[POST 1]

Had the car since December 2005, had a fair few issues with it over the years. The last year or two have been the easiest.... oh and Lynx Motorsport Supercharged it for me in April 2008, if you didn’t know already it was the first Rallye to get Supercharged by them.

End of June I decided my engine bay needed a bit of a clean up, and wanted to sort some wiring issues, all in preparation for a full blow over respray sometime in future.

Bought:

Quaife limited slip differential fitted in a gearbox (second hand, gbox with less miles than mine).
Timing belt kit and water pump
Clutch + clutch cable.
Gearbox oil + seals.
Nissen radiator and new hose to suit.
Camshaft sensor (few month old).
Thermostat, seal + thermostat housing.
Galvanised wishbones with new ball joints bushes fitted.
Group N engine mounts all round.
New CV boots fitted to my reasonably good conditioned driveshafts.
Oil catch tank.
K&N.
Rust remover (Deox Gel).
Zinc primer (put in name).
New bearings into my tensioner pulley, and two pulleys.
Few of primer, Bianca white and lacquer rattle tins.
Lots of new bolts and plastic clips from peugoet


Started stripping the engine out, got excited and forgot to take before pictures.

most of the dates on the pictures and videos are wrong/inconsistent so i have tried to put them in an order that makes sense... to me.



Bit rusy:





Can see wires here, not normally as obvious but I want to hide them.


Hoist in



Engine out,… with help from friends.





Rust looking even worse



Got top mount buffer off and discovered this



Then began using the Deox Gel to remove the rust!

This is after a few applications, I tended to put it everywhere then leave it a day. Pull the car out of the garage with my works van then pressure wash it off.













This is what happens after 2/3 days of leaving it on.







This is a spare slam pannel, my orginal one was pretty rusty. This one got same treatment





Date : August 2010, changed links due to Photobucket fail

________________________________________

TEAM HIGH BOOST SUPERCHARGED RALLYE

My Rallye project thread

[POST 3]

Newer Gearbox with LSD fitted in it



Timing belt done





Engine back together, also put on powder coated fuel rail



Got more bits powder coated









Forgot to show engine mount repair…

before:



after:



Some white primer Bianca white and lacquer… few days between each.













Days after the lacquer, engines ready to go back in









Few bits back on







Date : August 2010, changed links due to Photobucket fail

________________________________________

TEAM HIGH BOOST SUPERCHARGED RALLYE

My Rallye project thread

will add more tomorrow

________________________________________

TEAM HIGH BOOST SUPERCHARGED RALLYE

My Rallye project thread

awesome dan... just what the astor needs as last winter didnt treat it too well!

next time your travelling give me a shout i need a garage door fitting!

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Team Supercharged Gti-6

NV Motorsport
Automotive Performance Tuning
0121 448 7515
ECU Remapping/ DPF removal
VAG/BMW Diag and Option Coding
Peugeot Planet ECU coding/transponder programming etc
www.nvmotorsport.com
Facebook Page
Project S6

thats a bit random
how do you know that i work for a garage door company?

Chris, something up with my old engine loom. Broken wire/wires or solder touching where its not ment to. Have to replace Toms engine loom i used too

________________________________________

TEAM HIGH BOOST SUPERCHARGED RALLYE

My Rallye project thread

Good work keep it up.

Out of intrest did you change your charger fluid mate? and when you got a filter for charger oil how much did Rich charge for them or did you source your own 1?

also how rusty was it was mate, my rallye isint near as bad as that yet like an never been looked at before, must be the salty roads up north lol

luving the brembos to mate, looking good mate.

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In my garage just now

2003 BMW M3 & 2009 L200 Raging Bull
& Audi Q5 S Line
AX stock rod & Saxo Stock rod
Sold the bike an charged rallye an bought a caravan, midlife crisis or what!

okay


emm chris, i didnt change charger fluid as i had already done it like less than 10 month ago

i got a filter from a company RichW told me to phone, iirc they are around £10 to £15

and yeh it was pretty rusty, this was my road over a year ago, used to struggle to get car down it its a lot better now.

________________________________________

TEAM HIGH BOOST SUPERCHARGED RALLYE

My Rallye project thread

Russ's house is the 1 with a million old school phone and post boxes in it !!

ive just got my coilovers on but not sure how the main nut tightens

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In my garage just now

2003 BMW M3 & 2009 L200 Raging Bull
& Audi Q5 S Line
AX stock rod & Saxo Stock rod
Sold the bike an charged rallye an bought a caravan, midlife crisis or what!

[POST 6]

Fitted a cleaner one of these



Cleaned the brembos up



Started putting things back on










Still a few wee bits i want to do, i managed to break my 12v when taking my dash apart to give it a lick of paint plus TRE's and drop links then tracking at a garage

Was planning rigging the horn on my Momo Race steering to a second horn or something, cant really be arsed now happy to have it back on the road after lots of money spent

LSD is a worth while investment at low boost id say, torque steers a little bit more Cars feels a bit more easyer to accelerate, doesnt spin quite soo much in the wet, not that it was bad with standard diff...

heres how it was looking this morning, outside really needs a clean, that second hand bumper i bought off here a while ago is a mess!



Date : August 2010, changed links due to Photobucket fail

________________________________________

TEAM HIGH BOOST SUPERCHARGED RALLYE

My Rallye project thread

Great work and excellent pics and write up

The rust remover looks like good stuff

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Red GTB1756 powered Fabia VRS daily driver,LBSC Gti6 eater........

Mac1 ZR R1 kit car build in progress.

[POST 7]

Started in January in some pretty crap weather, with help from this:



I managed to get track rods off reasonably easy

Passenger side


Got it off from underneath, from here I knocked off the old cover using flat screwdriver and hammer, it was in bits by time I got it off, luckily I bought new ones for whole rack



Old and new



Using boiling hot water to soften the rubber ; I got the new cover on with decent amount of difficulty



Drivers side, really needed heat here, plus rack on full lock (had already removed the rubber gaitor here, was easier than passenger side)



Off



Old and new



And on



Car wasn’t road worthy by this point but this is when you go get your tracking done straight away.

will try and find more time to upload more later

From : January 2011, changed links due to Photobucket fail

________________________________________

TEAM HIGH BOOST SUPERCHARGED RALLYE

My Rallye project thread

Stunning

I love my China, but always wanted a white rallye

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Chris
1999 China Gti6 Supercharged [Fun car] >>Project Thread<<
2000 Bianca 306 Diesel [Work runabout]