hi gents decided to do a little project thread on my newly acquired white Rallye

(


so I drove down to Exmouth or there about a month or so back on a Saturday to go to buy
took my wife and daughter on a trip to the sea side and picked up the rallye

having agreeing a price with the then owner who assured me all was well with the car mechanically etc (under no illusion it would be a mint one and not expecting great things )

got there only to find a poor old dirty white rallye neglected and suffering at the hands of its recent owners

sufficed to say I didn't pay the asking price the guy wanted 1800
after an in depth discussion about the state of it I drove it away with a considerable reduction

the list to date is as follows:

the seats are worn n tatty so will be replacing them
the bonnet is dented beyond reasonable repair
the rear bumper will need replaced
the front bumper is cracked but salvageable
the suspension is soft and needs replacement
the rear beam is iffy in which I mean allows a lot of bounce not sure why yet ??? it has solid mounts and had been refurbished possibly just requires new dampers
the key barrel return spring is broken
it has a third party immobiliser with fobs that I want gone
the running gear bushes etc are all soft n bolloxed
the front lights are tatty and scarred
and the paint is possibly the worst ive seen with regards to ingrained dirt
the engine was pretty bad also not sure it was firing on all four cylinders
and possibly has knackered big end bearings
plus other issues of the usual nature scratched internal plastics and the front windscreen jet washer didn't work

the major bonus to this little gem is that the shell is almost rust free no previous welding has the usual rear of the front arch jacking / non jacking point bent metal but it has not split the steel and has no rot / rust

and so is a great starting point for a proper renovation

all considered and working from the view point that I want to restore as a project and get around to fully restoring her all of the above although not great really wont matter one I'm done

so I jumped in after parting with the cash and drove straight to the petrol station limping all the way there on fumes filled her up and set of on the three hour drive home fully expecting to not make the full distance

the wife and daughter where in my daily not with me )



she was almost screaming in pain as I pulled away the starter motor rattling the exhaust blowing from many places
possibly firing on only three cylinders the engine rattling and chocking as I accelerated the steering wheel juddering away
but in true British fashion we battled on in hope that all would be ok

about ten miles into my journey she began to pick up the exhaust began to quieten down the fourth cylinder appeared to kick in and all the vibrations began to settle as she picked up a stride
staying at low speed and not putting undue force into the old girl I hit the motor way stuck on some tunes slipped on my shades and dug in for the long haul

all seemed well for around 100 miles when the nocking began slight at first and with the increasing distance travelled getting worse
so I found a services and pulled in to check the oil , sure enough she was low so I topped her up let her cool a little before setting off again

as I pulled away various vibrations had returned and the exhaust was noisier than ever

thought to myself lets just do it having much unquantified faith and strongly believing in the force !! new we had a chance

any how a few long hours later pulled onto my drive rattled tired and smelling of old burnt oil and a dodgy air fragrance that was hanging in the car reflected on my drive home now considering that it could of been much worse and how valiantly she had done to make it considering her condition and decided to call her !! Valliant !!

________________________________________

BLACK RALLYE - phoenix
WHITE RALLYE - valliant

http://public.servicebox.peugeot.com/

https://www.gov.uk/check-mot-history

]so this week came and after handling a very busy bank holiday weekend set of in her once again with a car full of parts tools some cans of coke and some crisps for sustenance

I set of north to go and fit the new engine the engine was a very low mileage vts engine benefiting from new gates belts water pump valeo clutch many good quality hose pipes pas pipe new clips al round sensors etc etc attempting to create a quality long lasting finish

the existing engine was leaking oil from various points it seemed was very dirty and had may bodges and alterations it required many new and replacement bits









even down to an altered loom bodged pipes after removal we realised it was a mk1 engine and was not original to the car nor was the loom and gearbox

I later discovered that this car had been professionally modified at around 25k and at a guess had blown its engine not to long after and had the subsequent replacement all this I believe will have happened early in its life and left in storage hence the s**tty paint and the lack of rust and corrosion and the random workshop looking dents to the bonnet





oddly she did have a new clutch and the cam belt had been done within the last couple of years it seemed the aux belt was not new and looked very close to snapping boggles the mind ???

________________________________________

BLACK RALLYE - phoenix
WHITE RALLYE - valliant

http://public.servicebox.peugeot.com/

https://www.gov.uk/check-mot-history

whilst the engine was out I did manage to get time to spruce moose the engine bay to get the small amounts of surface rust and old flaky paint

upon taking the old engine out it became apparent the engine mount cup had fractured not rotted at all just broken up this I put down to the incorrect engine mount that had been fitted at some point it was half the size of the 6 mount and would of been allowing a massive amount of movement causing the fatigue and subsequent failure

having not anticipated this due to the lack of general corrosion we had no immediate plan for repair so I cut a spare steel plate to size panelled it into shape cleaned it all up and booked is a welder to come over and weld it in
my welding skills are limited 10 years back I considered my self as quite good but didn't fancy beginning again on such a task







I would love to have had a proper plate made to the exact but given the time allowance and available material it worked out quite well and gave a good solid base to mount to

________________________________________

BLACK RALLYE - phoenix
WHITE RALLYE - valliant

http://public.servicebox.peugeot.com/

https://www.gov.uk/check-mot-history

once everything on the engine was swapped over and all was set ready to go we proceeded to insert the new engine it went in nicely with no drama the other mounts where set installed then all bolted in and the crane removed



a shiny new ish rad some new clips
]

the cowling cleaned



a cleaned and polished slam panel



then it was just the rest to refit

the more keen eyed reader will have noticed the overspray on the various wiring shrouds yes sloppy I know much has since been removed and cleaned off and the rest will stay as additional atmospheric guarding

the heat shield at the bulk head and on the back of the engine was purchased some months back from our very own PUG306
I know he has more of these and they are now modified to fit well I forgot the fit this before putting the engine back in but with a little manoeuvring it slotted in the bottom left bolt was a pain but could be reached from underneath with the wheel off some nifty finger work and a ratchet spanner the others where fairly straight forward

they look superb and are a massive improvement from the original

she now drives beautifully and sets me up nicely for the running gear replacement I plan to remove the sub frame next
replaced the arb bushes clean and paint the frame and all the lower parts I couldn't easily get to this week

________________________________________

BLACK RALLYE - phoenix
WHITE RALLYE - valliant

http://public.servicebox.peugeot.com/

https://www.gov.uk/check-mot-history

Nice car and project but that welding on the cup looks shocking

________________________________________

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

Cheers guys

________________________________________

BLACK RALLYE - phoenix
WHITE RALLYE - valliant

http://public.servicebox.peugeot.com/

https://www.gov.uk/check-mot-history

I've got to weld mine up at some point as soon as a buy a new genuine mount

________________________________________

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