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Author Subject: Astor GTi-6 OEM+
matt evans

Seasoned Pro

Location: Stourbridge

Registered: 16 Sep 2009

Posts: 2,290

Status: Offline

Post #76
mark.evs wrote:
Very nice, makes me feel bad posting up pic's of my wrecker on here when theres cars as clean as yours.


Honestlty mate, im doing this mostly through Boredom LOL

Im sure in 12 months time it'll be covered in shoite, muck and dust like most cars that are used normally LOL

________________________________________

1999 Astor Grey GTi-6 OEM+ (now gone...)
2004 Aegean Blue 206 GTi 180 (also gone...)
2006 Skoda Fabia vRS in Sprint Yellow

honestly3k wrote:
Do you wrestle for a living matt? You sound like a monster LOL


owain wrote:
Nothing involving a 306 can be considered worthwhile.

Posted 25th Feb 2011 at 17:00
coskev

Seasoned Pro

Location: Oswestry

Registered: 01 Nov 2009

Posts: 3,132

Status: Offline

Post #77
matt evans wrote:
coskev wrote:
Spot onCool

What have you done to the trailing arms prep/rust removal wise before painting?Smile


Cheers Kev, as they were standard OE finish, i mechanically stripped the loose stuff of with a wire wheel in the grinder, then used the deox gel all over once or twice, cleaned that off, 2 coats of hydrate80, Bilt hamber etch primed then good old fashioned Black hammerite - 2 coats.

Hopefully that should stop the rust pickling back through

I left the bits of the arms where the ARB goes through, until im ready to get the ARB back in.


TidySmile

Going to soak mine in Deox C when get round to doing beamWink

Great tack Bilt Hamber stuffCool

Just noticed theres no brake balance valve on the rear of yours,looks much less cluttered without it and the four brake pipes that go to itSad

________________________________________

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

Mac1 ZR R1 kit car build in progress.
Posted 26th Feb 2011 at 03:43
matt evans

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Location: Stourbridge

Registered: 16 Sep 2009

Posts: 2,290

Status: Offline

Post #78
Im sure the phase 3 gti 6's had ABS with EBD which does away with the troublesome brake balance valve

________________________________________

1999 Astor Grey GTi-6 OEM+ (now gone...)
2004 Aegean Blue 206 GTi 180 (also gone...)
2006 Skoda Fabia vRS in Sprint Yellow

honestly3k wrote:
Do you wrestle for a living matt? You sound like a monster LOL


owain wrote:
Nothing involving a 306 can be considered worthwhile.

Posted 26th Feb 2011 at 13:22
matt evans

Seasoned Pro

Location: Stourbridge

Registered: 16 Sep 2009

Posts: 2,290

Status: Offline

Post #79
Been and collected the spare wheel cage from the powdercoaters today, just need to pop to the local factors Monday for a couple of exhaust clamps for the Magnex.

Whilst im in a show off mood...

Before..


and nearly done...



It should be back on its wheels Thursday.

________________________________________

1999 Astor Grey GTi-6 OEM+ (now gone...)
2004 Aegean Blue 206 GTi 180 (also gone...)
2006 Skoda Fabia vRS in Sprint Yellow

honestly3k wrote:
Do you wrestle for a living matt? You sound like a monster LOL


owain wrote:
Nothing involving a 306 can be considered worthwhile.

Posted 27th Feb 2011 at 03:55
davewagon

Senior User

Location: Corby / Northampton

Registered: 21 Feb 2007

Posts: 889

Status: Offline

Post #80
This is truly inspiring stuff!

I have 9 days off late April and am temtpted to do some of the things you have done here!


I just need tools, and skills ... and cash

________________________________________

Team: Moonstone GTI-6
Team: Working air-con™

ian7675 wrote:
Remember....a 6 isn't just a car, it's a part time job Thumbs up
Posted 27th Feb 2011 at 04:13
matt evans

Seasoned Pro

Location: Stourbridge

Registered: 16 Sep 2009

Posts: 2,290

Status: Offline

Post #81
davewagon wrote:
This is truly inspiring stuff!

I have 9 days off late April and am temtpted to do some of the things you have done here!


I just need tools, and skills ... and cash


My advice is to crack on with it, the most specialised tool to do the rear is a selection of hammers! Theres enough threads on here how to do a beam rebuild, just take your time and get all the bits and pieces round you first. Once you see how it goes comes apart/goes back together its easy.Big grin

________________________________________

1999 Astor Grey GTi-6 OEM+ (now gone...)
2004 Aegean Blue 206 GTi 180 (also gone...)
2006 Skoda Fabia vRS in Sprint Yellow

honestly3k wrote:
Do you wrestle for a living matt? You sound like a monster LOL


owain wrote:
Nothing involving a 306 can be considered worthwhile.

Posted 27th Feb 2011 at 04:17
matt evans

Seasoned Pro

Location: Stourbridge

Registered: 16 Sep 2009

Posts: 2,290

Status: Offline

Post #82
Update time.

Had the whole day to myself today so have been able to crack on with the pug.

First job was to get the rear brake pads in, then get the handbrake cables re-fitted. At this point i was ready to try the car back on its wheels to check to see what the ride height was. As i'd set the shock bolt distances to 306mm, meaning a 36 mm drop i was interested to see how it looked on the 16" comps.

Anyway i dropped it down (no ARB fitted and the suspension bolts just nipped up at this point) and it looked like so,





Bear in mind theres little fuel in the tank (about less than a ¼), no spare wheel or exhaust either.

I measured it and it was within 5mm side to side but i thought it looked too low. The plan is to take it across europe in the summer so i need some suspension travel when its loaded with luggage and people, SO, i got it back on the stands, removed the Shocks, and reset the shock bolt distances to 310mm, meaning a 30mm drop approx. It looked better - at this point i'd refitted the cyclones.






Again it was spot on each side, so, now happy with the height i could get it back on the stands, and set the trailing arm clearances using a feeler gauge, lock the torsion bars in with the screw adjusters, then set about re-installing the anti roll bar.

Id got a new set of anti-roll bar seals from pug...



So i fitted them and greased them, fitting it with the correct clearance to the trailing arms and loctiteing the 13mm bolts in as well.

I then put the car on some stands so that the weight of it was on its suspension and set about tightening all the rear suspension bolts up.

Once that was done i refitted the spare wheel cage..



Then the exhaust heat shield.. and took some pics of the shiny shit underneath!!








I fitted the Magnex next. Not sure on it TBH..





Its got a slight blow on the joint between back box and middle section, just need to get underneath it properly and have a good look.

All that needs doing at the back end is to fix the exhaust blow, refit the spare wheel, and bleed the back brakes.

I then set the front of the car up on axle stands, and removed the wheels to make a start on the front suspension.

Some pictures of the "before" !!





I got the drivers side caliper and disc off, then removed the suspension leg, ready to strip it on the bench in the garage one of the nights.

That was all i had time for today!

Opinions welcome as always.

________________________________________

1999 Astor Grey GTi-6 OEM+ (now gone...)
2004 Aegean Blue 206 GTi 180 (also gone...)
2006 Skoda Fabia vRS in Sprint Yellow

honestly3k wrote:
Do you wrestle for a living matt? You sound like a monster LOL


owain wrote:
Nothing involving a 306 can be considered worthwhile.

Posted 3rd Mar 2011 at 22:34
coskev

Seasoned Pro

Location: Oswestry

Registered: 01 Nov 2009

Posts: 3,132

Status: Offline

Post #83
Spot onCool

You need to bend the backbox exhaust hanger over slightly to get the tailpipe in the middle of the bumper cut outWink
The one that is bolted to rear panelSmile

IMO the 3 Inch Magnex tailpipe is by far the best tailpipe for the rear of the 306Big grin

The heatshield is along way from the back box with the Magnex fitted ain't it?

Thats why binned mine,not neededSmile

________________________________________

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

Mac1 ZR R1 kit car build in progress.
Posted 4th Mar 2011 at 01:47
matt evans

Seasoned Pro

Location: Stourbridge

Registered: 16 Sep 2009

Posts: 2,290

Status: Offline

Post #84
I'll have a tweak of the hanger when i'm next under it. Thanks for the tip.

Yeah the heatshields a fair way away but i might revert back to an OE exhaust at some point, and it looks pretty!! ha ha.

Kev, does your backbox angle slightly upwards? Or is it horizontal? Mines got a definate angle to it?

Might get the whole system off and start again when im less knackered! Spent nearly all day under the bloody thing LOL

________________________________________

1999 Astor Grey GTi-6 OEM+ (now gone...)
2004 Aegean Blue 206 GTi 180 (also gone...)
2006 Skoda Fabia vRS in Sprint Yellow

honestly3k wrote:
Do you wrestle for a living matt? You sound like a monster LOL


owain wrote:
Nothing involving a 306 can be considered worthwhile.

Posted 4th Mar 2011 at 01:53
coskev

Seasoned Pro

Location: Oswestry

Registered: 01 Nov 2009

Posts: 3,132

Status: Offline

Post #85
Yeah Matt,my back box is angled up slightlySmile

Have you de-catted yours too?

Be interested to see how loud it is if you have kept the CAT,mines de-catted and is pretty loud when between 2500-3000rpm Dry

Drones pretty bad.

________________________________________

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

Mac1 ZR R1 kit car build in progress.
Posted 5th Mar 2011 at 02:47
matt evans

Seasoned Pro

Location: Stourbridge

Registered: 16 Sep 2009

Posts: 2,290

Status: Offline

Post #86
Mines still got the OE cat on it. The decat "may" go on after the MOT.

________________________________________

1999 Astor Grey GTi-6 OEM+ (now gone...)
2004 Aegean Blue 206 GTi 180 (also gone...)
2006 Skoda Fabia vRS in Sprint Yellow

honestly3k wrote:
Do you wrestle for a living matt? You sound like a monster LOL


owain wrote:
Nothing involving a 306 can be considered worthwhile.

Posted 5th Mar 2011 at 02:50
matt evans

Seasoned Pro

Location: Stourbridge

Registered: 16 Sep 2009

Posts: 2,290

Status: Offline

Post #87
Sunday 10 minute update!

Got the drivers suspension leg off the car and got it on the table in the garage. Here it is in all its er.. glory?





I used my faithfull old spring compressors and my Xmas present off the wife, my new clarke 240v Impact gun, bought to replace my useless old snap on 18v one..



Once stripped this is what your left with, exciting eh?



Then old springs (bearing in mind the one off the car is 3 months old, genuine Pug as well...), next to the new Eibachs.




Thats it for today as we're just off to my nephews 7th birthday party so i'll be stuffing jelly and cake all afternoon instead of messing with old french car parts.

One thing im unsure about is the top mount bearing - the crusty looking thing 4th from left in the "exploded" pic. Does a replacement bearing sit inside the rusty angled plate, or does it come complete with the plate? The bearing may as well be replaced whilst its in bits.

Also anyone know how to get rid of etch primer overspray off springs??Unsure

________________________________________

1999 Astor Grey GTi-6 OEM+ (now gone...)
2004 Aegean Blue 206 GTi 180 (also gone...)
2006 Skoda Fabia vRS in Sprint Yellow

honestly3k wrote:
Do you wrestle for a living matt? You sound like a monster LOL


owain wrote:
Nothing involving a 306 can be considered worthwhile.

Posted 6th Mar 2011 at 15:38
rich306.

Regular

Location: Stourbridge

Registered: 26 Nov 2010

Posts: 286

Status: Offline

Post #88
I've just read this thread start to finish and the work you've done is incredible. I wish I had the time, money and know how to do it myself.

You need to let me know next time you plan to go up to The Greyhound for the performance meet because I'd love too see this car in the flesh Smile

________________________________________

Ex Bianca 6 Owner R.I.P

Mazda RX7 FD3s - Daily...
Posted 7th Mar 2011 at 18:11
matt evans

Seasoned Pro

Location: Stourbridge

Registered: 16 Sep 2009

Posts: 2,290

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Post #89
Im at the meet every other tuesday, as to when the car will be finished, gawd only knows!!

Got my new strut top mount bearings today and ordered a Zinc plating kit as well.... I have a feeling this might be getting out of hand....

Oh yeah, i got the overspray off the Eibachs with a cloth and some clean cellulose thinners.

More pics soon

________________________________________

1999 Astor Grey GTi-6 OEM+ (now gone...)
2004 Aegean Blue 206 GTi 180 (also gone...)
2006 Skoda Fabia vRS in Sprint Yellow

honestly3k wrote:
Do you wrestle for a living matt? You sound like a monster LOL


owain wrote:
Nothing involving a 306 can be considered worthwhile.

Posted 7th Mar 2011 at 18:20
rich306.

Regular

Location: Stourbridge

Registered: 26 Nov 2010

Posts: 286

Status: Offline

Post #90
matt evans wrote:
Im at the meet every other tuesday, as to when the car will be finished, gawd only knows!!


I was up last tuesday with a couple of mates, completely oblivious to what day it was until a good selection of cars started turning up Whistle

And lets face it, it's near impossible to finish a project on a car, because even when you get to what you think is the end, you find something else that you want to do LOL

________________________________________

Ex Bianca 6 Owner R.I.P

Mazda RX7 FD3s - Daily...
Posted 7th Mar 2011 at 18:26
blondie

Dirty Diesel Pro

Location: WestMids

Registered: 13 Feb 2004

Posts: 3,867

Status: Offline

Post #91
rich306. wrote:
I've just read this thread start to finish and the work you've done is incredible. I wish I had the time, money and know how to do it myself.

You need to let me know next time you plan to go up to The Greyhound for the performance meet because I'd love too see this car in the flesh Smile
The Greyhound Pub?Blink

________________________________________

A 306 EnthusiastWink
phillipm wrote:

But diesel is the devils fuel Devil


Ps3 IDRazzhils306

“S-H-I-T-H-O-L-E.. Shithole!”

Posted 9th Mar 2011 at 02:33
matt evans

Seasoned Pro

Location: Stourbridge

Registered: 16 Sep 2009

Posts: 2,290

Status: Offline

Post #92
blondie wrote:
rich306. wrote:
I've just read this thread start to finish and the work you've done is incredible. I wish I had the time, money and know how to do it myself.

You need to let me know next time you plan to go up to The Greyhound for the performance meet because I'd love too see this car in the flesh Smile
The Greyhound Pub?Blink


The Greyhound on the Norton Road, Stourbridge yeah.

________________________________________

1999 Astor Grey GTi-6 OEM+ (now gone...)
2004 Aegean Blue 206 GTi 180 (also gone...)
2006 Skoda Fabia vRS in Sprint Yellow

honestly3k wrote:
Do you wrestle for a living matt? You sound like a monster LOL


owain wrote:
Nothing involving a 306 can be considered worthwhile.

Posted 9th Mar 2011 at 02:48
matt evans

Seasoned Pro

Location: Stourbridge

Registered: 16 Sep 2009

Posts: 2,290

Status: Offline

Post #93
The plan is to get each suspension leg as tidy as possible hence the need to de-rust the top spring "cup" in Bilt-Hamber Deox-c solution.

Heres how it looked to start with..





Here is what it looks like with the strut top bearing knocked out of it.



After soaking in the Deox-c for 48 hours.




Then was acid etch primed, and painted in metallic silver.




New and old bearings side by side.




New suspension drop links ready to go on - these are the stronger sectional plastic type, as fitted originally by Peugeot.



This afternoon i took one of the discs and cleaned it all up and etch primed and painted the areas not touched by the pads. Hard to believe that these discs have done 1000 miles, BUT they have been standing on the car since november, hence the surface rust!!

Before...



And after!!




Graham popped around this evening and helped me remove the passanger suspension leg from the car, so i can strip that during the week and paint the top plate off that as well.

Tomorrow however my new Electrostatic zinc plating kit arrives.... watch this space!!

________________________________________

1999 Astor Grey GTi-6 OEM+ (now gone...)
2004 Aegean Blue 206 GTi 180 (also gone...)
2006 Skoda Fabia vRS in Sprint Yellow

honestly3k wrote:
Do you wrestle for a living matt? You sound like a monster LOL


owain wrote:
Nothing involving a 306 can be considered worthwhile.

Posted 9th Mar 2011 at 02:59
phillipm

Seasoned Pro

Location: Rotherham

Registered: 15 Oct 2006

Posts: 20,607

Status: Offline

Post #94
Caswell kit?

________________________________________

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Posted 9th Mar 2011 at 03:01
glenn_addo

Regular

Location: Poole, Dorset

Registered: 22 May 2006

Posts: 183

Status: Offline

Post #95
Wow only just seen this and seen how clean it is underneath. Going to have a proper read of the full thread nice work!
Posted 9th Mar 2011 at 03:06
matt evans

Seasoned Pro

Location: Stourbridge

Registered: 16 Sep 2009

Posts: 2,290

Status: Offline

Post #96
phillipm wrote:
Caswell kit?


Mines coming from a firm in Lincoln, Gateros Plating. One of the guys on Detailingworld used it on his golf gti engine bay refurb and the results looked amazing

________________________________________

1999 Astor Grey GTi-6 OEM+ (now gone...)
2004 Aegean Blue 206 GTi 180 (also gone...)
2006 Skoda Fabia vRS in Sprint Yellow

honestly3k wrote:
Do you wrestle for a living matt? You sound like a monster LOL


owain wrote:
Nothing involving a 306 can be considered worthwhile.

Posted 9th Mar 2011 at 03:06
coskev

Seasoned Pro

Location: Oswestry

Registered: 01 Nov 2009

Posts: 3,132

Status: Offline

Post #97
Deox C is the dogs fairdosCool

Looking forward to seeing your plated partsSmile

How much is the kit and what colours can you do?Wink

________________________________________

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

Mac1 ZR R1 kit car build in progress.
Posted 10th Mar 2011 at 02:05
matt evans

Seasoned Pro

Location: Stourbridge

Registered: 16 Sep 2009

Posts: 2,290

Status: Offline

Post #98
coskev wrote:
Deox C is the dogs fairdosCool

Looking forward to seeing your plated partsSmile

How much is the kit and what colours can you do?Wink


It was just under 60 quid, and you can do the blue ish tint and the yellow passivate finish.

Just opened the kit - i think i should have paid more attention in chemistry!!Unsure Unsure

________________________________________

1999 Astor Grey GTi-6 OEM+ (now gone...)
2004 Aegean Blue 206 GTi 180 (also gone...)
2006 Skoda Fabia vRS in Sprint Yellow

honestly3k wrote:
Do you wrestle for a living matt? You sound like a monster LOL


owain wrote:
Nothing involving a 306 can be considered worthwhile.

Posted 10th Mar 2011 at 02:10
matt evans

Seasoned Pro

Location: Stourbridge

Registered: 16 Sep 2009

Posts: 2,290

Status: Offline

Post #99
Zinc plating update.

My zinc plating kit arrived the other day and i set about having a bash at some bits tonight, with the help of my trusty sidekick, my Son James!




First step, after having the rusty bits soaking in deox-c for a few days was to Acid "pickle" them for 60 seconds, rinse, then set up in the plating tank.

50 mins is the required length of time, then rinse, 15 seconds in the clear passivate, rinse then 90 seconds in the yellow/gold passivate tank.

Final rinse then job done, leave to dry somewhere warm (ish).







This is how they look. They look pretty good for a home effort.







Now i've got my head round the process, i'll get some better before and after pics next time, as the finished product above doesnt show how ropey they were before i started.

Matt

________________________________________

1999 Astor Grey GTi-6 OEM+ (now gone...)
2004 Aegean Blue 206 GTi 180 (also gone...)
2006 Skoda Fabia vRS in Sprint Yellow

honestly3k wrote:
Do you wrestle for a living matt? You sound like a monster LOL


owain wrote:
Nothing involving a 306 can be considered worthwhile.

Posted 13th Mar 2011 at 02:39
Ed_van_dijk

Senior User

Location: Halesworth

Registered: 10 Jan 2007

Posts: 636

Status: Offline

Post #100
Wanna come and do my astor after? Smile

________________________________________

Astor 6
Posted 16th Mar 2011 at 21:43

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