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Author Subject: High Boost Supercharged Rallye
russbez

Seasoned Pro

Location: Inverness-Shire

Registered: 19 Dec 2005

Posts: 7,459

Status: Offline

Post #1
[POST 1]

Had the car since December 2005, had a fair few issues with it over the years. The last year or two have been the easiest.... oh and Lynx Motorsport Supercharged it for me in April 2008, if you didn’t know already it was the first Rallye to get Supercharged by them.

End of June I decided my engine bay needed a bit of a clean up, and wanted to sort some wiring issues, all in preparation for a full blow over respray sometime in future.

Bought:

Quaife limited slip differential fitted in a gearbox (second hand, gbox with less miles than mine).
Timing belt kit and water pump
Clutch + clutch cable.
Gearbox oil + seals.
Nissen radiator and new hose to suit.
Camshaft sensor (few month old).
Thermostat, seal + thermostat housing.
Galvanised wishbones with new ball joints bushes fitted.
Group N engine mounts all round.
New CV boots fitted to my reasonably good conditioned driveshafts.
Oil catch tank.
K&N.
Rust remover (Deox Gel).
Zinc primer (put in name).
New bearings into my tensioner pulley, and two pulleys.
Few of primer, Bianca white and lacquer rattle tins.
Lots of new bolts and plastic clips from peugoet


Started stripping the engine out, got excited and forgot to take before pictures.

most of the dates on the pictures and videos are wrong/inconsistent so i have tried to put them in an order that makes sense... to me.



Bit rusy:





Can see wires here, not normally as obvious but I want to hide them.


Hoist in



Engine out,… with help from friends.





Rust looking even worse



Got top mount buffer off and discovered this



Then began using the Deox Gel to remove the rust!

This is after a few applications, I tended to put it everywhere then leave it a day. Pull the car out of the garage with my works van then pressure wash it off.













This is what happens after 2/3 days of leaving it on.







This is a spare slam pannel, my orginal one was pretty rusty. This one got same treatment





Date : August 2010, changed links due to Photobucket fail

________________________________________

TEAM HIGH BOOST SUPERCHARGED RALLYE

My Rallye project thread
Posted 12th Jul 2017 at 15:17
russbez

Seasoned Pro

Location: Inverness-Shire

Registered: 19 Dec 2005

Posts: 7,459

Status: Offline

Post #2
[POST 2]

It comes off and leaves a decently bare metal finish





Done this around 4/5 times in my spare time, didn’t get final picture of the result

Just for good measure I primed the engine bay with a zinc primer







Meanwhile a Peugeot mechanic from the garage down the road came and helped me put my gearbox back on, didn’t want to stress myself out too much…. he also done timing belt and water pump.



new clutch on



Date : August 2010, changed links due to Photobucket fail

________________________________________

TEAM HIGH BOOST SUPERCHARGED RALLYE

My Rallye project thread
Posted 12th Jul 2017 at 15:17
russbez

Seasoned Pro

Location: Inverness-Shire

Registered: 19 Dec 2005

Posts: 7,459

Status: Offline

Post #3
[POST 3]

Newer Gearbox with LSD fitted in it



Timing belt done





Engine back together, also put on powder coated fuel rail



Got more bits powder coated Yes









Forgot to show engine mount repair…

before:



after:



Some white primer Bianca white and lacquer… few days between each.













Days after the lacquer, engines ready to go back in









Few bits back on







Date : August 2010, changed links due to Photobucket fail

________________________________________

TEAM HIGH BOOST SUPERCHARGED RALLYE

My Rallye project thread
Posted 12th Jul 2017 at 15:17
russbez

Seasoned Pro

Location: Inverness-Shire

Registered: 19 Dec 2005

Posts: 7,459

Status: Offline

Post #4
[POST 4]

Tapped out a few threads, including the earths! Buffed them with 300 grit wet and dry too.



Got this far



And had about a weeks worth of hell/pulling my hair out because the engine loom was damaged some how!

Had a few mechanics over trying to source problem. Finally got a local electrician over to take a look, he was following the live from the battery around the engine loom… he moved the fuel relay from down behind the battery – on to the battery so he could bridge something into the fuse box – and the fuel pump primed!! Que lots of confused looks.

Sourced a spare Engine loom then had to change a few connectors, and extend a few to suit supercharger conversation.







Date : August 2010, changed links due to Photobucket fail

________________________________________

TEAM HIGH BOOST SUPERCHARGED RALLYE

My Rallye project thread
Posted 12th Jul 2017 at 15:20
russbez

Seasoned Pro

Location: Inverness-Shire

Registered: 19 Dec 2005

Posts: 7,459

Status: Offline

Post #5
will add more tomorrow Yes

________________________________________

TEAM HIGH BOOST SUPERCHARGED RALLYE

My Rallye project thread
Posted 17th Aug 2010 at 22:01
darkgti6

Seasoned Pro

Location: Bracknell

Registered: 07 Jun 2008

Posts: 1,361

Status: Offline

Post #6
Cheers for this dude, looking goodSmile

________________________________________

Team Peugeot Sport 308 Gti�

Black T'99 Gti - may she rest in peace - written off in a shunt on the A329m
Posted 17th Aug 2010 at 22:09
mabgti

NV motors

Location: Bham tunnel @7400rpm

Registered: 28 Aug 2003

Posts: 9,127

Status: Offline

Post #7
awesome dan... just what the astor needs as last winter didnt treat it too well!

next time your travelling give me a shout i need a garage door fitting!

________________________________________

Team Supercharged Gti-6

NV Motorsport
Automotive Performance Tuning
0121 448 7515
ECU Remapping/ DPF removal
VAG/BMW Diag and Option Coding
Peugeot Planet ECU coding/transponder programming etc
www.nvmotorsport.com
Facebook Page
Project S6
Posted 17th Aug 2010 at 22:16
eddy_gti6

Seasoned Pro

Location: Durham

Registered: 20 Oct 2008

Posts: 8,716

Status: Offline

Post #8
lookin good mate. what was the problem with it in the end?

________________________________________


Clicky: [url =http://www.306gti6.com]click here[/url] remove the space between [url & =
Posted 17th Aug 2010 at 22:45
russbez

Seasoned Pro

Location: Inverness-Shire

Registered: 19 Dec 2005

Posts: 7,459

Status: Offline

Post #9
mabgti wrote:
next time your travelling give me a shout i need a garage door fitting!


thats a bit random LOL
how do you know that i work for a garage door company?

Chris, something up with my old engine loom. Broken wire/wires or solder touching where its not ment to. Have to replace Toms engine loom i used too Yes

________________________________________

TEAM HIGH BOOST SUPERCHARGED RALLYE

My Rallye project thread
Posted 17th Aug 2010 at 22:48
jonny b

Newbie

Location: wycombe

Registered: 14 Jul 2007

Posts: 46

Status: Offline

Post #10
looking sweet as bud
Posted 17th Aug 2010 at 22:56
peugeot306

Newbie

Location: West midlands

Registered: 24 Sep 2009

Posts: 19

Status: Offline

Post #11
Good work keep it up.
Posted 17th Aug 2010 at 23:40
rwgti

Seasoned Pro

Location: Yorkshire

Registered: 08 Jul 2008

Posts: 1,727

Status: Offline

Post #12
Looking good Thumbs up

________________________________________

Team Astor Grey Supercharged GTI 6


Posted 18th Aug 2010 at 01:35
chrisd306

Seasoned Pro

Location: Perth Scotland

Registered: 26 Nov 2005

Posts: 10,061

Status: Offline

Post #13
Out of intrest did you change your charger fluid mate? and when you got a filter for charger oil how much did Rich charge for them or did you source your own 1?

also how rusty was it was mate, my rallye isint near as bad as that yet like an never been looked at before, must be the salty roads up north lol

luving the brembos to mate, looking good mate.

________________________________________

In my garage just now

2003 BMW M3 & 2009 L200 Raging Bull
& Audi Q5 S Line
AX stock rod & Saxo Stock rod
Sold the bike an charged rallye an bought a caravan, midlife crisis or what!
Posted 18th Aug 2010 at 05:22
mabgti

NV motors

Location: Bham tunnel @7400rpm

Registered: 28 Aug 2003

Posts: 9,127

Status: Offline

Post #14
russbez wrote:
mabgti wrote:
next time your travelling give me a shout i need a garage door fitting!


thats a bit random LOL
how do you know that i work for a garage door company?

Chris, something up with my old engine loom. Broken wire/wires or solder touching where its not ment to. Have to replace Toms engine loom i used too Yes


There are powers that be that you have no knowledge of...

LOL think it was small talk a few years ago!Big grin

________________________________________

Team Supercharged Gti-6

NV Motorsport
Automotive Performance Tuning
0121 448 7515
ECU Remapping/ DPF removal
VAG/BMW Diag and Option Coding
Peugeot Planet ECU coding/transponder programming etc
www.nvmotorsport.com
Facebook Page
Project S6
Posted 18th Aug 2010 at 05:37
russbez

Seasoned Pro

Location: Inverness-Shire

Registered: 19 Dec 2005

Posts: 7,459

Status: Offline

Post #15
mabgti wrote:
LOL think it was small talk a few years ago!Big grin


LOL okay


emm chris, i didnt change charger fluid as i had already done it like less than 10 month ago

i got a filter from a company RichW told me to phone, iirc they are around £10 to £15

and yeh it was pretty rusty, this was my road over a year ago, used to struggle to get car down it Yes its a lot better now.

________________________________________

TEAM HIGH BOOST SUPERCHARGED RALLYE

My Rallye project thread
Posted 8th Jul 2011 at 17:35
russbez

Seasoned Pro

Location: Inverness-Shire

Registered: 19 Dec 2005

Posts: 7,459

Status: Offline

Post #16
[POST 5]

Started to put hoses and radiator on, mounted the slimline fans onto radiator with some thin bolts that I got from chrisd306.



For about a year iv had my fans running off switch on dash, im used to it so I thought I would hide the wires because they were visible when looking under the bonnet.

I have hidden the wires to the switch inside the Chassis loom, the relay I placed in the fuse box ... bit more room in Rallye fuse box without aircon bits taking up space/weight LOL









Electrical tape is actually now black… make sense of this picture, I have wires hidden everywhere.





Earths meet here, I actually have 3 earths in soldered here. Fans, relay and a spare Ninja for another relay maybe one day. Put in some Peugeot coil wrappy stuff, managed to use a fair bit of this stuff all over car to cover up wires.



Sorry Chris, the switch is still that dirty dirty green colour LOL



Earth for the switch, again done my best to hide it under drivers arch.



Date : August 2010, changed links due to Photobucket fail

________________________________________

TEAM HIGH BOOST SUPERCHARGED RALLYE

My Rallye project thread
Posted 12th Jul 2017 at 15:25
chrisd306

Seasoned Pro

Location: Perth Scotland

Registered: 26 Nov 2005

Posts: 10,061

Status: Offline

Post #17
Russ's house is the 1 with a million old school phone and post boxes in it !!

ive just got my coilovers on but not sure how the main nut tightens

________________________________________

In my garage just now

2003 BMW M3 & 2009 L200 Raging Bull
& Audi Q5 S Line
AX stock rod & Saxo Stock rod
Sold the bike an charged rallye an bought a caravan, midlife crisis or what!
Posted 18th Aug 2010 at 15:44
russbez

Seasoned Pro

Location: Inverness-Shire

Registered: 19 Dec 2005

Posts: 7,459

Status: Offline

Post #18
school phones? LOL
thats my old mans phone boxes, you cant see them all! theres more now

get them fitted then! ohh and i see what you mean about the all round group N engine mounts
they are interesting turns your seat into a kind of like massage chair, bareable tho!

________________________________________

TEAM HIGH BOOST SUPERCHARGED RALLYE

My Rallye project thread
Posted 18th Aug 2010 at 15:49
russbez

Seasoned Pro

Location: Inverness-Shire

Registered: 19 Dec 2005

Posts: 7,459

Status: Offline

Post #19
[POST 6]

Fitted a cleaner one of these



Cleaned the brembos up



Started putting things back on










Still a few wee bits i want to do, i managed to break my 12v when taking my dash apart to give it a lick of paint plus TRE's and drop links then tracking at a garage

Was planning rigging the horn on my Momo Race steering to a second horn or something, cant really be arsed now happy to have it back on the road after lots of money spent

LSD is a worth while investment at low boost id say, torque steers a little bit more Yes Cars feels a bit more easyer to accelerate, doesnt spin quite soo much in the wet, not that it was bad with standard diff...

heres how it was looking this morning, outside really needs a clean, that second hand bumper i bought off here a while ago is a mess!



Date : August 2010, changed links due to Photobucket fail

________________________________________

TEAM HIGH BOOST SUPERCHARGED RALLYE

My Rallye project thread
Posted 12th Jul 2017 at 15:40
chrisd306

Seasoned Pro

Location: Perth Scotland

Registered: 26 Nov 2005

Posts: 10,061

Status: Offline

Post #20
just been out with my coilovers jesus f*ck its a stiff ride now like, not good on the road at all, well my smooth race track stage was spot on!

________________________________________

In my garage just now

2003 BMW M3 & 2009 L200 Raging Bull
& Audi Q5 S Line
AX stock rod & Saxo Stock rod
Sold the bike an charged rallye an bought a caravan, midlife crisis or what!
Posted 18th Aug 2010 at 17:47
coskev

Seasoned Pro

Location: Oswestry

Registered: 01 Nov 2009

Posts: 3,132

Status: Offline

Post #21
Great work and excellent pics and write upCool

The rust remover looks like good stuffWink

________________________________________

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

Mac1 ZR R1 kit car build in progress.
Posted 6th Sep 2010 at 01:50
russbez

Seasoned Pro

Location: Inverness-Shire

Registered: 19 Dec 2005

Posts: 7,459

Status: Offline

Post #22
will be updating this, dont want it lost in switchover to new site

stripped down back end, more of list for me to update pictures of….

old rear beam off
de-rusted underneath rear of the car a few times using coats of Bilt Hamber Deox Gel and then blasted clean using pressure washer
Then few coats of Hydrate 80, isopon zinc 182 anti rust primer, then few tins of gloss white spray tins, then lacquered
sand blasted a few items, also primed and painted
all new brake lines on rear beam and shoulder nuts
new solid mounts fitted onto rear beam
helicoil used to repair thread for bolt that holds ARB plate in place, (no pictures sorry)
new exhaust clamps, with hangers adjusted slightly
track rods
track rod ends
2 covers for power steering ram
2 new tyres and track done also LOL

took lots of pictures!

passed its Mot the other day, still a few wee issues such as clunks from rear beam direction. I do intend to replace old rear beam as it is the original one since I have had the car. A hybrid rear ARB has been purchased

not 100% sure if I am liking the solid mounts as roads up here are too shite, might just be getting old.

will see though Smile

________________________________________

TEAM HIGH BOOST SUPERCHARGED RALLYE

My Rallye project thread
Posted 16th Mar 2011 at 19:35
russbez

Seasoned Pro

Location: Inverness-Shire

Registered: 19 Dec 2005

Posts: 7,459

Status: Offline

Post #23
[POST 7]

Started in January in some pretty crap weather, with help from this:



I managed to get track rods off reasonably easy

Passenger side


Got it off from underneath, from here I knocked off the old cover using flat screwdriver and hammer, it was in bits by time I got it off, luckily I bought new ones for whole rack



Old and new



Using boiling hot water to soften the rubber ; I got the new cover on with decent amount of difficulty



Drivers side, really needed heat here, plus rack on full lock (had already removed the rubber gaitor here, was easier than passenger side)



Off



Old and new



And on



Car wasn’t road worthy by this point but this is when you go get your tracking done straight away.

will try and find more time to upload more later

From : January 2011, changed links due to Photobucket fail

________________________________________

TEAM HIGH BOOST SUPERCHARGED RALLYE

My Rallye project thread
Posted 12th Jul 2017 at 15:51
oecken

Seasoned Pro

Location: Mt Cook, New Zealand

Registered: 17 Feb 2009

Posts: 4,751

Status: Offline

Post #24
The solid mounts will be fine once you sort your rear beam you big girl! the road in edinburgh are not exactly ideal with pot holes and cobbles and mine didnt exactly have "soft" suspension LOL Looking a lot cleaner though now Thumbs up

________________________________________

Sad Ex-Black 6 Ninja - Speed has never killed anyone, suddenly becoming stationary... That's what gets you.
Posted 22nd Mar 2011 at 16:28
cjm_harris

Seasoned Pro

Location: Parts for Sale section

Registered: 04 Dec 2007

Posts: 7,442

Status: Offline

Post #25
Stunning Love

I love my China, but always wanted a white rallye Yes

________________________________________

Chris
1999 China Gti6 Supercharged Devil [Fun car] >>Project Thread<<
2000 Bianca 306 Diesel [Work runabout]
Posted 22nd Mar 2011 at 16:29

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