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Peugeot 205 Dakar Turbo Official Build STAGES 63 - 68 Options
roymattblack
#1 Posted : 21 February 2026 12:16:29

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STAGE 63A:

Left roll cage.

Pic 1: Retrieve the assemblies from the previous stage and position them as shown.

Pic 2: Fix the seat belt brackets to the front of the tank and fix from behind with 4 x AP screws.

Pic 3: Fit the tank assembly in place on the floor, in front of the black fixing brackets.
To do this you will need to remove the top of the battery.

Pic 4: Shows the parts in place.

Pic 5: Fix the assemblies together using 4 x AP screws.

Pic 6: Locate the roll cage parts 63A and 63F.

Pic 7: Peel the backing from 63F and carefully wrap it around the top of the roll cage 63A.

roymattblack attached the following image(s):
PARTS 63.JPG
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roymattblack
#2 Posted : 21 February 2026 12:19:27

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STAGE 63B:

Pic 8: Locate the roll cage parts 63D and 63B.

Pic 9: Peel the backing from 63D and carefully wrap it around the top of the roll bar 63B.

Pic 10: Position the ‘Sabelt’ sticker 63E as shown.

Pic 11: Fit the roll bar between the tank and the front of the floor as shown.

Pic 12: Press-fit the front reinforcing panel to the front of the floor as shown.

Pic 13: Locate the suspension parts 63G, 63H and 63I.
They will fit together in the order shown.
Make sure the small hole in the shaft of 63H is in line with the slot in 63G.

Pic 14: Using the compression tool from stage 40, assemble the spring and fit the retaining pin 63J as shown.
If you do not still have the tool 40I, compress the assembly on a firm surface and fit the pin.

Pic 15: Store all parts safely for now.

roymattblack attached the following image(s):
63 (8).JPG
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roymattblack
#3 Posted : 22 February 2026 15:27:31

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STAGE 64:

Upper roll cage.

Pic 1: Locate the roll cage parts 64A and 64E.

Pic 2: Peel the backing from 64E and carefully wrap it around the bar indicated.

Pic 3: Fit the front clip 64D to the centre of the bar as shown and fix with 2 x ZP screws.

Pic 4: Fit the visors 64B and 64C in place as shown.
They are each marked ‘L’ and ‘R’.
Fix from each end with 1 x KP screw.

Pic 5: Fit the upper cage 64F to the outer frame 63A as shown and fix with 1 x AP screw.

Pic 6: Press-fit the 4 x top brackets 64G in place where indicated.
Make sure they face forwards as shown.

Pic 7: Fit the centre frame as shown and fix with 1 x AP screw and 1 x KP screw.

Pic 8: Locate the suspension parts 64J, 64K and 64I.
They will fit together in the order shown.
Make sure the small hole in the shaft of 64J is in line with the slot in 64I.

Pic 9: Using the compression tool from stage 40, assemble the spring and fit the retaining pin 64L as shown.
If you do not still have the tool 40I, compress the assembly on a firm surface and fit the pin.

Pic 10: Store all parts safely for now.

roymattblack attached the following image(s):
PARTS 64.JPG
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roymattblack
#4 Posted : 23 February 2026 13:24:17

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Joined: 04/06/2011
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STAGE 65A:

Right roll cage.

Pic 1: Locate the roll cage parts 65A and 65F.
Peel the backing from 65F and carefully wrap it around the bar indicated.

Pic 2: Retrieve the roll cage assembly and fix the new frame 65A in place as shown.
Fix with 2 x AP screws.

Pic 3: Locate the side bar parts 65B, 65D and 65E.
Peel the backing from 65D and 65E and wrap them around the bar 65B as you did on the other side.

Pic 4: Retrieve the interior assembly and fit the bar 65B in place as before on the other side.

Pic 5: Press-fit the front support 65C in place as shown.

Pic 6: Locate the servo parts 65H and 65J.
They will fit together as indicated.

Pic 7: Fix the parts together with 2 x ZP screws.

roymattblack attached the following image(s):
PARTS 65.JPG
65 (1).JPG
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roymattblack
#5 Posted : 23 February 2026 13:27:17

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Joined: 04/06/2011
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Location: ipswich
STAGE 65B:

Pic 8: Fit the brake pump parts 65I and 65K together.

Pic 9: Fit the 2 x connectors 65M to the pump as shown.

Pic 10: Press-fit the assembly to the servo as shown.
It will only fit one way.

Pic 11: Cut the tube 65N into 2 x 150mm lengths and 1 x 170mm length.

Pic 12: Fit the 2 x 150mm tubes to the angled connectors on the pump and the 170mm tube to the pin on the servo.

Pic 13: Press-fit the support 65L into place as indicated.

Pic 14: Press-fit the servo assembly in place as shown.

Pic 15: Store all parts safely for now.
roymattblack attached the following image(s):
65 (8).JPG
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65 (11).JPG
65 (12).JPG
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