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Author Subject: 99rallye's Clubsport
99rallye

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Location: Hitchin

Registered: 26 Aug 2009

Posts: 348

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Post #126
Wilde Haren wrote:
Impressive list of mods! Where did you get that flywheel and how light is it and do you notice the difference?


Mine was purchased from Pug1off. The car had a lightened flywheel in it when I bought it but I refreshed it with the below. The difference was minimal, becauae they were both lightened, but I'm pleased I changed it because the teeth were pretty worn.

https://www.peugeot-tuning-parts.co.uk/~cn49882a/306-gti6-billet-steel-flywheel-s16-lightened-balanced-peugeot.html
Posted 22nd Apr 2020 at 08:27
Wilde Haren

Newbie

Location: Utrecht

Registered: 10 Sep 2018

Posts: 28

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Post #127
Thanks! I've had my eye on that one too. Have you ever driven with a standard non-lightened flywheel and how do those compare? How is the quality of the P1 flywheel in your opinion?
Posted 22nd Apr 2020 at 12:28
pug_306

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Location: Great Hockham

Registered: 28 May 2013

Posts: 1,593

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Post #128
Spoox are cheapest for these I believe. Great upgrade.

________________________________________

1998 Supercharged White Rallye
1992 205 GTi6
205 Turbo 340bhp
Posted 23rd Apr 2020 at 19:27
99rallye

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Registered: 26 Aug 2009

Posts: 348

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Post #129
Time to get this thread back up to speed! At the end of 2018 My wife decided she wanted to change career and start her own dog grooming business from home. Which, given it was a complete voyage into the unknown doing it from home meant that she could quickly find out if she liked it or not, and if it was going to be profitable without a huge amount of investment. However, it did mean that being the supportive husband I am (!?), I had to give up the garage and the Rallye’s home for a length of time. So I moved it back to my parents house in Leicestershire but on the 2hr drive home it overheated twice and looked like it was burning oil. In the 11 years of ownership it had never overheated, so I knew something was properly wrong, and I’d noticed it was using a bit more oil than usual a few weeks previous.

After diagnosing that it was a blown head gasket, and lacking in time and space I got the Rallye recovered and sent down to the guys at Pug1Off to be repaired. While there my man maths brain went into overdrive…..What else would make sense to do while the engines apart? I went from a full engine rebuild with throttle bodies and solid lifters (argh, the sound!) all the way to just replacing the engine (I don’t need anymore power do I, I just need something reliable to get laps in!). So, while I’m saving for a cage, and as with most life choices I ended up somewhere in the middle with a cylinder head rebuild, Catcams 4903106 and a Pug1Off remap which I thought gave the most bang for the buck. During the rebuild Matthew said that there looked like there was some staining in the bottom of two of the cylinders where water had been sitting, and that it might need the bottom end looking in the future.

20190630_061417 by Nick Buxton, on Flickr

When I picked up the Rallye I was really impressed with how it drove. Since I’d had it there had always been an issue with it getting bogged down at very low revs in high gears, and chugging. This was completely solved and it now excitedly revved so much freer all the way to 7,300rpm. It felt like a new engine and the uncorked potential it should have come with from the factory; in terms of spend Vs performance I’d highly recommend it. The engine now felt like it was brought up to the same level as the chassis and drivetrain.

The next big trip out for the Rallye was to Pugfest where Pug1Off very kindly asked me to join their stand. It’s been a few years since I’d been so I was happy to get back there with a fully functioning car that I was happy with.

20190630_131726 by Nick Buxton, on Flickr

There were so many interesting cars there but here’s a handful of my favourites.

20190630_104720_HDR by Nick Buxton, on Flickr

20190630_104534 by Nick Buxton, on Flickr

20190630_102959_HDR by Nick Buxton, on Flickr

20190630_103831 by Nick Buxton, on Flickr

The Spoox 205 really is something to behold.

20190630_121143_HDR by Nick Buxton, on Flickr

20190630_122215_HDR by Nick Buxton, on Flickr

20190630_122508 by Nick Buxton, on Flickr

Stef’s 205 is such a wonderful build. It was great to see it in real life again

20190630_122650_HDR by Nick Buxton, on Flickr

Nice to see Goldie.

20190630_123043 by Nick Buxton, on Flickr

This guy has got a pretty good Instagram charting his build (axleblackjack)

20190630_123114 by Nick Buxton, on Flickr

After a couple of hours car perving I managed to get a slot on the weigh bridge that had been sneakily set up towards the top of the hill.

20190630_110307 by Nick Buxton, on Flickr

20190630_111621 by Nick Buxton, on Flickr

I haven’t had it weighed since I’d removed some more interior and fitted the carbon bonnet and boot so I was interested to see what difference it had made. It was previously 1,075kg on the scales at Brands

20190630_182731 by Nick Buxton, on Flickr

So if I believe both scales are correct I’d lost 20kg which I was pretty happy with. I think I had an extra ¼ tank of fuel on this occasion, but I’m not particularly chasing a goal weight (although being sub 1,000kg would be nice) so any added lightness is a win. What I thought was interesting was how balanced the car was in general; 51% cross weight. Has anyone else had theirs corner weighed like this? I’d be really interested in how it compares to other 306s.

The final highlight of the day was meeting Ben on the Pug1off stand who owns the 106 that won “Best 106 Rallye”. A very nice guy, and I spent a while talking cars and pouring over his 106 which was a very deserved winner of the award, it’s beautifully finished and maintained.

20190630_132840_HDR by Nick Buxton, on Flickr

20190630_132829_HDR by Nick Buxton, on Flickr

20190630_132817_HDR by Nick Buxton, on Flickr

Given my plans for a rollcage as the next big evolutionary step for the Rallye, I paid close attention to his design, fit, finish and what he’d done to the rest of the car to make it feel so complete. It gave me lots of inspiration.

The weather for Pugfest was amazing and it made the drive home a joy but as we got closer to home the engine started getting noisier and noisier. The temperatures were good so I knew it wasn’t anything to do with the headgasket. It was the end of a long day so I didn’t know if my ears were playing tricks on me, I put it back in the garage and came back to look at it a few days later. Even after letting it warm up and enough oil circulate around the cam lifters and rest of the engine it was still tapping more than ever. It sounded more like a bottom end failure which was annoying given that the top end had just been apart, but not completely unexpected.

So off it went again back to Pug1Off to have it looked at. The eagled eye’d will also notice my tool box and matting out of the garage in the photo. After months of dog grooming in my precious garage I took the opportunity to give it a really deep clean with the jetwash Smile.

20190330_165240_HDR by Nick Buxton, on Flickr

Matthew and Pug1Off indeed diagnosed piston slap on cylinder 3 and the big end starting to fail on 2 so it was torn down for machining, new sleeves, bearings, cambelt, waterpump and fluids. All to standard spec.

While the Rallye was away getting the work done I went to Caffeine & Machine in the M3 for the first time with some friends and family.

20190525_123606 by Nick Buxton, on Flickr

20190525_143153_HDR by Nick Buxton, on Flickr

If you haven’t been I’d highly recommend it if you get the chance, it is a wonderful place for any automotive geek. The founder describes it as a physical car forum, and it feels like it with an amazing array of cars, bikes and memorabilia. It’s one of those rare places you could take your misses or family members who aren’t really into cars and they’d enjoy it...and you get to indulge in more car perving.

When I got the Rallye back I had a very patient 120 miles of only 4,500rpm running-in to do, which I managed to get in across a couple of trips to see family, and a drive out with the local car club.

20190608_092157 by Nick Buxton, on Flickr

20191117_093418_HDR by Nick Buxton, on Flickr

Despite not being able to drive it as spritedly as I would of liked it felt tight, fresh, and better than ever.

20191006_132337_HDR by Nick Buxton, on Flickr

With all the slow driving and time away from the Rallye I’d had some good time to consider what sort of cage would suit it. I couple of years ago I spoke quite seriously to JCWeld Fab about fitting a cage and I’d decided that, unlike most other parts on the car, I should invest in the best cage I could afford because A) it’s a safety device that needs to look after me and other occupants B ) it’s not modular, it’s part of the structure of the car that will be difficult to change in the future and C) the 306 isn’t a light car so any added weight needs to be kept to a minimum.

After a lot of website searching and forum reading I decided that a weld in, multipoint cage would be the safest and strongest option and T45 would keep the weight down. I also learnt during my second researching pass that JC Weld Fab had sadly closed, but Jonathan put me in touch with CustomCages and after some more backwards and forwards I settled on a 306 Challenge Multipoint cage in T45 which they would fit.

So just as COVID-19 lockdown hit I found I had some more time at home to strip the Rallye down and get it to CustomCages.

20200322_171649 by Nick Buxton, on Flickr

20200331_165216 by Nick Buxton, on Flickr

Stripping everything in a single car garage with limited space was a good test of patience but I was very pleased not to find any nasty hidden surprises.

20200331_165257 by Nick Buxton, on Flickr

It also gave me a good opportunity to clean some of the parts of the car that don’t often get any love, like the rear light pockets.

20200407_093253 by Nick Buxton, on Flickr

20200407_104009_HDR by Nick Buxton, on Flickr

I spent some time prepping the interior for when it comes back and before it goes to get painted (colour TBC). I want to get rid of any of the brackets that are no longer needed so I got a spot weld remover to remove the rear seat brackets….on some of them I went a little too deep which will need repairing.

20200404_104731 by Nick Buxton, on Flickr

20200404_122249 by Nick Buxton, on Flickr

The glue that held the headlining to the roof skin really annoyed me so I spent probably far too long cleaning it off, but I plan on getting the whole interior painted once the cage is in so it will be worth it in the end.

20200331_161658 by Nick Buxton, on Flickr

20200331_165104 by Nick Buxton, on Flickr

Then it was packed off to CustomCages for it’s new climbing frame

20200423_130404 by Nick Buxton, on Flickr
Posted 25th May 2020 at 09:53
Joep

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Location: Urmond (The Netherlands)

Registered: 19 Sep 2013

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Post #130
Looking good!

As I am also stripping my track day car, can I ask you some advise?

What did you use to get the roof skin glue removed?

Thanks!

________________________________________

My car park:
'96 Sigma Blue XSi6
'98 Diablo Red GTi6
'99 Onyx Black S16

All RFS powered!

Plus various other Peugeots
Posted 25th May 2020 at 10:12
99rallye

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Registered: 26 Aug 2009

Posts: 348

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Post #131
Hi Joep, I used about 500 rags, a lot of elbow grease and Autofinesse ObliTARate https://www.autofinesse.com/en/oblitarate-500ml which is really good stuff
Posted 25th May 2020 at 10:39
hovis16

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Location: Reading/parts for sale

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Post #132
That a good weight without cage. Mine is 1104kg with just under half tank.
Crossweight of 49.07 with carbon bonnet skin partial strip cage and small sub and amp. Removed a load of tar and fitted cut down bracket recently so should of saved myself some more weigh

________________________________________

Ph2 Black GTI 6!

EX black 6 owner
But now a Black caged rallye owner

Hunting for Go faster bits!


SEARCH

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Posted 25th May 2020 at 11:01
Joep

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Post #133
Thanks! Looks the same as HG Sticker remover from the description. Have a bottle of that at home, so will try that first.

________________________________________

My car park:
'96 Sigma Blue XSi6
'98 Diablo Red GTi6
'99 Onyx Black S16

All RFS powered!

Plus various other Peugeots
Posted 25th May 2020 at 11:01
99rallye

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Registered: 26 Aug 2009

Posts: 348

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Post #134
Hi Hovis, that is interesting thank you. I'm interested to see some more total weight and cross weight stats from everyone else. I know 306s handle well but I'm surprised they are that well balanced.
Posted 25th May 2020 at 18:25
hovis16

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Post #135
99rallye wrote:
Hi Hovis, that is interesting thank you. I'm interested to see some more total weight and cross weight stats from everyone else. I know 306s handle well but I'm surprised they are that well balanced.


Yeah not bad at all I see you run more psi in the front than the rear where as I'm the opposite

________________________________________

Ph2 Black GTI 6!

EX black 6 owner
But now a Black caged rallye owner

Hunting for Go faster bits!


SEARCH

click here
Posted 25th May 2020 at 19:06
eiei0

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Post #136
Hi can I ask what size and offset are those wheels please,

Cool cars have had a quick read over it and it's a tidy motor,

Thanks
Posted 25th May 2020 at 20:24
blandy

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Post #137
Looks stunning as always Thumbs up

99rallye wrote:
Hi Hovis, that is interesting thank you. I'm interested to see some more total weight and cross weight stats from everyone else. I know 306s handle well but I'm surprised they are that well balanced.


Mine is was corner weighted at 1029 (with 100kg in seat) and around 10-15 lites fuel on board.
Posted 25th May 2020 at 20:57
hovis16

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Post #138
blandy wrote:
Looks stunning as always Thumbs up

99rallye wrote:
Hi Hovis, that is interesting thank you. I'm interested to see some more total weight and cross weight stats from everyone else. I know 306s handle well but I'm surprised they are that well balanced.


Mine is was corner weighted at 1029 (with 100kg in seat) and around 10-15 lites fuel on board.


More weight to be removed from mine

________________________________________

Ph2 Black GTI 6!

EX black 6 owner
But now a Black caged rallye owner

Hunting for Go faster bits!


SEARCH

click here
Posted 26th May 2020 at 08:14
Joep

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Location: Urmond (The Netherlands)

Registered: 19 Sep 2013

Posts: 463

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Post #139
eiei0 wrote:
Hi can I ask what size and offset are those wheels please,

Cool cars have had a quick read over it and it's a tidy motor,

Thanks


Let’s see if my wheel knowledge is getting better:

Think those are flat-faced MO5’s.

________________________________________

My car park:
'96 Sigma Blue XSi6
'98 Diablo Red GTi6
'99 Onyx Black S16

All RFS powered!

Plus various other Peugeots
Posted 26th May 2020 at 08:27
blandy

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Location: Bucks

Registered: 25 Feb 2007

Posts: 2,437

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Post #140
hovis16 wrote:
blandy wrote:
Looks stunning as always Thumbs up

99rallye wrote:
Hi Hovis, that is interesting thank you. I'm interested to see some more total weight and cross weight stats from everyone else. I know 306s handle well but I'm surprised they are that well balanced.


Mine is was corner weighted at 1029 (with 100kg in seat) and around 10-15 lites fuel on board.


More weight to be removed from mine


my last one was no where near that weight as was 1000kg unloaded whereas this one is 929kg unloaded. only gripe is could'nt get to 50% cross weight with driver so sat at 51% as run out of height adjustment on the front left coilover
Posted 26th May 2020 at 15:09
99rallye

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Registered: 26 Aug 2009

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Post #141
Yes, they are 16inch Speedline Challenge. They are a set offset which I can't remember but you can find it of you search for the Peugeot fitment. They look very similar to MO5's!

eiei0 wrote:
Hi can I ask what size and offset are those wheels please,

Cool cars have had a quick read over it and it's a tidy motor,

Thanks
Posted 27th May 2020 at 20:11
99rallye

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Registered: 26 Aug 2009

Posts: 348

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Post #142

I’ve got some exciting pictures back from CustomCages. I’m really happy with how tight the design hugs the roof and pillars.

DSCN2576 by Nick Buxton, on Flickr

DSCN2575 by Nick Buxton, on Flickr

DSCN2583 by Nick Buxton, on Flickr

DSCN2584 by Nick Buxton, on Flickr

DSCN2585 by Nick Buxton, on Flickr
DSCN2709 by Nick Buxton, on Flickr

It looks like a really tidy route through the bulkhead to the front suspension towers.

DSCN2711 by Nick Buxton, on Flickr

I can’t wait to get it back.
Posted 28th May 2020 at 20:23
blandy

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Post #143
That’s looks brilliant, proper bit of kit
Posted 28th May 2020 at 20:32
eiei0

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Location: Kildare

Registered: 08 May 2020

Posts: 192

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Post #144
Thanks for the reply there is no info on that site to say what the offset is just the will be best fit??

If you have the wheels off anytime soon could have a look and report back,

Trying to find out what 16" wheels fit is proving tricky,


99rallye wrote:
Yes, they are 16inch Speedline Challenge. They are a set offset which I can't remember but you can find it of you search for the Peugeot fitment. They look very similar to MO5's!

eiei0 wrote:
Hi can I ask what size and offset are those wheels please,

Cool cars have had a quick read over it and it's a tidy motor,

Thanks
Posted 29th May 2020 at 15:10
hovis16

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Location: Reading/parts for sale

Registered: 21 Nov 2008

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Post #145
Oooooo big big cage. Think of the weight added hahah. Looks great mate. Need to get my front bar welded as it seems fatigue as got to it and spit were it bolts up Sad

________________________________________

Ph2 Black GTI 6!

EX black 6 owner
But now a Black caged rallye owner

Hunting for Go faster bits!


SEARCH

click here
Posted 29th May 2020 at 20:03
Day666

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Location: Bristol

Registered: 20 Apr 2013

Posts: 5,206

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Post #146
Looks fantastic Nick Thumbs up
Posted 29th May 2020 at 22:21
99rallye

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Registered: 26 Aug 2009

Posts: 348

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Post #147
Well I got my garage ornament back from CustomCages and I must say I'm really pleased with the job they've done.

20200528_180442_HDR by Nick Buxton, on Flickr

20200528_181845_HDR by Nick Buxton, on Flickr

20200607_140641 by Nick Buxton, on Flickr

20200607_140659 by Nick Buxton, on Flickr

I've had a bit of a delay with getting it and the interior painted. The body shop I wanted to use has changed management and I'm not confident they'll do the Rallye justice. So I'm now looking for someone who'll be up to the job.
Posted 7th Jun 2020 at 17:29
hovis16

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Location: Reading/parts for sale

Registered: 21 Nov 2008

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Post #148
Love looks wicked mate

________________________________________

Ph2 Black GTI 6!

EX black 6 owner
But now a Black caged rallye owner

Hunting for Go faster bits!


SEARCH

click here
Posted 7th Jun 2020 at 17:47
hovis16

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Location: Reading/parts for sale

Registered: 21 Nov 2008

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Post #149
Need to get rid on the sound deadening on the floor now. Perfect time to do it and weight saved

________________________________________

Ph2 Black GTI 6!

EX black 6 owner
But now a Black caged rallye owner

Hunting for Go faster bits!


SEARCH

click here
Posted 7th Jun 2020 at 17:48
prism7guy

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Location: DoncastAAAAARGH

Registered: 13 Jan 2008

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Post #150
Looking good Thumbs up

________________________________________

Goldie the track car.
Posted 7th Jun 2020 at 22:04

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