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Author Subject: Mik's Rallye
mik

Seasoned Pro

Location: Kent

Registered: 17 Feb 2011

Posts: 2,100

Status: Offline

Post #351
I changed the oil today for some Miller CFS 10w40 triple ester synthetic (over-spec I know, I'm sure semi-synth would be fine). I also changed the gearbox oil for the new OE standard type (single grade Mobil 75, part number 9730 AG as discussed elsewhere) and as others said, it is fine, and the gearbox is very smooth - possibly smoother than the old stuff. Whether this actually is so, or if it is the placebo effect, the warm weather we are having at present or a combination of the two remains to be seen. I also reinstalled the undertray and made wooden bits for my ramps to so I can get up on them without any risk of the splitter getting caught.

See below for a pic of my ramps and the nice new oil.



The next projects on the go are:

- The tailgate glass replacement (got the new glass stored safely away and pick up a new tailgate soon), including repainting the bonnet.

- New rear axle (standard Rallye/GTI6 spec).

- Recover my steering wheel with some nice leather.

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Cherry Rallye SOLD

Posted 16th Nov 2016 at 19:03
mik

Seasoned Pro

Location: Kent

Registered: 17 Feb 2011

Posts: 2,100

Status: Offline

Post #352
To illustrate the performance of Bilt Hamber Electrox zinc primer, here is a pic of the rear disc protector that was removed after it started getting noisy as described above. Before installation it was scuffed up, the bare metal painted with Electrox and then overpainted with high temp silver. It was on the car for about 4 years (installed in early 2012 IIRC).

Note there is no rust visible, and the clean part was where I wiped some road grime off the paint. This shows Electrox definitely works effectively to prevent rust. Lucky that, or all my work on the underside of the car would have been wasted as that is what it is painted with.

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Cherry Rallye SOLD

Posted 21st Sep 2016 at 17:53
mik

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Location: Kent

Registered: 17 Feb 2011

Posts: 2,100

Status: Offline

Post #353
In addition to my 3 other ongoing jobs listed above, I've also decided to reinstate the remote control stalk.

For those who have read through this project thread, they may remember I attempted to make the stalk functional back in 2011 when I installed the Blaupunkt San Francisco 300. For this I used an Autoleads adaper in conjunction with the original Phase 2 type stalk. While it worked after a fashion, it changed the radio station when I attempted to change the volume. Several attempts were made to rectify this, including purchasing another stalk, but to no avail.

I decided to remove it altogether and do without. But I've become aware that it might be useful not to have to reach toward the radio and look at it to change the station when driving. So I have now purchased a Phase 3 stalk from deeturbo on here, and a Dynamic Sounds CTSPG0004.2 adapter kit, with a Blaupunkt patch lead. The Phase 3 stalk has a different connector and is a direct replacement for the Phase 2 item as they both attach to the steering wheel cowling with 3 small screws. Now I need to find a bit of time to install it. The pic below has the lead and patch lead connected to the stalk. The installation guide is not very informative, so I hope it is basically plug and play.

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Cherry Rallye SOLD

Posted 24th Sep 2016 at 21:24
russbez

Seasoned Pro

Location: Inverness-Shire

Registered: 19 Dec 2005

Posts: 7,458

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Post #354
nice work as always
always bugged me the stalk not working, think i removed mine a long time ago, be good to see if you can get it working

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TEAM HIGH BOOST SUPERCHARGED RALLYE

My Rallye project thread
Posted 26th Sep 2016 at 10:48
mik

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Location: Kent

Registered: 17 Feb 2011

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Post #355
I'll let you know, am keen to get it sorted myself.

Just got to find some time to do it as well as pick up the tailgate for painting around nappies-related activity with small children.

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Cherry Rallye SOLD

Posted 5th Oct 2016 at 00:55
mik

Seasoned Pro

Location: Kent

Registered: 17 Feb 2011

Posts: 2,100

Status: Offline

Post #356
Picked up my Cherry Ph3 tailgate today from pug_306, thanks very much. It is not an upgrade - mine already has a Ph3 tailgate, but has a poorly-repaired ding that has resulted in a couple of rust bubbles at the bottom edge of the glass. So I'm going the get the tailgate I've acquired stripped, painted and fitted with the new glass I got from Belgium. I thought it was better to start with an undamaged, non-rusty one than get my dog-eared one repaired. While the paint is in the gun I'm going to get my bonnet redone, and a new bumper painted and fitted. I ordered a tailgate moulding (wasn't going to bother, but decided to get one for a proper job ), and have been recommended a painter by a mate of mine who has used them for years. The VIN on the tailgate glass is only 5 off the one on my car but that will get changed for the new item I've found.

Also suddenly realised it had been a while since the clutch and brake fluid was done, so got that sorted last week and had the calipers greased while I was at it.

Next thing is to order an axle to be stashed for fitting when I've got an opportunity - young kids are very time-consuming!

I also found my original Rallye wheel which I'm going to get covered in OEM+ leather (I want something more leathery and less plasticky than OE GTI-6 wheels, as these cars are all about tactility). It will also be slightly fatter than OE which will suit my sausage fingers.

Once all this is done it will be a nice drive, but there will be a few more jobs coming up I'm sure.

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Cherry Rallye SOLD

Posted 10th Oct 2016 at 22:50
mik

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Location: Kent

Registered: 17 Feb 2011

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Post #357
An update - I ordered an axle in November from Jord294 after numerous testimonials that he was the best. I've PMed him about arranging pick-up, and I'll sort out delivery next time I'm back in the UK at the end of the month. I'm working away at present, but am building up a good list of jobs to get done when I'm home.

I am obtaining a set of the inner wing brackets that retain one of the wheel arch clips on the passenger side and that black canister thing on the driver's side from a vehicle dismantler in New Zealand, where they don't use road salt, so I can get non-rusty brackets. I got the idea from someone on here. As an aside, if anyone was wanting to reshell a car, getting a shell from NZ or Aus would be ideal as they are highly likely to be in perfect nick having not had road salt blown into every crevice for 15+ years. The only exception would be if it had been parked next to the sea for long periods.

I've also got a quote to recover the steering wheel in nicer leather from LS Design.

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Cherry Rallye SOLD

Posted 18th Feb 2017 at 14:48
mik

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Location: Kent

Registered: 17 Feb 2011

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Post #358
One of the brackets I've ordered from NZ to replace my crumbly ones:

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Cherry Rallye SOLD

Posted 12th Jan 2017 at 09:04
mik

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Location: Kent

Registered: 17 Feb 2011

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Post #359
My nice rebuilt powdercoated Jord294 axle has been picked up from him by the courier and I should see it delivered here tomorrow. I'm really looking forward to seeing it.

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Cherry Rallye SOLD

Posted 7th Feb 2017 at 17:44
mik

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Location: Kent

Registered: 17 Feb 2011

Posts: 2,100

Status: Offline

Post #360
Nice rebuilt and powdercoated axle from Jord arrived this morning. I haven't had time to unpack it yet but from what I can see it looks great.

A big thank you to Andy for sorting out the axle for me and managing to get it ready for the time window when I was back in the UK. Really well packaged too - the delivery driver commented on what a tidy packaging job it was.

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Cherry Rallye SOLD

Posted 8th Feb 2017 at 12:28
mik

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Location: Kent

Registered: 17 Feb 2011

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Post #361
I've also decided I'm going to replace the front pads as the braking has never been the same since a run of CV boot incidents when the pads got contaminated with CV grease. Might do the discs as well depending on how they look. The initial bite is OK, but an 'oh s***' moment on a motorway when everyone halves their speed suddenly is less impressive, feeling distinctly squirmy after the initial bite. I had thought I'd got away with it but maybe not. I'm theorising the CV grease on the pads gets heated up and causes the squirmyness. Still passes MOTs with no problem though.

Will probably go for OE, but might look at what is recommended on the brakes forum posts such as something from Pagid or Mintex.

Got a fair list of jobs building up now.

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Cherry Rallye SOLD

Posted 8th Feb 2017 at 12:37
mik

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Location: Kent

Registered: 17 Feb 2011

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Post #362
Five minutes ago the doorbell went and a set of Valeo black masks from gnrlee arrived. I've already got black masks on the car which were done by a really good bloke called Rich about 3 years ago, but a chance to get some original Valeo black masks was too good to pass up.

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Cherry Rallye SOLD

Posted 8th Feb 2017 at 12:48
walker_texasranger

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Location: Sunny Retford

Registered: 26 Jan 2008

Posts: 2,502

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Post #363
Mik,

If you are doing the pads then a set of DS2500's is well worth the investment over a standard pad. Fit straight onto a standard disc, no noisier and plenty more stopping power. Great upgrade if you are keeping the calipers OE Thumbs up

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Almost standard 1999 Bianca Rallye
Hilux InvincibleX daily

306 No.13 Doh

Carp and specialist Anglers Click here
Posted 11th Feb 2017 at 08:05
mik

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Location: Kent

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Post #364
Thanks - might as well make an improvement while I'm in there. Will look into that.

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Cherry Rallye SOLD

Posted 11th Feb 2017 at 15:34
mik

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Location: Kent

Registered: 17 Feb 2011

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Post #365
...and a big thank you to Photobucket for ruining, not only this and countless other forums, but in particular the 15 pages and 6 1/2 years of work I put into this thread by changing its policy with no warning to require $400 per year to host images. This thread is useless now with no pictures unless I spend hours finding the images and hosting them somewhere else, and matching them to the narrative.

Whoever made that decision at Photobucket, I hope you stand in some really nasty dog poo and not notice until you've gone into your house and trodden it into the carpet in every single room. Cleaning that up, disgusting though it would be, would still be way quicker than finding and resurrecting the images on this thread so you would be getting off lightly overall. Bellends.

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Cherry Rallye SOLD

Posted 14th Jul 2017 at 16:49
prism7guy

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Location: DoncastAAAAARGH

Registered: 13 Jan 2008

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Post #366
I concur!
Ive got to find time also to upload all my project images then put the new links in the right places. Not a task I'm looking forward to.
For some reason Flickr won't let me log in as I started registering but it turns out Ive already got an account, its like an endless loop I'm stuck in with them and de-registering my email address didn't seem to work either Sad

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Goldie the track car.
Posted 14th Jul 2017 at 18:30
mik

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Location: Kent

Registered: 17 Feb 2011

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Post #367
Well I'm back in the UK for a month so naturally the priority was sorting the Rallye where she has languished for almost a year. Although I have no pics thanks to photobucket's new policy as discussed elsewhere, so I need to sort an image solution. My wife sorted insurance and a MOT appointment and it was off to the lockup to bring her to life.

Following advice on here I pulled the spark plugs, put a teaspoon of oil down each cylinder and I turned it over with no spark plugs and fuel pump fuses pulled. I put it back together and put some fresh fuel in the tank and she fired straight up. In for a MOT, change coolant, change brake fluid and installation of Mintex M1144 pads and Brembo standard replacement discs as also recommended on here.

I changed the oil as well because the old stuff was was over 11 months old, and even though it had only 1000 miles on it, it was a dark colour so I thought best replace it. I replaced like for like - Millers 10w40 CFS full synthetic.

Now taxed, I've been driving around and it is going as sweet as a nut, although I've had no time to install Jord's new rear axle and the new stereo stalk. Off to France tomorrow for some appropriate driving roads.

I have had my Rallye steering wheel recovered in smooth black leather for an OEM+ look by DesignLS but have not yet received it - I had hoped to get it on there before we went across the Channel but it was not to be.

Hopefully I'll get some pics up soon. In the meantime I'm really enjoying the Rallye.

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Cherry Rallye SOLD

Posted 25th Sep 2017 at 18:33
mik

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Location: Kent

Registered: 17 Feb 2011

Posts: 2,100

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Post #368
I renewed my membership today.

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Cherry Rallye SOLD

Posted 25th Sep 2017 at 18:33
mik

Seasoned Pro

Location: Kent

Registered: 17 Feb 2011

Posts: 2,100

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Post #369
...and also today I received in the mail my retrimmed steering wheel from DesignLS. It is a top-quality job and the stitching, leather quality etc are all first class. Highly recommended if you want a retrimmed wheel. It is recovered in smooth black leather which is higher quality than that on the standard OE Peugeot wheel, but is done for an OEM look with black stitching etc. I got the original rubber Rallye wheel retrimmed (as did someone else on here - was it mechanical_repairs?) This produces a steering wheel that is slightly thicker than standard, which feels better in my opinion, but it looks close to OEM. As the Rallye is all about the tactile driving experience I thought this long-awaited upgrade was a good one. I'm still to get the airbag back on and will see if I can get my upgraded stalk controls fitted and working at the same time when I resume tomorrow. Once I sort an image solution I'll post up some pics.

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Cherry Rallye SOLD

Posted 26th Sep 2017 at 10:06
mik

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Location: Kent

Registered: 17 Feb 2011

Posts: 2,100

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Post #370
For the first time since owning the car (6 1/2 years), I have a functioning radio stalk with the Blaupunkt San Francisco 300 head unit (which in 2011 replaced the non-working OE unit that came without a code). This morning I replaced the airbag, completing the steering wheel installtion, and while the cowling was off I installed the new Dynamic Sounds CTSPG0004.2 adapter kit, with a Blaupunkt patch lead and Phase 3 stalk that I purchased a year ago.

I'm pleased to report that everything is functional and works as intended. If you have read through this project thread you may remember that I installed a patch interface with the original Phase 2 stalk in 2011 and I could not make it work - the stalk changed the volume and changed the station at the same time.

Now all is well and the new one works perfectly. The only downside is the loss of the ability to turn the radio on while the ignition is off. Previously when you turned the car off, the radio went off, but if you pressed the on button the radio would start. Now with the patch lead installed this does not happen. I've seen previous reference to re-wiring to regain this functionality, but I've run out of time and it is not a great loss.

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Cherry Rallye SOLD

Posted 26th Sep 2017 at 19:26
Ben_W

Formerly gpm

Location: Lutterworth

Registered: 01 Sep 2007

Posts: 2,941

Status: Offline

Post #371
Should be a simple case of switching the permanent and ignition live wires....

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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

Posted 26th Sep 2017 at 10:07
mik

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Location: Kent

Registered: 17 Feb 2011

Posts: 2,100

Status: Offline

Post #372
Indeed, but it will have to wait for another day.

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Cherry Rallye SOLD

Posted 26th Sep 2017 at 10:10
mik

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Location: Kent

Registered: 17 Feb 2011

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Post #373
I replaced a non-working rear light bulb this morning and in the process noticed some corrosion around the bulb holders and on some of the bulbs. The bulbs were cleaned up or replaced, and the holders given some Scotch-brite treatment followed by some WD40. If not addressed the increased resistance will make the lamps dimmer and eventually could have caused wiring problems etc. One of the rear lights had water in it, so the rear lights will have to be properly sealed at some point.

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Cherry Rallye SOLD

Posted 28th Sep 2017 at 13:26
deeturbo

Regular

Location: Leighton Buzzard

Registered: 22 Feb 2003

Posts: 283

Status: Offline

Post #374
I used to get water in the 206 rear lights and had loads of corrosion that I had to clean up as all the lights failed to illuminate after a period the car was off the road.

I carefully spit the parts I could and sealed between the joints with silicone. After that they've been fine.
Posted 28th Oct 2017 at 09:32
mik

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Location: Kent

Registered: 17 Feb 2011

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Post #375
I moved the Rallye from its rented home in a garage a couple of miles away into its new home. It has been bucketing down with rain here so any salt would have washed away some time ago, so I felt it was safe to move it from the rented garage (I never use the car in the salt after 18 months laying under it grinding the rust away back in 2012-13). I've now got a double garage at the bottom of the garden with brick cavity walls, insulated electric door, power and loft trusses so I can board it out for storage upstairs. The garage cost about 14 times what the car is worth that I'm putting in it. But it is worth it IMO - I still love this car after almost 7 years.

I'll put pics up when I have a moment to work out a new images solution for this thread.

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Cherry Rallye SOLD

Posted 27th Dec 2017 at 18:20

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