasks.

🛠️ Stage 1: Preparation & Strip Down (The Foundation)

Goal: Get the shell completely bare, clean, and ready for critical safety and chassis modifications.

Phase 1A: Mechanical Disassembly & Storage

Task No. Task Description Status Notes
1.1 Disconnect and safely remove the battery. [ ]
1.2 Drain and safely store/dispose of all fluids (fuel, oil, coolant, brake fluid). [ ] Critical Safety Step
1.3 Detach and label all wiring connectors running to the engine/gearbox. [ ] Use numbered tags for complex looms.
1.4 Remove the bonnet, front bumper, and front wings (fenders). [ ] Store carefully to prevent damage.
1.5 Detach the exhaust system. [ ]
1.6 Remove the engine and gearbox as a complete unit. [ ] Store on a stand or covered pallet.
1.7 Remove front/rear suspension subframes, control arms, and braking components. [ ] Bag and label all bolts by location.
1.8 Remove the fuel tank and fuel lines. [ ]

Phase 1B: Interior & Trim Strip

Task No. Task Description Status Notes
1.9 Remove all seats, carpets, and sound deadening material. [ ] Use heat gun/scraper for sound deadening.
1.10 Remove all door cards, plastic trims, and headlining. [ ]
1.11 Remove the dashboard, steering column, and pedal box assembly. [ ]
1.12 Carefully remove the heater matrix/blower assembly. [ ]
1.13 Remove all glass windows (or plan for Polycarbonate replacement). [ ] Windscreen is bonded and requires cutting.
1.14 Label and remove the entire main wiring loom (or prepare for simplification). [ ]

Phase 1C: Shell Cleaning & Prep

Task No. Task Description Status Notes
1.15 Scrape/wire brush remaining seam sealer and underseal from the floor and arches. [ ]
1.16 Thoroughly degrease and clean the shell (especially where the cage will be welded). [ ] Crucial: No flammable residue left!
1.17 Protect door and boot hinges from welding spatter. [ ]

🔩 Stage 2: Chassis & Safety (The Critical Work)

Goal: Complete all structural and safety modifications compliant with Motorsport Australia regulations.

Phase 2A: Roll Cage Installation (Professional Work)

Task No. Task Description Status Notes
2.1 Deliver the stripped, clean shell to the fabricator. [ ]
2.2 Consult on and confirm Motorsport Australia-compliant cage design (Schedule J). [ ]
2.3 Have the multi-point roll cage professionally welded in. [ ] Ensure tie-ins to suspension points (if specified).
2.4 Collect the shell from the fabricator. [ ]

Phase 2B: Chassis Reinforcement & Body Prep

Task No. Task Description Status Notes
2.5 Seam weld suspension pick-up points and load-bearing areas (Optional, Recommended). [ ] Increases shell rigidity.
2.6 Weld in FIA/Motorsport Australia-compliant race seat mounts. [ ]
2.7 Weld in fire extinguisher system mounting points. [ ]
2.8 Drill holes for required items (kill switch cables, through-the-floor brake lines). [ ] Grommet and seal holes correctly.
2.9 Perform any necessary bodywork repairs (rust or damage). [ ]
2.10 Sand, prime, and paint the interior and roll cage. [ ] Use a high-visibility colour (e.g., White or Grey).

⚡ Stage 3: Systems & Wiring (The Functionality)

Goal: Install essential race-spec systems (electrical, fuel, and fire safety).

Phase 3A: Wiring Loom and ECU

Task No. Task Description Status Notes
3.1 Install external and internal safety cut-off switches and run battery cables. [ ]
3.2 Simplify the existing loom or install a custom lightweight race loom. [ ] Remove non-essential circuits (AC, stereo, etc.).
3.3 Mount the race-spec ECU in a safe, dry location. [ ]
3.4 Install new circuit breakers/fuses for main systems (ignition, fuel pump, lights). [ ]

Phase 3B: Fuel and Fire Systems

Task No. Task Description Status Notes
3.5 Install the new safety fuel tank/fuel cell. [ ] Secure according to regulations.
3.6 Run new, robust fuel lines (e.g., braided PTFE) from cell to engine bay. [ ] Ensure lines are secured and protected.
3.7 Install engine-bay components of the fire extinguisher system (nozzles and lines). [ ]
3.8 Install the cabin components of the fire extinguisher system (bottles, actuation handles). [ ] Ensure handles are easily accessible.

🚗 Stage 4: Reassembly & Running Gear

Goal: Assemble the mechanical components and controls.

Phase 4A: Engine & Drivetrain

Task No. Task Description Status Notes
4.1 Install new uprated engine/gearbox mounts. [ ]
4.2 Re-install the engine and gearbox into the shell. [ ]
4.3 Connect all engine wiring and cooling hoses. [ ]
4.4 Install race-spec air intake and exhaust system. [ ]
4.5 Install a competition gear shift mechanism (short-shifter). [ ]

Phase 4B: Suspension & Brakes

Task No. Task Description Status Notes
4.6 Install new race-spec suspension (dampers, springs, top mounts). [ ]
4.7 Re-install subframes and control arms, using new bushes (Polyurethane/Solid). [ ]
4.8 Install the new braking system (calipers, pads, discs). [ ]
4.9 Install the hydraulic handbrake mechanism (if used). [ ]
4.10 Run new brake lines securely to all four corners. [ ] Consider internal routing for protection.
4.11 Install a brake bias adjuster in the cabin. [ ]

Phase 4C: Steering & Control

Task No. Task Description Status Notes
4.12 Re-install the pedal box and steering column. [ ]
4.13 Install a competition steering wheel (with a quick-release hub). [ ]
4.14 Re-install the dashboard and instruments (race dash/gauges). [ ]

🏁 Stage 5: Final Race Prep & Compliance

Goal: Complete final fitment, testing, and regulatory sign-off.

Task No. Task Description Status Notes
5.1 Install the race seats and secure the FIA-approved harnesses. [ ]
5.2 Install polycarbonate/Lexan side and rear windows (if replacing glass). [ ]
5.3 Install a fresh windscreen and ensure wiper functionality. [ ]
5.4 Mount mandatory external compliance items (rain light, towing eyes, kill switch decals). [ ]
5.5 Install plumbed-in window wash/demist system (if required). [ ]
5.6 Fill all fluids, bleed the brakes, and check for leaks. [ ] First fluids in!
5.7 Initial engine start, run-up, and system check (ECU mapping/tuning). [ ]
5.8 Schedule professional wheel alignment and corner weighting. [ ] Essential for handling performance.
5.9 Final compliance check against the Motorsport Australia Manual (Schedule J). [ ] Confirm everything is legal for tech inspection.
5.10 Apply final livery and race numbers. [ ]