Mark, thanks. I assume part 35 is the bit ive circled and kt the bit im after?

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Cherry Red Rallye .... On going OEM spec resto

China Blue GTi6 .... Weekend toy

Black 208 GTi .... Wife's car now

Silver BMW 550i.... The executive missile

I looked at this and the drawing is not very clear.

To me it looked initially as though 14 goes on top of A and includes the cross-member people jack on (same with B and 15). But then I looked at it again and it looked as though you were correct, and that it is the inner bit next to the tunnel as 14/15 appear closed at the end, meaning they would not fit over A and B.

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Cherry Rallye SOLD

Didnt get as much done as i thought i might this weekend, but i still made some progress....

So, Saturday i was intending to go to the gym first thing. Can i make it clear i was intending to? One or two ciders more than the prescribed friday 'youve got the gym in the morning' limit meant i might not have made it.....forgive me!

I went to the local Post office collection depot to pick up a parcel (my shell fixings kit) and then shot over to my parents to start and drive their cars as they are in Australia for 3 months. Then came home for a brew.

Now, my intent was to get the underside done with the epoxy mastic. Again, intention....i ended up going through the fixing kit and putting notes in bags as to what was what and then trying to sort the garage out as ive a buggy and pretty much most of a 306 in there....in the end, i sorted a load of 306 stuff, emtpied the buggy of 306 stuff and got its battery on charge and then spent time time drinking with a few of the other kids parents in the sun as we watched our kids play in the cul-de-sac....

Today, the forecast wasnt great so started by washing off 2000 miles of crap from the daily GTD. Got that finished and the rain arrived......and then stopped an hour later and the sun came out so i mixed up a batch of epoxy mastic and got busy. Started and completed the passenger side rear arch and the went onto the underisde.

Despite me using a non thinned batch of mastic, im still not happy about using a brush. It feels wrong, given the level of finish im trying to achieve. The finish levels domt look too bad but im not happy with them. Ive been in touch with a mate who paints stuff for a living about spraying the mastic. Ive a 150cfm compressor available if i need so lm looking at spraying the mastic rather than using a brush. Bilt Hamber do something called flatface which appears to be a super high build primer that sits well over the mastic and should get rid of any brush marks.

A few pics:













[url=https://ibb.co/mVm81n]
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Cherry Red Rallye .... On going OEM spec resto

China Blue GTi6 .... Weekend toy

Black 208 GTi .... Wife's car now

Silver BMW 550i.... The executive missile

No interior other than a passenger seat and dash. All the other panels still attached.

________________________________________

Cherry Red Rallye .... On going OEM spec resto

China Blue GTi6 .... Weekend toy

Black 208 GTi .... Wife's car now

Silver BMW 550i.... The executive missile

Ben looking at what you have done to the under side of the car in all honesty i would completely start again from scratch. I'm a paint sprayer and to be honest the look doesn't look good at all I realise you have brushed it all on. But here Is a tip for you. You don't gave to take any advice from me but this is how I would do it. Get it all blasted off now you have it on a jig. Once blasted go around cleaning and grinding what needs to be done. Next would be to put 2 coats of etch primer not to thick. Then stone chip and of course the red gloss. Here's is another tip people seem to think the more paint or stone chip you put on the better protection. In fact the more you put on the worse it will be for example if the paint gets damaged the moisture will sit in the damaged part more and sit there longer. More paint doesn't mean better protection. If you did it the way I have just explained you wouldn't be chasing your tail all the time and also this is the quickest and best way to get the look you are after. Sorry if I sounding a bit brutal

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http://www.306gti6.com/forum/showthread.php?id=163869

No it won't make it Smooth it will make it like a texture finish but flat. It would look like the finish you see on the sills on some cars. And it's also to do with how you put the stone chip on also I would give it one light coat of stone chip then red gloss on top while the stone chip is still wet. I know what ive said above sound harsh but if ben is looking a good finish to the under side of the car this is the way I would do it also. Plus it's a lot cheaper

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http://www.306gti6.com/forum/showthread.php?id=163869

Touching on the stone chip, I found a very good 3M product previously. Part of their bodyguard range.

Never been a fan of the wavy finish you get with a lot of stone chips. 3M do a flat finish stone chip which leaves a very good finish. I've only found it in aerosol cans so far, I'm.trying to find if they do it as a sprayable version as I seem to recall they did.

I'd appreciate any feedback you may have on that lot Lee, especially the stone chip. I can find sprayable cans of 3m (I assume with a Shultz type gun) but they continually make reference to a textured finish. Is it possible to alter gun settings to reduce the texture to flat as much as possible?

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Cherry Red Rallye .... On going OEM spec resto

China Blue GTi6 .... Weekend toy

Black 208 GTi .... Wife's car now

Silver BMW 550i.... The executive missile

Typed Upol stone chip into google and found this video which looks like the same stuff. The guy's an amateur but looks like he's done an OK job (the pros may think differently!)

Ben, would you consider this? It comes in grey as well and it's over paintable. It's not a smooth finish but looks regular instead of brush marked.

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1999 GTi-6 (china blue)
1999 Rallye (black)

Someone on DW mentioned foam brushes. You could blot the mastic on application to give a somewhat stone-chip looking finish - better than brush marks and a lot easier than spraying something with a hardener in it.

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Cherry Rallye SOLD

Just when you thought you were getting somewhere, in we step with the 'oooo, I wouldn't have done it like that' comments

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1999 GTi-6 (china blue)
1999 Rallye (black)

Not updated this for ages.....fair few things.

Firstly, i managed to break my windscreen, with the car on the jig, i dropped the bonnet holding the plastic sheeting over the engine bay and broke the screen. Seriously annoyed as it wad the original screen, VIN stamped and everything. Managed to find another properly Rallye screen at a dealers in Anglesey.







All the genuine Peugeot markings, apart from the VIN....

Decided i would replace both bent, mangled stiffener panels. Finding them was easier said than done. A dealers in Belgium said they had a pair, but could only find one when they looked.





Located another, which turned out to be the same side as this. The search for the drivers side continues.

It became apparent fairly quickly that removing this panel was exactly the right thing to do. Drilling spot welds around the section where it wraps around the main chassis leg was interesting....lots of rust coming out. I knew it wasn't great, this had me worried though.













I eventually drilled though enough spot welds (and the floor in a couple of places.....) to enable me to get a cold chisel between panel and chassis leg. The metal was so thin and brittle, it took next to no effort to split it and peel it back. Yuck. Chassis leg appears solid, although I won't know for sure until the panel is fully stripped off but the inside of this panel is rusty too. As said, I'm happy I've taken the decision to strip it off.









The other side of the car is worse. It's already been patched previously to me owning it. It's a tidy job but there is double skinned section very near a subframe mount which looks very rough indeed. It's a double skinned section and I can see the second layer....red circled bit...



It took a while and it was a pig of a panel to get off, but its off.







Appears only the panel itself was the rusty/rotten bit. Chassis leg has some surafce rust and a very small amount of pitting but other than that, is all good underneath. New panel fits well, which to be honest, i guess you'd expect being a peugeot panel.














Then onto the next job. Still have the servo I took off the 6 I broke. One in the Rallye currently isn't great at all cosmetically so decided to clean this one up and will replace the one in the car with this.

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Cherry Red Rallye .... On going OEM spec resto

China Blue GTi6 .... Weekend toy

Black 208 GTi .... Wife's car now

Silver BMW 550i.... The executive missile

Have copied and pasted my last two posts from DW as forgpt to update here too.....

Today, having watched the last half hour of Le Mans (really got into that this year….watched it late into the night last night, loved it!) and having done all the fathers day stuff (including going to see my dad, who wasn't in, and landing sunday dinner cooking duties!!), i got to play a bit with the Rallye.

Started out by doing a test section on the underside where i wet sanded the zinc primer. Like the small section of Epoxy mastic, im not happy with the brush marks in the finish. BHs guide say it can be wet sanded to a point. Im planning on wet sanding and then asking my mate if he can spray the new 1ltr tin i have (again, can be sprayed if thinned correctly). I'd like a really decent finish on the underside too. Not sure if i'll have to wet sand too much of the original coat to the point it wont protect properly so as i've got some more, i'll get it sprayed on. Didn't get any pics of this although i'm sure you've all got an imagination

Next step was to get rid of some more of the blast media that still seems to in there. This inside the inner wing.



A slight opening up of the panel and out it came.

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So with that done, i decided to move onto the heater fan….thanks to Mr Blaster who just seemed to shove the nozzle anywhere, including fan air intake, the fan was full of media. Joy. So i started by popping out the glovebox (pain as the hinges have two plastic pins needing removal, one of which you need to be a contortionist with the hands of a 5 year old to get to. Removed eventually. Popped the rubber cover off the power & earth wires and media is peeing out already. Not good.



Wires removed. You can see around the joint line on the fan unit and on the bracket i removed the evidence of the matrix failure.



What has someone been doing to the wiring? I need to chase this back further and see what is what...



The fan innards…..yuck.








This is what came out of it….



Evidence of the previous (known about) matrix failure



Then, the piece de resistance…. I had a look at the bulkhead and though hmmmm, sound deadening looks a bit odd. Because it is. Someone has been at it with a stanley knife.



Couldn't figure out why, until i pulled the carpet forward. WTF is that i thought? Very quickly dawned on me that someone has drilled the bulkhead. Ill guess to run a power cable to the boot for some stereo gear, i can't think why else, unless its had a battery relocation done at some point in its past (i know it was stripped to be a track car) but havent found anything else to suggest this is the case



The offending bulkhead hole.



So a little more welding to do and more parts on the shopping list. Ill test the fan motor on the bench but might put a new one in for good measure. The housing it sits in has clearly been prised open as the two halves don't go together properly and clips are broken. Pain to change that and i may well yet have the dash out completely. Need to chase back that fan wiring and see whats what and im half tempted to chuck another matrix in it while the dash is out.Did a bit more to the Rallye today. Since finding what i found previously, its becoming more obvious the dash needs to come out. But for now, it was about removing the passenger seat and carpets.

First job was to get it off the jig again as i need to be in and out of the car frequently. Not doing that with it on the jig so for now, its back on axle stands again and with it back in terra firma, out came the seat and i got busy on removing the carpet. Centre console comes out first and the first thing i find is a broken mount.





Not the end of the world but maybe something else to replace. With that out, i undid the dash mounts at the base of each A pillar and removed door seals. Little surface rust underneath but nothing to worry about.





Then removed the front carpet. First thing i noticed is that its been cut in half and it's in two pieces rather than one. Not a huge issue as you cant tell once everything is in and it's perhaps easier to remove. The foam backing to the front carpet sections was very wet though, so they are in the back garden drying out. Interesting there is a polystyrene section under the drivers side carpet which goes under the footrest to the left of the clutch pedal.



Then the lump in the floor from being jacked in the wrong place..



The bigger surprise was the passenger side floor. The sound deadening was already cracked and lifted but taking out the body plug, which had been sealed in, revealed it hadn't sealed very well at all…..



The bigger surprise was yet to come…..i pulled up the bottom of the bulkhead sound deadening to find…….



A 13mm ring spanner thats clearly been there for some time! And then, on removing the rear carpet….



A T10 torx bit! I know this car has been apart before but leaving tools in it? Well, ill take them.

So, with all the carpets removed, there was plenty of mess to clean up.





I took the opportunity to have a look at the seat pretensioner wiring for the driver's seat. This is the one i had to cut off from the seat and, i suspect, the cause of the airbag light on the dash. Interestingly, the drivers side wiring has an odd date code, 18/10/1999, which leads me to think this has already been replaced once as its different to the date on the other side, and, manufactured after the car was built.




Still, it will be replaced again and see where we go. Theres also plenry of evidence of it being poorly put back together at some point. Hacked fittings, and thats assuming they actually bother to do the nuts/bolts/screws up etc...



There isn't a huge amount else i can do right now until i find this other stiffener panel, which still hasn't appeared anywhere. I may well investigate and see if this panel is common across the 306 range (im hoping so and cant see why not?) and may try and find a shell with one still intact. No point having any of the welding work done until i know what's happening with that.

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Cherry Red Rallye .... On going OEM spec resto

China Blue GTi6 .... Weekend toy

Black 208 GTi .... Wife's car now

Silver BMW 550i.... The executive missile

Jesus, good job! Came up really well!