My Indigo Blue Throttle Bodied 106 Rallye - Manifold Update Last Page!

[Lewisimo]

To cut a long story short, I sold my Saxo to Pauly Dixon and bought Hanks 'old' Rallye. Plan is to fit my engine and box (now complete) fit my seat and other parts and mint it up a bit more, then have it as a road/track toy. Anyways here's the latest...

Right i've had a chance to do a bit more of a proper write up regarding the engine installation so here it is:

I loaded up the van on saturday with all the parts - engine, gearbox, Grp N wishbones, Steering, and other various nuts and bolts etc and then got up pretty early on the Sunday to head to Hanks gaff in Newport Wales. Bit of a debacle en route as I didn't have enough dosh for the severn bridge (assumed it would be about £3 and it turned out to £15!) :eek: So anyway they let me through and I just had to pay by post instead...and if you don't pay within the week it goes up to £90!!! Robbin' bastards!

That aside, I got to Hanks about elevenish and we made a start straight away.

First Job was to check all the hoses in the bay were ready, and to remove the old Fuel pressure regulator that Hank had installed for his engine - mine already has one so we did away with that. 2nd pic shows Hank modeling the latest fashion in Wales, otherwise known as the '106 Rallye Frock'! :D

http://i56.photobucket.com/albums/g178/Lewisimo_69/EngineFitting01.jpg

http://i56.photobucket.com/albums/g178/Lewisimo_69/EngineFitting02.jpg

2nd job was to mate the engine to the Gearbox - this was done without too much trouble once we had lifted the engine up a little using the crane, and then located the input shaft into the clutch. We then bolted everything up and checked it was all tight etc:

http://i56.photobucket.com/albums/g178/Lewisimo_69/EngineFitting03.jpg

http://i56.photobucket.com/albums/g178/Lewisimo_69/EngineFitting04.jpg

http://i56.photobucket.com/albums/g178/Lewisimo_69/EngineFitting05.jpg

Next job was to try the brakes on the car to see if they fitted...needless to say they didn't, but the discs sure looked sexual regardless:

http://i56.photobucket.com/albums/g178/Lewisimo_69/EngineFitting10.jpg

Next up was the actual engine fitment. ALthough the pics give the impresion that this was an easy task, while it was relatively straight forward there was a lot of heaving and fecking about to move it into postion while we lowered the car down onto it using the crane, all the while trying not to scratch or break anything (which we managed fine!)

http://i56.photobucket.com/albums/g178/Lewisimo_69/EngineFitting06.jpg

http://i56.photobucket.com/albums/g178/Lewisimo_69/EngineFitting07.jpg

http://i56.photobucket.com/albums/g178/Lewisimo_69/EngineFitting08.jpg

We then 'simply' lowered the car to the ground, and pulled the engine up into place using the crane, then onto then bolted it all in:

http://i56.photobucket.com/albums/g178/Lewisimo_69/EngineFitting09.jpg


We then had to modify the throttle cable to fit, which we did. Meanwhile Hank discovered he had somehow implaed himself with some braided hose in his leg - stings like a bitch! :D

http://i56.photobucket.com/albums/g178/Lewisimo_69/EngineFitting12.jpg

http://i56.photobucket.com/albums/g178/Lewisimo_69/EngineFitting15.jpg

http://i56.photobucket.com/albums/g178/Lewisimo_69/EngineFitting13.jpg

After that we connected pretty much everything else, fitted the wishbones, checked it all and we were done! All that was left to do was admire our handiwork. :cool:

http://i56.photobucket.com/albums/g178/Lewisimo_69/EngineFitting16.jpg

http://i56.photobucket.com/albums/g178/Lewisimo_69/EngineFitting14.jpg

http://i56.photobucket.com/albums/g178/Lewisimo_69/EngineFitting17.jpg


The car get's delivered to my house this weekend so more updates to come! :afro:

[Paul]

Looks lovely.

Fuse box / ECU and other stuff inside car?

[Lewisimo]

Thanks mate. Yes all of that is inside. I still need to get the actual engine wired as it's not done yet. Also I am getting an exhaust done by primary designs as the bore on the Pugsport that was on it is WAY too small for the engine and KRS manifold.

[adamsax]

Awesome doesn't cover it.

Wow.

[Mochachino]

Absolutley stunning..again.

Was the Saxo sold as it was or did you put it back to standard? Whats the new owner doing with that one now?

[leeroybrown]

Hey Lewis son....2 bloody years or so its took to get that engine into an engine bay and I must say its loooking swwwwwwwwwwweeet!

I take it Pauly D must have sold the type r, as I heard on the grape vine he was back in another black saxo.

[3cott]

OMG

That car is one of the best around imo...

[MR_N]

Seen you put the engine in on shed or ssc, does look fantastic. Was well worth the wait of having the enigne as an ornament for a long time lol. Really want to pop the ecu and fuse's inside the car when i do this, how "involved" is it?

[Proffitt]

Pure sex.

Wish my engine looked like that!

[Sparco_Tom]

looks lush very nice indeed

[Maxamus]

Ive fallen in love! what an engine bay you have they ;)

[Mieran]

Did you sell your crazy spec'd VTS?

Btw is Pauly Dixon the same guy from Consett with the EP3 and MK1 golf?

[jimbo06]

awesome awesome awesome :y: Cant wait to see more updates.

That engine could of been a peice of furniture lol

[leeroybrown]

Mieran, thats him

[Maxamus]

Gotta get some vids up of it running tbh!

[Aly]

One word..

Weapon

[Karl]

Yummy.

[Mieran]

Mieran, thats him

Hes on my local cruise site, hes funny as fook haha

I loved that matt black MK3 golf he had, it was awesome

[toms_vtr]

is that the super s1600 engine?
how much bhp will it be running..
i love this car lol!!!

[benJee_VTR]

Awesome, so clean! Now all you have to do is never drive it!

[Jamie]

OMFG thats nice.

[Anthony]

Sexy.........

[ryan_g86]

you just made me want a rallye even more! Awesome!

[VTSTomE]

Is that Hank Marvinson from rallye reg if so seen the work gone into this car nothing short of perfect with your lump in there. Didn't he have one in there on sandy's gsxr set-up running 190?

[Berg]

under the bonnet is just a work of art!!

looks stunning

[Mardgee]

Im in love with this absolute sex glad to see the engine might see the outside of a garage hehe.

[Wayne]

absouletly love it:y: real weapon, engine and gearbox are a work of art:) you could eat your dinner of the whole of the car:P

[ankers]

thats fucking well nice m8t well done

[Lewisimo]

Thanks very much for the comments lads :)

To try and answer some questions..it's a Longmans Super 1600 207Bhp Engine with a Close Ratio Quaife Box and LSD. All the rest of the work was done by Hank prior to me buying the car but I intend to do a few bits to make it own so to speak. Aye i'm pleased as hell with it, should arrive tomorrow! :D (Sunday)

All that's left to do is fit the altenator, get a primary designs exhaust system from manifold back, and get wire wizard to wire it....that's a few grand just there!

[stevo67]

Looking Top dollar that car.

Steve.

[AlexR]

I expected nothing less from you Lewis ;)

Top work as always, chop chop and get it finished though :P

[Lewisimo]

thanks again lads! :D

Right, a few updates tonight:

I have done a more comprehensive list of work but i haven't had time to do a proper write up, and my laptop is dead so currently using my g/f's cumbersome pc...anyways, that aside, here are some snaps and a list of work done so far:

All bolts changed for lightweight aluminum one's where safe to do so, otherwise stainless steel or black high tensile socket head bolts were used. I fitted the seat, steering wheel, harnesses, and quick shift, and roof ariel blank too, and swapped all the stainless bolts in the cabin for back one's to tone it down a little. Also removed the map pockets as I don't really like them, plus the flock was peeling too! I also washed it so it's like new again now. I cannot emphasise how pleased i am with the car - pics do not do it justice, it's absolutely stunning in the flesh! Also swapped the jubilee clips for proper strong motorsport items - pics to follow. Spent two days working on it so far and got most of the small jobs done that I had in mind.

Here it is on it's arrival:

http://i56.photobucket.com/albums/g178/Lewisimo_69/Rallye09.jpg



I washed it and did some work that night, now onto the next day:

Coming out of 'bed' for the evenings work:

http://i56.photobucket.com/albums/g178/Lewisimo_69/Rallye10.jpg

Seat Fitted:

http://i56.photobucket.com/albums/g178/Lewisimo_69/Rallye11.jpg

http://i56.photobucket.com/albums/g178/Lewisimo_69/Rallye13.jpg

Doorcards with black bolts & removed map pockets:

http://i56.photobucket.com/albums/g178/Lewisimo_69/Rallye12.jpg

Overall quick snap:

http://i56.photobucket.com/albums/g178/Lewisimo_69/Rallye14.jpg

Like I said i will do a proper write up when i get a chance!!

Things to do still:

*Buy new alternator
*Get exhaust system made
*Fit brakes/sort brakes out
*Get wiring loom done

These are expensive jobs so it'll be a while yet!

Lewis

[Lewisimo]

Also it is sitting a bit high up front so I intend to get lower springs for the front coils when I get time (and money)!

[AlexR]

Are you keeping those ghey wheels? They rock on 205s but i just don't like them on 106s and saxos personally. Get something a bit more modern and lightweight on there :P

Top work again!

What are you doing with the brakes?

[pjm300]

Are you keeping those ghey wheels? They rock on 205s but i just don't like them on 106s and saxos personally. Get something a bit more modern and lightweight on there :P

Top work again!

What are you doing with the brakes?

selling them, buying something else, selling them, buying something else :D

love it lewis :D

[Toad]

Didn't this car used to be black? ;)

[rushy_23]

That engine and gearbox look amazing. Hanks bay looks porn, Wow.

Nice to see progress Lewis anyhow.

Agree with AlexR on the wheels.

[Mike_Saxo_Furio]

i want !! thats lush
where to in newport was it done ?

[Lewisimo]

Lol at you boys! You think you know me so well paul!:P Hey I like those wheels, you need to see them in the flesh, it honestly does look way better on the wheels. Pics don't do them justice for some reason.. I like the fact they are a bit retro too, kind've de-chavs it! :afro:

Brakes i may keep if they fit with 5mm spacers..we shall see. Either that or it's black comp 2 time!

[Andy_K]

Loved this when Hank had it, read all the way through his thread on RReg, but now with your engine and bits and pieces in there is waaay better :y:

[jimbo06]

awsome awsome stuff mate, it looks soo clean and tidy!

[Lewisimo]

cheers dude - it's getting there alright!

[leeroybrown]

Marry me.

Then I will divorce you saying you hump Pauly D's (AGAIN)

And then I can take this car as settlement fee! :}

[S8TTG]

Car is amazing, i love the carbon trumpets and the c2 cover in carbon, looks the nuts!

[paulydixon]

Myself and the entire internet community are dying for the udated P clip shots :D

[Mieran]

Oh look its pauly dixon (with a small 'p')

[paulydixon]

Mieran! Loving the Banksy Av homie :)

What are you doing on here? Do you drive french?

[Lewisimo]

Lol Pauly...it all in the details homes! :P

[Lewisimo]

Right a few more updates tonight... I finally had time to upload my other pics onto photobucket, with the initial progress, so i'll get those up and then put the latest updated after that....

Steering wheel fitted:

http://i56.photobucket.com/albums/g178/Lewisimo_69/NewRallye02.jpg

http://i56.photobucket.com/albums/g178/Lewisimo_69/NewRallye03.jpg


Quick Shift fitted:

http://i56.photobucket.com/albums/g178/Lewisimo_69/NewRallye07.jpg


All bolts replaced with aluminum one's (where safe to do so of course):

http://i56.photobucket.com/albums/g178/Lewisimo_69/NewRallye06.jpg

http://i56.photobucket.com/albums/g178/Lewisimo_69/Rallye20.jpg


Jubilee clips banished and replaced with proper fasteners:

http://i56.photobucket.com/albums/g178/Lewisimo_69/NewRallye05.jpg

OE cable retainers on pillar banished and replaced with tidy ones (you can also see i'm in the process of fitting black roll cage bolts instead of the stainless ones):

http://i56.photobucket.com/albums/g178/Lewisimo_69/Rallye22.jpg

http://i56.photobucket.com/albums/g178/Lewisimo_69/Rallye24.jpg

http://i56.photobucket.com/albums/g178/Lewisimo_69/Rallye25.jpg

Stainless Steel Engine Mount bolts fitted:

http://i56.photobucket.com/albums/g178/Lewisimo_69/Rallye21.jpg

Stainless bolts fitted on brake balance bar:

http://i56.photobucket.com/albums/g178/Lewisimo_69/Rallye23.jpg


Gold bolts on engine all swapped for black aluminum ones (decided it's a cleaner more subtle look than the gold type!)

Before:

http://i56.photobucket.com/albums/g178/Lewisimo_69/Rallye15.jpg

Take these:

http://i56.photobucket.com/albums/g178/Lewisimo_69/Rallye16.jpg

And you get this:

http://i56.photobucket.com/albums/g178/Lewisimo_69/Rallye17.jpg

http://i56.photobucket.com/albums/g178/Lewisimo_69/Rallye19.jpg

Still a few to swap in this pic - not quite done yet as I ran out!

http://i56.photobucket.com/albums/g178/Lewisimo_69/Rallye18.jpg

Also ground off this random stud in the bay using my good mothers dremmel (amazing tool this!) and touched it up with paint - looks better than a stud sitting there doing nothing but may get it smoothed over professionally eventually but it will do for now - no pic of it painted but it does look nice, I did a tidy job of it!

http://i56.photobucket.com/albums/g178/Lewisimo_69/Rallye26.jpg

And that's about it for now - doing all the small detailing type jobs for now until I have enough dough to crack on with the exhaust and wiring!

Lewis

[Steffrallye]

wow, didnt know you had already done so much to it, great work lad and is good to see ur taking as much care of it as well as attention to detail.

top marks :D

[benJee_VTR]

awesome, great attention to detail

[furio09]

that is one awesome lookung car pal

[Lewisimo]

cheers lads! I can't stay away from it currently I love it! :D

[AlexR]

Lewis where do you get your fasteners and fixings from? My place only sell huge bags and it starts to get expensive, i've spent £300 on various nuts bolts and washers :o

[Lewisimo]

normally use trident in silverstone dude. still expensive though!!

[leeroybrown]

Epic Fail

The pictures dont work you southern fairy!

[AlexR]

They did but the fanny has exceeded his bandwidth y0

Cheers Lewis. I think i'll stick to buying bags of 100 bolts lol It's suprising how quick they go!

[b0t13]

ah poo, i wanted to see these pics, unpassword ur photobucket lewis so we can browse ;)

[Ashleyp]

is it just me that the pics dont work for? lol although ive see pic's of hanks car before

[Lewisimo]

they should work now as i've deleted a load?? Anyone know anything about photobucket?

[moxy89]

your a whore



the car is awesome mate... good work i could only ever dream that i would have the cash to do that to my saxo

[S8TTG]

Car is perfect!

[willsy]

Cant compete with that, Its sheer perfection :)

[AlexR]

The problem was caused because photobucket dropped their limit for free users, i was over double the new limit so had to delete a load of pics :(
Solution? Register a 2nd album lol

[benwh555]

Totally awesome mate. I cant believe the amount of detail that has gone into this. Then again i read your black saxo thread and that was amazing as well.

[Lewisimo]

thanks boys! Now gone 'pro' on photobucket so the pics should work again now...

[Lewisimo]

Right lots of updates today. I fitted my AP's (total arse of a job) achieved with the help of 5mm spacers and a little grinding. Also installed my fuel lines in the bay, replaced my bonnet lifters as they were creaking, and removed my rear caliper as it was leaking like fuck (only realised when I pushed the car out of the garage and saw the stain on the floor from brake fluid, so that will need to be replaced at some point. Also perfected my throttle cable as it was a bit gammy before, and took a pic of my group N wishbones fitted too. Also fitted my carbon number plates, as the old one's were a little haggard! I will let the pics do the talking anyways.

Good morning little Rallye:

http://i56.photobucket.com/albums/g178/Lewisimo_69/Rallyeingarage-1.jpg

Old Bonnet Lifters removed:

http://i56.photobucket.com/albums/g178/Lewisimo_69/BonnetLifters01.jpg

New OE ones from Peugeot:

http://i56.photobucket.com/albums/g178/Lewisimo_69/BonnetLifters02.jpg

Linkage was fouling my fuel line fitting so i ground it down a little bit with a dremmel (such a handy tool!)

Before:

http://i56.photobucket.com/albums/g178/Lewisimo_69/ThrottleAssembleyPriortomodifica-1.jpg

After (tiny corner ground off for clearance):

http://i56.photobucket.com/albums/g178/Lewisimo_69/ThrottleAssembleyAftermodificati-1.jpg

Throttle cable sorted:

http://i56.photobucket.com/albums/g178/Lewisimo_69/ThrottleCable01.jpg

Throttle cable secured to bulkhead:

http://i56.photobucket.com/albums/g178/Lewisimo_69/ThrottleCable02.jpg

AP's brakes ground down a little (still need to touch them up):

http://i56.photobucket.com/albums/g178/Lewisimo_69/APCaliperGrinding01.jpg

Pads in (very easy) At this point the caliper was upside down so I swapped it after - doh!):

http://i56.photobucket.com/albums/g178/Lewisimo_69/APBrakePadsInstalled.jpg

Tight like a tiger!!:

http://i56.photobucket.com/albums/g178/Lewisimo_69/APCaliperGrinding02.jpg

http://i56.photobucket.com/albums/g178/Lewisimo_69/APCaliperGrinding03.jpg

All fitted:

http://i56.photobucket.com/albums/g178/Lewisimo_69/APCaliperGrinding04.jpg

[Lewisimo]

Mint new Earls Black fittings:

http://i56.photobucket.com/albums/g178/Lewisimo_69/EarlsFitting01.jpg

Fuel lines and filter installed (using hole already present in the bay, didn't have to drill anything!):

http://i56.photobucket.com/albums/g178/Lewisimo_69/FuelLinesInstalled01.jpg

http://i56.photobucket.com/albums/g178/Lewisimo_69/FuelLinesInstalled02.jpg

Return Line:

http://i56.photobucket.com/albums/g178/Lewisimo_69/ReturnFuelLine01-1.jpg

Group N wishbone:

http://i56.photobucket.com/albums/g178/Lewisimo_69/GroupNWishbone.jpg

New Carbon plates off Bic @ Streamline Carbon (thanks again!):

http://i56.photobucket.com/albums/g178/Lewisimo_69/CarbonPlate01-1.jpg

Leaking Caliper (Now removed):

http://i56.photobucket.com/albums/g178/Lewisimo_69/LeakingRearCAliper.jpg

New coilpack badge (there is a piece of paper on it here but you get the idea!)

http://i56.photobucket.com/albums/g178/Lewisimo_69/NewCoilPackBadge01.jpg

Bay as it stands now:

http://i56.photobucket.com/albums/g178/Lewisimo_69/EngineBayLAtest.jpg

[Liam_]

Awesome mate, just awesome! Bet you can't wait to drive it!

[D4N91]

i love this car :y: looks the mutts nutts buddy :)

[jdizzy]

very nice mate, and soooo clean :)

[benkelsall]

This car is a work of art! Gets better and better every day

Brakes are fooking close tho ay!

[AlexR]

Your engine bay is worthy of manjuice excretion :D

Keep it coming ;)

[jpsaxo]

Your getting there Lewis, just need to save up for that exhaust and loom now :D

[Lewisimo]

Lol cheers lads! :D Yes she is definitely coming on - it's like a big lego set, I love it!

A few more bits I want to do are as follows:

Lower the front more, which in turn means new springs etc, another fuck about. Get an alternator, get Rallye decals. New scuttle cover and wiper motor cover as the current one is a bit tatty (very noticeable when the bay is freshly painted!). Perhaps get lower profile tyres but thats on the long finger just now. Need the new exhaust and loom sorting primarily! These little jobs just crop up as you go along. Also need to deal with the holes that have been drilled by spank that I won't need anymore. I feel some carbon covers coming on!

More updates today anyway. I have done a hard days graft today again on the Rallye. Hank must have driven on a road that was recently resurfaced (in fact he told me he did) as the front wheels were literally COVERED in black tar spots and they wouldn't come off for shit, so i had to buy some 'muc off' tar remover from halfords to clean them up. It wasn't much good, and I had to spend an hour (per wheel) painstakingly cleaning each wheel and scraping the spots off with my finger nail...my hands are now killing me, but the wheels are like new again! I also P clipped in my clutch cable so as to allow room for my return fuel line to run along side without the risk of chaffing it etc. I also put a threaded insert in the back of the P clip fixing the fuel filter for ease of removal if i ever need to, as it was fiddly as hell with a nut a bolt. I also fitted a black bolt to it too, looks better now! :)

Some pics of the updates, and random shots too. The wheels look like they protrude loads in the pics but it's just the camera!

Engine bay:

http://i56.photobucket.com/albums/g178/Lewisimo_69/Rallyeupdate04.jpg

Brakes (prior to wheel clean I might add!):

http://i56.photobucket.com/albums/g178/Lewisimo_69/Rallyeupdate03.jpg

http://i56.photobucket.com/albums/g178/Lewisimo_69/Rallyeupdate02.jpg

Overall snap:

http://i56.photobucket.com/albums/g178/Lewisimo_69/Rallyeupdate01.jpg

Clutch cable P clipped in (bitch to do with engine in place - enter the dremmel again!)

http://i56.photobucket.com/albums/g178/Lewisimo_69/Rallyeupdate05.jpg

http://i56.photobucket.com/albums/g178/Lewisimo_69/Rallyeupdate06.jpg

Filter:

http://i56.photobucket.com/albums/g178/Lewisimo_69/Rallyeupdate07.jpg

[TU-Tuning]

Wow. Was stunning when Hank had it, its unreal now. Love it, as everyone else on here is Im green with envy haha. That engine is simply amazing. And the box is porn. Really like the wheels too.

Ive gotta ask though, and this isnt a dig, as amazing as this car is in both its spec and attention to detail, do you not ever get bored of throwing money at it especially on things like hose fitments theyre crazy for what they are, and never getting to drive it? One day youll run out of shiny things to buy lol, again this isn't meant in an offensive way but are you more into building stunning examples of cars than actually driving them to their limit?

I cant imagine this careering down the B roads or a track it would thrive on so intently, simply because things would get dirty after 5 minutes and youd need to buy new ones :P

[JamieB]

just had a quick read through mate, sounds amazing and the car looks stunning!

look forward to seeing the finished article!! :y:

[RichRap]

Fanatstic project, real credit to you:y:

The engine install looks great,

How about a proper pedal box and master cylinder setup to make the most of the brakes and would fantastic in the 'bay

[jimbo06]

It gets better and better and better :clapping:

Its by far in a way my most favourite car/project at this present moment in time, its class mate!

[rushy_23]

That bay is unreal.

Lewismofo you rock.

[Karl]

that is awesome.
put some rallye steels on it please!

[craigy_87]

is looking pretty amazing i do luv it :y:

with the tar thing on the wheels there is a product called "tardis" by autosmart just melts tar away :y: ..... for future reference of course lol

http://i45.photobucket.com/albums/f68/craigy_87/306005-1.jpg

[Lewisimo]

Lol now you tell me after I spent 2,5 hours cleaning my rims! :D Cheers though man, i'll bear that in mind for future :)

Oh steelies are WAY too small for my brakes dude!

[ricksimmonds]

i think this is my favourite car on saxp! absolutely amazing!

[Jamie]

This is the best 106 ive seen.

[Lewisimo]

Anyways yesterday I did some more work on the Rallye. I fitted my pug sport High tensile stud and nut conversion, touched up the calipers that I ground down (probably will redo them as they're still not 100% perfect, that's how we roll yo)! I fitted my new wish bone bolts too, so they're all hunky dory now.
I also finished P clipping the brake liness in with Stainless P clips. Added one more on the rear bulkhead to secure it more tidily - no pics of that as yet but will sort some soon.

Here's the pics anyway.

Wheel stud kit (front only until I can afford the rears!):

http://i56.photobucket.com/albums/g178/Lewisimo_69/WheelStudKit01.jpg

http://i56.photobucket.com/albums/g178/Lewisimo_69/WheelStudKit02.jpg

http://i56.photobucket.com/albums/g178/Lewisimo_69/WheelStudKit03.jpg

http://i56.photobucket.com/albums/g178/Lewisimo_69/WheelStudKit04.jpg

http://i56.photobucket.com/albums/g178/Lewisimo_69/WheelStudKit05.jpg


Bit of thread lock on them to ensure they don't work loose (they are screwed in very tightly but this is how you're meant to fit them):

http://i56.photobucket.com/albums/g178/Lewisimo_69/FittingWheelStuds01.jpg

All done:

http://i56.photobucket.com/albums/g178/Lewisimo_69/FittingWheelStuds02.jpg

http://i56.photobucket.com/albums/g178/Lewisimo_69/FittingWheelStuds03.jpg

http://i56.photobucket.com/albums/g178/Lewisimo_69/FittingWheelStuds04.jpg


Masked off the caliper to paint it (you can see the finished result in the pic above):

http://i56.photobucket.com/albums/g178/Lewisimo_69/CaliperPaint01.jpg

New wishbone bolts:

http://i56.photobucket.com/albums/g178/Lewisimo_69/NewWishboneBolts01.jpg

All fitted:

http://i56.photobucket.com/albums/g178/Lewisimo_69/NewWishboneBolts02.jpg

Will get some snaps of the brakes lines soon!

[DusheR]

very smart :y: looking good

[Lewisimo]

cheers bro! :D

[Lewisimo]

Oh I also took another few mm off the brakes prior to touching them up, so there is plenty of clearance now for them :)

http://i56.photobucket.com/albums/g178/Lewisimo_69/BrakeClearance01.jpg

http://i56.photobucket.com/albums/g178/Lewisimo_69/BrakeClearance02.jpg

[Colin]

Proper studs ;) SNAP! (not as in break lol)

Car looks epic dude, keep it up!

[Lewisimo]

Yea you get what you pay for, these are the proper one's for the job! Last thing I want to do is risk a wheel falling off due to a snapped cheap ass wheel stud.

Anyway some more updates last night. I finally took delivery of my top hose from Spoox (4 week lead time as it was made to order). Had to cut it down as it was too long but it's all fitted now and looks great - just need some decent hose clips to secure it each end. Also received my 120 degree fitting from earls to secure the return fuel line to the bulkhead connector so fitted that too - fits perfect! Pics below:

http://i56.photobucket.com/albums/g178/Lewisimo_69/NewTopHose01.jpg

http://i56.photobucket.com/albums/g178/Lewisimo_69/NewTopHose02.jpg

http://i56.photobucket.com/albums/g178/Lewisimo_69/NewTopHose03.jpg

http://i56.photobucket.com/albums/g178/Lewisimo_69/FuelLineBulkheadConnectors.jpg

And an overall snap of the bay, getting there! :D

http://i56.photobucket.com/albums/g178/Lewisimo_69/EngineOverall.jpg

[3cott]

This is car porn imo...

[Colin]

Yeah these studs are the best. I got the same with the tapered nuts. £200! Car looks the nuts dude!

[AlexR]

I just bought a stud and nut kit also, cost a little less than the pugsport kit. Hopefully my wheels don't fall off :o

Get yourself some stainless mikalor hose/exhaust clamps, they are where it's at. I'm rocking them on all of my coolant hoses now!!!

[rushy_23]

I love the attention to details Lewis, same as the Saxo.

The brakes are beautiful. But Im just really not feeling those wheels. I know you like them and all. I think some Mag Speedlines (2020s) would look the bomb on this car. Your car is mental so you may as well buy them. Oh thats imo by the way. :D

[AlexR]

I agree with rushy, i think some other speedlines should be tried

[rushy_23]

Alex did you ever get the prices of those wheels I mentioned to you? You bloody wasteman!

[AlexR]

Edit: PM'd lol

[wickedrob]

stunning

[CHIP]

I don't know how i've missed this car on here, but that is 100% stunning mate. The best finish of a modified car i have ever seen. Well done :y:

[Adam_Q]

Totally mental dude! Really really amazing!

I want that engine!!!!!

[Lewisimo]

A few more updates today...I started to fit all my little carbon covers to go over the OE 'holes' in the shell. I have gone about this in a practical way this time in contrast to the Citroen where I just siliconed everything into place. This time I have kept the covers that go over bolts etc (for the rear beam for example) removable so fitted threaded inserts and bolted the covers down. However the other ones that just merely cover holes have been secured using a few dobs of silicon as before. I also tidied up my harnesses, and also swapped the plastic P clips securing the brake lines for stainless one's to keep them in place a bit more firmly. It has also straightened them all up so they look a lot neater now! I fitted one more to the rear bulkhead too to pull the hose down a little more - I reckon it looks a lot tidier now.

One more think i did is remove the Safety Devices stickers from the cage back stays as i thought it looks a bit fussy before. Goes better with the blue and black theme too! I've obviously kept the one in the inside of the cage which states it's FIA approval etc etc.

Anyway here are some pics:

Carbon Covers (all hand made by me I may add!):

http://i56.photobucket.com/albums/g178/Lewisimo_69/CarbonCover01.jpg

http://i56.photobucket.com/albums/g178/Lewisimo_69/CarbonCover02-1.jpg

http://i56.photobucket.com/albums/g178/Lewisimo_69/CarbonCover03.jpg

Here's all the Carbon fitted, and you can just see how the brake lines are now also:

http://i56.photobucket.com/albums/g178/Lewisimo_69/CarbonCover04.jpg

http://i56.photobucket.com/albums/g178/Lewisimo_69/CarbonCover05.jpg

http://i56.photobucket.com/albums/g178/Lewisimo_69/CarbonCover06.jpg

Harnesses tidied up:

http://i56.photobucket.com/albums/g178/Lewisimo_69/HarnessesTidy.jpg

Stickers off:

http://i56.photobucket.com/albums/g178/Lewisimo_69/SafetyDevicesStickersRemoved.jpg

A little snap:

http://i56.photobucket.com/albums/g178/Lewisimo_69/Rallye.jpg

thats all for today!

[jamiemol]

WOW! this car is truely amazing between hanks work and your engine/box is THE best n/a 106/saxo around may i ask what your job is?:p

[Lewisimo]

Thanks mate. I work for an engineering firm, i'm no engineer though!

[5AMBO]

This car looks immense! I dont have a great deal of knowledge when it comes to spec but just the wheel and brake set up does it for me. Good work

p.s just seen a post on 106ralleye forum as well that you were selling the brake set up as it didnt fit. It obvioulsy did in the end and glad it did mate.

[VTomR]

awesome, just awesome. the best example of a rallye ive ever seen!

[jamiemol]

Thanks mate. I work for an engineering firm, i'm no engineer though!

well the work you have done looks to a very high standard i now want your job(as i want your car)lol are the windows polocarb? any future plans?

[Chappers2606]

Amazing project buddy!!

[gavbey]

i cant stop smiling, awsome lil pug

[_ELECTABUZZ_]

that is and always be my favourite pug haha :y:

[starletcal]

Love it mate, attention to detail is immense :)

[Firth]

Thats pure porn mate! Clean as fooook! U could eat ur dinner off it, love the carbon too, wish i ad that in my engine bay

[Sean_VTS]

Like its been said quite a few time before mate.

WOW

[Xsi16v_Jk]

Fuck me, that car is stunning!

:D

[S8TTG]

Car is perfect!
Love it

[RallyeMP]

Stunning basicly

[Raz]

Gorgeous car Lewis. It really is. I assume once you have sorted all the niggly bits you will be ragging this round track!?

[Lewisimo]

thats the idea although i'm already scared of it! :P thanks for the kind words too boys :)

[Saxo_Scott]

Love the attention to detail!

I prefer this than the saxo

[renagademaster4]

pure car porn :D

[VTSTomE]

Your attention to detail is unreal! Whens the expected completion date?

[gavbey]

absolutley stunning m8

[Lewisimo]

Yea not bad thanks mate - here's the latest!

Cheers lads!

Right a few updates tonight....firstly a disaster! I was making a little carbon panel for the alarm sensor in the roof where the interior light sits, and whilst drilling a hole the drill went through a bit too suddenly and dinged the roof a little, it basically looks like a little nipple on the roof from the outside but never mind... I will get it sorted and possibly weld over the ariel hole too as I can't be assed with that plastic grommet! FUCK!

Anyway, that's a small issue. I picked up a full set of OE Rallye decals today from Peugeot - I seem to be graced with a good/helpful local dealer as they only took a few days to arrive. I also bought some more hosing to fit my oil cooler, black stuff again as the braided stuff I got with it was too stiff to bend around the rad etc. Also, big news is that it's been picked up and is now in the Wire Wizard workshop being wired - so if it all goes to plan and it doesnt explode on first ignition then it should technically be working in 2 weeks or so! *fingers crossed* It still needs an exhaust mind so I won't be driving it for a while. To be honest I am shitting it - I just so hope nothing goes wrong and all the plans and hard work on the engine have been worth it!

[Mathias]

Im sure it'll be well worth it mate, best 106 ive seen by a while to be honest!!

Thanks for the help with the brake lines by the way ;)

[3cott]

This car is epic:y:

[7unner172]

stunning bud

wish i could do this to my rallye...maybe one day lol

[coffs_vtr]

i swear i saw this in peformance french cars mag?? did i lol

[moxy89]

yeah was simons car... the engine in that feature had 193bhp by sandy brown is it the same engine ?? car is fucking epic

[Lewisimo]

Yea I bought it off Simon without engine, brakes, seat, or steering wheel and i've fitted my parts (Si helped with the engine) and i've been adding my own touches. The engine is Bics old one, which I had rebuilt by Longmans - it's 207Bhp ;)

Few more updates anyway. As you know I had that heater matrix hose debacle a while back which Mankee eventually sorted out for me - here are some pics of the wrong type which I kept getting from Citroen (it's due to the plastic housing being different I eventually discovered) and some pics of the right one fitted courtesy of Mr Chang, the Chinese arms, I mean parts dealer! :D

Also nipped to Earls today to get my catch tank (thanks to Bruce @ COmpetition Supplies for coming up with the goods uber quick) and cheers to Ashley @ Earls for sorting out all the little adaptors I needed to run the pro lite hose. Also got decals too! So no more questions about that please! :D Here we go anyway:

Hose from Citroen:

http://i56.photobucket.com/albums/g178/Lewisimo_69/NewHose02-2.jpg

http://i56.photobucket.com/albums/g178/Lewisimo_69/NewHose01-2.jpg

Correct Hose from Mankee now fitted:

http://i56.photobucket.com/albums/g178/Lewisimo_69/CorrectHeaterHose01.jpg

http://i56.photobucket.com/albums/g178/Lewisimo_69/CorrectHeaterHose02.jpg

http://i56.photobucket.com/albums/g178/Lewisimo_69/CorrectHeaterHose03.jpg

New Decals:

http://i56.photobucket.com/albums/g178/Lewisimo_69/NewRallyeDecals01.jpg

New Catch Tank:

http://i56.photobucket.com/albums/g178/Lewisimo_69/MocalCatchTank01.jpg

Earls Adaptors and hose ends:

http://i56.photobucket.com/albums/g178/Lewisimo_69/EarlsAdaptor01.jpg

http://i56.photobucket.com/albums/g178/Lewisimo_69/EarlsHoseEnd01.jpg

Fitted Up:

http://i56.photobucket.com/albums/g178/Lewisimo_69/MocalCatchTank02.jpg

http://i56.photobucket.com/albums/g178/Lewisimo_69/MocalCatchTank03.jpg

Thats all for now...just waiting on Bob to finish my wiring now!

[Anthony]

Total sex mate. Nice attention to detail wish i had money like that to throw at my sax lol.

[CHIP]

I absolutely love this car :y:

[Liam_]

Looks class mate. :) That a Mocal catch tank? Where can I get one/ how much?

Cheers

[rushy_23]

Ahh so its Bics old engine. I was thinking that the manifold looked a bit "too" crazy!

Nice work as usual.

[Lewisimo]

cheers guys. Yea it is Bics one, was gonna keep it as a 'surprise' lol but never mind! Catch tank is from a supplier in Silverstone, £115. They've gone up in price as they're made in europe and the exchange rate is all fucked up now....

[AlexR]

Ghey :D

Been there with the denting the roof :( Forgot how little space there was and put a big screw into the roof panel with an 18v dewalt driver LOL Left a nice dint! Excuse for you to get a carbon roof panel? ;) Or are you just going for smooth aerial holeage and a roof respray?

[rushy_23]

Shit didnt even read the roof issue update. Ahh. CF me thinks ;)

[Lewisimo]

A few more updates today anyway...Bob @ Wirewizrds sent me a picture message of a few bits, new engine loom is now ready to go in, my fan has been fitted and also the oil cooler. You'll have to excuse the pics but like I said they are phone pics!

Loom (Work of art!):
http://i56.photobucket.com/albums/g178/Lewisimo_69/WireWizard.jpg

Fan:
http://i56.photobucket.com/albums/g178/Lewisimo_69/Fan.jpg

Oil Cooler:
http://i56.photobucket.com/albums/g178/Lewisimo_69/Oilcooler-1.jpg



Should be running soon hopefully!

[CHIP]

*Drools* Nice one mate :y:

[Toad]

This is exactly why I don't want to take any pics of my engine bay. Puts my car to shame :(

[turbotom]

Have read this thread like 3 or 4 times now and it gets better every time!! the attention to detail is am-az-ing! this car WILL be a show winner and its quite clear that nothing is been missed out!!

One thing ate, the bolts you use for the P clips on brake lines inside, are they a self taper bolt or are you drilling a hole and using nut and bolt?

keep it up!!!

[Claki]

looks amzing mate :y: Extreamly neat! love every inch of it.

[Lewisimo]

This is exactly why I don't want to take any pics of my engine bay. Puts my car to shame :(

Don't be silly mate - yours is mint in a different kinda way, track beast!

Cheers for the comments guys :)

Turbotom - i used threaded inserts dude!

[Toad]

Do you buy new bits every time you mug some old lady on the street? :D

Appreciate it mate. I need to do some cleaning though, that's for damn sure!

[jimbo06]

whats next for this then dude?...or is it all top secret

[Lewisimo]

Once the wiring is done i'll get the exhaust made, then it's ready to drive!

Toad - something like that mate lol! :p

Few more updates today - went over to Bob's workshop to fit my catch tank and breather pipes etc (with Bob's help) so I took a few pics. The loom is all fitted, alternator fitted, oil has been filled up in the gearbox, just need some engine oil (they ran out at Silverstone) and it should be ready to start on Tues - so fingers crossed! :D Massive thanks to Bob - the wiring is absolutely SEXUAL and it's so minimal you can hardly notice it. Really sets off the engine bay well. You'll have to excuse the turd pics as they're off my phone as I forgot to bring my camera over!

Loom and details:

http://i56.photobucket.com/albums/g178/Lewisimo_69/WizardLoom04.jpg

http://i56.photobucket.com/albums/g178/Lewisimo_69/WizardLoom05.jpg

http://i56.photobucket.com/albums/g178/Lewisimo_69/WizardLoom02.jpg

http://i56.photobucket.com/albums/g178/Lewisimo_69/WizardLoom01.jpg

Alternator in:

http://i56.photobucket.com/albums/g178/Lewisimo_69/RallyeEngine03.jpg

Catch tank done (thanks to Bic for his old mounting bracket) top man! :D

http://i56.photobucket.com/albums/g178/Lewisimo_69/RallyeEngine02.jpg

http://i56.photobucket.com/albums/g178/Lewisimo_69/RallyeEngine01.jpg

[Sean_VTS]

Awsome again Lewis. Cars such an insperation mate.

[rushy_23]

Job of the wiring looks brilliant. Sounds like a very indepth job to get it to that standard?

[Lewisimo]

Thanks boys!

Rush - yea it's an entire new engine loom job, all made from scratch from individual strands of cable so yes, big job, but worth it though! :)

Few more little updates - got my new 6" coilover springs off Tommy to try (cheers dude!) and some snaps of the manifold downpipe to show the 'girth'! :D It's actually 2.5" not 3"!

Springs:

http://i56.photobucket.com/albums/g178/Lewisimo_69/NewCoiloverSprings01.jpg

Downpipe:

http://i56.photobucket.com/albums/g178/Lewisimo_69/Manifolddownpipe01.jpg

http://i56.photobucket.com/albums/g178/Lewisimo_69/Manifolddownpipe02.jpg

http://i56.photobucket.com/albums/g178/Lewisimo_69/Manifolddownpipe03.jpg

http://i56.photobucket.com/albums/g178/Lewisimo_69/Manifolddownpipe04.jpg

[Toad]

Awesome. :D

Didn't see those pics before.

Can you tell me a little more about the loom work and the folk doing it? I've got loom everywhere, a right mess. :(

[rushy_23]

The loom looks great doesnt it Toad. The level of detail in this car is unreal. Im sick of saying it.

[Strikevts]

Pure Greatness, you must be really happy to own such a smart and clean car like that. Top job well deserved mate

[raunchz]

Looking amazing!! You got the engine going yet? Must be almost there!!

[Lewisimo]

Thanks very much again lads. If all goes to plan we'll be starting it tomorrow...i'm shitting myself! :D

Toad, the loom is around £1500 all done by Bob of Wirewizard (he owns and runs the company himself). I will say it's the best £1500 i've spent, it makes such a huge difference to the bay - also protects all the cables from the heat so functional too. I'd get one on your engine you'd love it.

[Olly]

Very nice wiring! Just wish it was cheaper to have it done! :p

Think it suits the car though!

[Phsyco_Paff]

Lost for words...............

[Toad]

I would love it, but I just can't warrant such a cost unfortunately. If only I had a sponsor. Haha. :D

[Lewisimo]

Lol we all need one of those mate! :p

Cheers guys.

Right, serious update tonight......it's alive! :D

Went over to Bob's to do a few more bits and pieces, fitted my new powder coated PAS bracket and battery tray, and Bob started it up again so I could hear it running. He had already got it running in the week but said he wanted to do that when I wasn't there as I worry too much! :D Well my word it sounds so crazy, I cannot wait to have a drive of it! Few minor issues, we're still waiting on an oil pressure sensor, and it's running super rich at the moment which I think is partly due to the bodies being out of balance slightly. Bob has a tool to sort this out which he should be able to do next week. He's also done my front brake lines leading to the calipers so it's really making progress now. Again a huge thanks to Bob for all his hard work so far, really pleased. One slight bogey is I seem to have a tiny bit of oil seepage from the Oil cooler sandwich plate so I suspect it's been over tightened - either way it's a tiny amount, so i'll sort that when I do the first oil change. Don't want to be wasting the current oil at over £60 a pop! :rolleyes: The plan is to get the exhaust made up next, then probably get the map tweaked so it's not so rich - I felt high as a kite after being in the garage with the engine running for ten minutes - my eyes were burning too! :D I got a couple of pics and 2 vids to whet the appetite - all I can say is it's going to be naughty once it's driveable! I had another video of it really revving up but my camera ran out of memory halfway through so it lost the info..never mind. Got some slightly better photo's of the wiring job too. We also need some more hose retainers to tidy the lines to the catch tank but we're on the case with that too...all in all i'm dead pleased/excited!

http://i56.photobucket.com/albums/g178/Lewisimo_69/RallyeGettingThere01.jpg

http://i56.photobucket.com/albums/g178/Lewisimo_69/RallyeGettingThere02.jpg

http://i56.photobucket.com/albums/g178/Lewisimo_69/RallyeGettingThere03.jpg

Video 01:

http://s56.photobucket.com/albums/g178/Lewisimo_69/?action=view&current=RallyeAlive01.flv

Video 02:

http://s56.photobucket.com/albums/g178/Lewisimo_69/?action=view&current=RallyeAlive02.flv

[Wayne]

Awesome news Lewis:D absouletly love it:hug: bay is immense, whole car is just stunning:)

[raunchz]

Great news, almost ready for the road!!!

[Sean_VTS]

Awsome news about it running Lewis!

Cant complain atal despite the little problem with the oil but it hasnt seemed to knock you atal which is great!

Always keep a close eye on this!!

[Toad]

Videos asking for a password.

[Sean_VTS]

Videos asking for a password.

Glad it wasnt just me!

1st one yea Toadus?

[Toad]

Yeah...

[Andy_K]

Absolutely awesome Lewis. Everytime I look at thread I'm just in awe, and am constantly spotting new little details.

Just depresses me because I know mine will never be up to the same standard :(

Keep it up though. The 1st drive will be special :y:

[Lewisimo]

Thanks very much guys - appreciate the kind words!

Here is the first video again, wouldn't work via photobucket...

http://www.youtube.com/watch?v=ypPbJwSmFOQ

[Steffrallye]

:y: great work, wish i could make mine become half as beautiful as this :fcuk:

[Lewisimo]

thanks mate!

[jimbo06]

Sounds nice just at iddle, god knows how good it will sound when your giving it some. Its gonna be savage mate :panic: lol

[Lewisimo]

Lol yea it should be a screamer! :fcuk: Really cannot wait to drive it!

[Toad]

Lol yea it should be a screamer! :fcuk: Really cannot wait to drive it!

What are you waiting for!!?? :D

[Lewisimo]

....money to buy an exhaust! :P

[J222JRA]

Awesome car, sounds awesome in the video. That engine bay is perfect!

[rushy_23]

Money to buy an exhaust lol.. Get printing more of those £20 notes!

Cant see the video as Im at work but great stuff Lewis.

[Andy8v]

Amazing car Lewis, thought the Saxo was great but this is in a different league.

[Toad]

£1500 on cables, but forgot to budget for an exhaust. Opps. lol. ;)

[tjbaker91]

Amazing car mate, can not stop reading all of the work that has gone into this engine off your threads. Real inspiration dude, im going to work triple if not quadruple time so i can try and follow in your footsteps :)

[Lewisimo]

thanks again boys - it's getting there!

Few more updates today - spent most of the day driving all over the place to collect stuff i'd bought. Firstly my STACK dash (from a genuine 106 Maxi works car, hence the pug logo) which I had to collect from a couriers depot over an hours drive away...then to collect my new rear caliper that I won on ebay for 85 quid - they are just shy of 300 new so bargain!! Then nipped over to Bob's to drop off said items, then back home to modify my crank sensor I bought on ebay - purely to cover the exposed area in the gearbox. So I knocked out the sensor and made a little carbon cover for it - looks mint and will be functional too - sweet! Also wire wooled the brake caliper carrier from the old caliper and painted it black. Should be heading over to Bob's again tomorrow to get these bits fitted. ALso waiting on some info from STACK so we can wire in the dash - tedious customer service from them I tell ya...
Bob sent me a pic of it powered up tonight and I so hope we can get it working as it's mint!

Pics:

Dash:

http://i56.photobucket.com/albums/g178/Lewisimo_69/NewStack01.jpg

http://i56.photobucket.com/albums/g178/Lewisimo_69/NewStack02.jpg

http://i56.photobucket.com/albums/g178/Lewisimo_69/NewStack03.jpg

Stack in my van anyone?! :D

http://i56.photobucket.com/albums/g178/Lewisimo_69/VWVanwithSTACK.jpg

Dash powered up:

http://i56.photobucket.com/albums/g178/Lewisimo_69/StackWorking01.jpg

New Brake Caliper (Rear - genuine pug/cit):

http://i56.photobucket.com/albums/g178/Lewisimo_69/NewCaliper01.jpg

http://i56.photobucket.com/albums/g178/Lewisimo_69/NewCaliper02.jpg

Carrier painted up:

http://i56.photobucket.com/albums/g178/Lewisimo_69/CaliperCarrier01.jpg

My modified crank Sensor:

http://i56.photobucket.com/albums/g178/Lewisimo_69/ModifiedCrankSensor.jpg

It's getting there slowly - more updates soon!

[m8davem8]

how fast will this go now then?

[Andy_K]

Loving the Stack display Lewis. Is that from that guy over in Blackpool?

[Lewisimo]

cheers mate! No he's in lancashire!

The answer to the other question is: very fast....

[Andy_K]

Ah right. I'd read your posts on Rallye Reg re. the bloke from near Blackpool with the Maxi. I got my rods off him the other week - really really sound bloke.

[rushy_23]

Each update is a work of art.. :S

[turbotom]

was the stack off pistonheads? i saw one on there few weeks back!! that is going to look quality!!

[Lewisimo]

yea it is mate - although i've been talking to that guy for a while now about rally car parts as he owns a maxi himself.

[jpsaxo]

Love the stack Lewis, may have to invest in one myself... tempted to get bob to do my loom over next winter as well!

Missed the updates of the start up, great news, bet your well excited now :D

[Lewisimo]

thanks mate! Yea i'm stoked, although i'm currently having clutch probs, as in it won't work!

Check this thread:

http://www.106rallyeforum.com/forum2008/showthread.php?t=69293


You should get yourself a wizard race loom though for sure, so nice!

[raunchz]

Sounds like the release bearing.

I fitted a new clutch to mine, ran it for 15mins, then when I came to change gear/reverse out of the drive I had no clutch and selecting gears wasn't possible - adjusted the clutch a lot and only just could get gears.

Took the box back off and the release bearing had melted - if I had knocked it off the clutch fork prongs or it was just a bad one - who knows. Put the old one back on and was fine.

[Lewisimo]

ok cheers dude, that may be the case. Some of the other boys on another forum have mentioned that because it's an AP twin plate clutch it may need the release bearing spacing out to release the clutch properly. May have to ring GMC tomorrow lol.... apparently they modify theirs for the super charged cars..

[raunchz]

ok cheers dude, that may be the case. Some of the other boys on another forum have mentioned that because it's an AP twin plate clutch it may need the release bearing spacing out to release the clutch properly. May have to ring GMC tomorrow lol.... apparently they modify theirs for the super charged cars..

Sounds logical - GMC will be spot on with an answer to the problem !

[Mathias]

Jealous of the stack - was gutted i couldn't get the cash together quick enough for the last one you sold :wall:

Not long now till its on the road then?

[Lewisimo]

well that's if the clutch issues dont slow things up mate!

[Ryan]

wheres this shiny black knob you like in your hand then? :homme:

[Toad]

I remember seeing that dash in Bic's thread a while back. Great piece of kit, but like most things in your car Lewis, shockingly expensive. I'm sure you're up to no good you know... :detective:

[Lewisimo]

Lol Toad - No I just up to the hilt all the time mate!

Ryan - still hasn't arrived dude! :p

Fuck if I need to buy a new clutch i'll regret buying the stack....for a short while!

[Ryan]

lol buying bits then something fails, I had that on friday, spent a good couple of grand on camera shizzle, then later that day smashed a wheel up in some potholes (3-4cracks)...

wrong day for it to have happend :(

[LEE_VTR1]

lewis your a whore. love the progress though and the standard that you get things done too :)

glad I'm not the only person with clutch issues though lols, hope all goes well for you mate

[Lewisimo]

I have the wonrg type of release bearing it seems, so a new clutch and flywheel assembly seems the easiest route to sort the problem...fucking nightmare, and an expensvie one!

[Ryan]

I have the wonrg type of release bearing it seems, so a new clutch and flywheel assembly seems the easiest route to sort the problem...fucking nightmare, and an expensvie one!

Im just using a valeo ;)

[Toad]

Me too :)

[Ryan]

Me too :)

lol, quite a few NA boys have come back to valeos and in some cases they last longer than expensive helix's etc..

[LEE_VTR1]

I have the wonrg type of release bearing it seems, so a new clutch and flywheel assembly seems the easiest route to sort the problem...fucking nightmare, and an expensvie one!

great minds think alike there lewis, turns out I may also be using an incorrect release bearing so atm I'm trying to source a light and balanced flywheel and a nice simple valeo clutch had one fitted in my saxo a while back felt great nice and smooth not heavy just perfect :)

[Toad]

The problem I've had with my last 2 clutches is the springs fail. I've never even come close to wearing out the plate. Weird.

[Lewisimo]

I don't have a problem with the clutch, or the flywheel, it's the fact my release bearing is the wrong type for my clutch - i'm having to get one custom made by a place in silverstone. So again a huge thanks to Bob for sorting that all out, I really couldn't do it without having him involved with the project. My other plan was to revert to a standard flywheel if I couldn't get a release bearing as the a standard clutch wouldn't work on my flywheel as it's a kitcar type..

http://i56.photobucket.com/albums/g178/Lewisimo_69/ClutchFlywheel.jpg

[unreal106]

good work lewis that photo look porn tbh really good shot!

[Toad]

Flywheel? Sure you didn't install an Aerobie by mistake? :D

[LEE_VTR1]

I was thinking the same thing dave it's not really a fly wheel lols more of a thin sheet of metal.

looks so good though :D

I was always under the impression though lewis you need a crank sensor, unless with standalone management you don't and can rule it out

[LEE_VTR1]

on another note aswell lewis give me your speedlines please I would like a set

[AlexB]

ill swap flywheel and clutch with you dude lol!


looks good man as usual the attention to detail is top notch
i loved this before tbh but since youve owned it its gone to another level
shame theres not much rallye left to it but hey its still an amazing car :y:

[Lewisimo]

Lol - it is a 'thin' flywheel alright lads! :P

Lee - my crank sensor is on the other side - takes the reading of the bottom pulley ;)

Cheers guys - think this problem is kinda sorted now. Gearbox had to come off the car, Bob did a lot of messing around to sort it out...to cut a long story short we're getting a proper release bearing made up by a place in Silverstone so hopefully it'll work come the weekend! Total pain in the arse and more money on my bill, but what can you do - facking cars! :D

Here were my updates prior to the clutch crisis! :p

Area of gearbox that required covering:

http://i56.photobucket.com/albums/g178/Lewisimo_69/Gearbox01-2.jpg

Cover fitted (Modded crank sensor):

http://i56.photobucket.com/albums/g178/Lewisimo_69/Gearbox02-1.jpg

http://i56.photobucket.com/albums/g178/Lewisimo_69/Gearbox03.jpg

Caliper fitted:

http://i56.photobucket.com/albums/g178/Lewisimo_69/RearBrake01.jpg

http://i56.photobucket.com/albums/g178/Lewisimo_69/RearBrake02.jpg

Rallye during 'surgery':

http://i56.photobucket.com/albums/g178/Lewisimo_69/RallyeOperation01.jpg

http://i56.photobucket.com/albums/g178/Lewisimo_69/RallyeOperation02.jpg

New black Quaife type gearknob (Quaife don't do a black one so this is a copy - just as good though!) Everyone is getting white so I wanted a change:

http://i56.photobucket.com/albums/g178/Lewisimo_69/BlackQuaifeKnob01.jpg


Thats about it for now - hopefully we'll have some good fortune/progress come the weekend.

[jimbo06]

Yet more top work :y: hope the rest all runs smoothly for ya dude.

Really really hope this is at some shows next year, would love to see it in person...its quickly turned into my favourite car in the whole 'scene'

[Ryan]

ooo your big black shiny knob must feel so good in your hands :homme: lol!

[Bickerton]

Looking mint matey, yet another decent progress blog i have managed to miss till recently ;)

[Lewisimo]

Cheers guys, appreciate the kind words :)

Lol Ryan, ooo errr it does too! :P

[raunchz]

lol, looks amazing !!! So close to being on the road !!!!

Will be hard to keep it this clean with the weather as it has been the past few weeks!!

[Bickerton]

lol, looks amazing !!! So close to being on the road !!!!

Will be hard to keep it this clean with the weather as it has been the past few weeks!!

A clean car is only a jet wash away ;)

[raunchz]

loool very true

[Ryan]

A clean car is only a jet wash away ;)

in my case a dirty car is driven for months until my mother decides she wants to go wash the fleet :D

[miamibluebaby]

looks awesome as allways top job!!!!

[E3D]

:o looks so sweet!

[Liam_]

Looks awesome man - nice to see it finally coming together. :)

Might just be me, but are the brake pads not the wrong way round. I'm pretty sure the pad with the notch slots into the piston?

[Lewisimo]

Cheers boys - she won't be coming out in any 'inclement weather' that's for sure, it'll be tucked up in a warm dry salt free garage! :D

[Liam_]

Just checked and the pad with the lug should be against the piston mate - see here (http://www.peugeot206cc.co.uk/repair-206/206/info/gb/b3fg24k3.htm). Not sure if it makes a great deal of difference?

[Lewisimo]

not sure what you mean dude?

[Liam_]

http://i56.photobucket.com/albums/g178/Lewisimo_69/RearBrake01.jpg

That pad at the front with the lug on it should be facing the piston bud. :) Could swap the pads over but not sure if it makes a difference.

[Ryan]

Cheers boys - she won't be coming out in any 'inclement weather' that's for sure, it'll be tucked up in a warm dry salt free garage! :D

I allways knew youe wouldnt drive this just ponse about in your garage with it :D

[rushy_23]

As silly as it sounds, driving this thing would be a sin.

Belongs indoors only.

[Colin]

Just checked and the pad with the lug should be against the piston mate - see here (http://www.peugeot206cc.co.uk/repair-206/206/info/gb/b3fg24k3.htm). Not sure if it makes a great deal of difference?

Yeah that lug slots inside a cut out on the piston to stop the pad coming out and loose.

Keep up the work Lewis :y:

[AlexB]

I'm sure some pads all 4 have the bits on
hence the clearance in the carrier to accomodate it
so he may have it right as
and colin I thought it was to stop the piston winding back in not holding the pad?

[Lewisimo]

Cheers for the tip boys - I will get the pads swapped over :)

Lol, I will drive it, but just not in shitty weather!

[Colin]

I'm sure some pads all 4 have the bits on
hence the clearance in the carrier to accomodate it
so he may have it right as
and colin I thought it was to stop the piston winding back in not holding the pad?

Either or ;) but yes its a locating lug and to stop it winding back :y:

[CHIP]

Lol, I will drive it, but just not in shitty weather!

As said, it would be a sin to dude. I cleaned my car yesterday and then it pissed it down when i went to Sheffield last night. I was guttered, actually didnt want to drive it. And my car's no where near as nice and clean as yours. (Washed car again today... let's hope it dont rain lol)

EDIT: It rained :( lol

[Lewisimo]

Thanks Gentlemen! :D

A bit more news tonight - Bob rang yesterday, and aftter winding me up a bit by saying it still wasn't working, he conceded and told me that he mangaged to sort the clutch. This was after fitting the new bearing and spacer made up by Mardi Gras, and having to remove the box AGAIN as it still wasn't biting properly. SO, took it off again, took another 5mm off the spacer and re-assembled it all, now it works! :afro: He took it for a road test on sunday avro just to check everything, and he said 'it goes well' and it's loud as fuck (especially without a full exhaust) lol :P So the program for this week is get the dash wired in, and all being well it should be coming home on sunday. Just need the exhaust making up then and she's good to go. I cannot wait to drive the poxy thing! :

[Bickerton]

Thanks Gentlemen! :D

A bit more news tonight - Bob rang yesterday, and aftter winding me up a bit by saying it still wasn't working, he conceded and told me that he mangaged to sort the clutch. This was after fitting the new bearing and spacer made up by Mardi Gras, and having to remove the box AGAIN as it still wasn't biting properly. SO, took it off again, took another 5mm off the spacer and re-assembled it all, now it works! :afro: He took it for a road test on sunday avro just to check everything, and he said 'it goes well' and it's loud as fuck (especially without a full exhaust) lol :P So the program for this week is get the dash wired in, and all being well it should be coming home on sunday. Just need the exhaust making up then and she's good to go. I cannot wait to drive the poxy thing! :

Not gonna drive it in the wet are ya? ;)

[Lewisimo]

nope! :homme:

[Olly]

Awesome news Mate! :d Hope it all goes well!

[CHIP]

Good stuff! It'll feel great when you finally get to drive it complete :y:

[LEE_VTR1]

great news lewis :D hows it feel knowing someone drove your car before you after all the time money and effort involved between buying from hank and fitting all your parts etc?

its going to be a weapon i know it though :D

[Lewisimo]

Lol i'm a bit envious but still...at least I will be safe in the knowledge that it works properly! :D

Cheers boys...not long now! Should be home on sunday *rubs hands together* May nip over to Bob's on thursday night too so I can give it a quick test drive...probably won't be able to drive it I bet! :D

I rang him again this evening - it's got new spark plugs now (old one's were quite fouled up) - gawd knows why Longmans didn't change them the cheap cunts, especially as my bill was over £1200! Bodies are now all balanced properly, she starts up lovely and idles nice, goes well too. Apparently the gearing is majorly short though so i'll have to see how I get on with it. That can be the next project! Bob is starting the dash wiring too tonight (STACK) so should be able to get some more decent pics on thursday eve. I'm excited now! You almost loose interest when you don't see it for ages, and have problems (like the clutch etc) but i'm starting to get stoked on it again now! :D

[Ryan]

As silly as it sounds, driving this thing would be a sin.

Belongs indoors only.

lol what a load of tosh, spend several grand on bits to make it go fast and not use them? :homme:

[rushy_23]

This car isnt about spec in my eyes. Its about the attention to detail!

Its actually disgusting how clean this car is.

[beaver28]

this car is epic!!!
did you have the engine professionally re-built?
such a mint car mate!!

[Lewisimo]

Lol, it's still not as mint as your hair do Rush! :P I will of course be driving it, but it will be well looked after and cleaned a lot etc. Afterall, it's a lot of money 'invested' in it too. It's a toy for me but also something that's taken me a lot of time and effort to create (what with the years invested in the saxo etc). I see it as a part of my life if that makes sense...sounds sad but it's years of my life in these french shit boxes!

[Lewisimo]

this car is epic!!!
did you have the engine professionally re-built?
such a mint car mate!!

yes by Longmans.

[Toad]

You are a little whore Lewis. :D

I reckon you will give it around 5 hours of cleaning for every 1 hour it gets driven!

[jpsaxo]

You are a little whore Lewis. :D

I reckon you will give it around 5 hours of cleaning for every 1 hour it gets driven!

Prob even more than that?!! Lol.

I was like that with mine once it was built, after a while you want to enjoy the thing for what its been built for i guess

[Toad]

I want to do the same with mine, but 1) I seem to have so little time nowadays, and 2) The weather has just been so bad. I really want to get a lockup like Lee and Matt have.

[jpsaxo]

Same Dave, Once im back this time next year im going to find somewhere local to store the car as its not going to be used in the winter at all!

[beaver28]

updates?

[dean1992]

Nice work
Bet your happy with it

[betty02]

Bump deserved here lewis, remember reading through your saxo progress years back thinking nothing will ever beat it, in fact sure i saved pretty much every picture and showed it my mates who were into cars and we just drooled all over it, then what happens? You got buy a mint 106 and make it ever better and dare i say miles miles miles better then the Saxo.

No expense spared anywhere on this project and it is just truly amazing attention to detail is top class. Has to be the car of the year for the next 5 years by the sounds of it.

Can't wait to read and update Lewis buddy keep it up!