cwspellowe
Post #1
(AKA the colour formerly known as sigma 
)Righty ho, figured i'd start a new thread seen as the car is almost completely different now from the car it once was.
To summarise, this:
Now looks like this:
You can see the original project thread HERE if you're in any way bothered about reading 20 pages of nonsense.
As it stands:
P-reg Peugeot 306 GTi6 phase 1 converted to phase 2.5/3 (ish)
Engine:
2.0 16v XU10J4RS with aircon on approx 147,000 miles
Full head rebuild by previous owner at approx 110,000 miles (former snapper)
Carbon enclosed induction kit
Helmholtz resonator on inlet manifold blocked off
Advanced inlet cam timing
PTFE inlet manifold gasket
Standard genuine BOSAL exhaust system and cat
New ICV, MAP, green and brown temp sensors
Last RR'd April 2011 at a lumpy 175bhp and 147lbft with blowing Magnex stainless steel system and Freeflow decat and a couple of dodgy sensors.
Transmission:
Standard 6 speed gearbox
New genuine clutch cable
New genuine three part clutch kit
New nylon clutch arm bushes
Miles' Group N gear linkages
GE quick shift
Engine bay:
Battery relocated to boot with in-line killswitch
Painted head and inlet manifold with "ooh, shiny bits" sticker
Battery box cut down to hold ECU, killswitch and brake bias valve
Anodised blue oil catch tank
Helmholtz resonator removed from inlet manifold
Air con pipes removed
Suspension:
OEM front dampers with Spax -40mm progressive springs
All suspension components replaced with new parts, inc
Wishbones
Balljoints
Top mounts
Bearings
Track rod ends and steering arms
Drop links
ARB bushes
New subframe
Group N lower engine mount and chocked upper mount
Refurbished rear beam lowered 40mm
Citroen ZX Volcane rear shocks
New rear beam mounts
Brakes:
GTI6 front calipers with 283mm Brembo discs and OEM pads
All new copper pipes from MC to flexi's
ABS removed
Rear compensator replaced with Compbrake bias valve
Rear calipers rebuilt with OEM discs and pads and new bleed nipples
New rear disc protectors
Wheels:
Speedline Challenge 2110 16x7 refurbished in anthracite
205/45/16 tyres
20mm hubcentric spacers and extended bolts
Exterior:
Phase 3 front bumper
Phase 3 bonnet
Phase 3 grille
Graphite grey phase 3 rubstrips and fuel cap trims
New black masked Depo headlights with white LED sidelights and +90% H7's all round
Pulled arches
Graphite grey bonnet badge
Smoked side repeaters
HEKO wind deflectors
Phase 3 boot lock
Badges sprayed graphite grey
Full respray in sundance yellow
Roof and bonnet sprayed gloss black
Stickerbombed rear window
Interior:
Standard GTI6 leather/alcantara seats
Blue S16 carpet
Black GTi6 embroidered mats
Blue stitched gear stick gaiter
Metal Monkey dials
Metal monkey heater controls
Carbon fibre mirror blanks
Stickerbombed glovebox
White LED courtesy lights
Blue LED dash and centre console
RMD suede 330mm steering wheel
Phase 3 fascia with cigarette lighter and rear fog switch moved to blank under driver's vent
Black A,B,C pillars
Black interior light surround
Custom home made sub enclosure and false floor
Phase 3 stealth shelf
ICE:
Sendai cheap crappy head unit with USB and iPod interface
Alpine SXE 1725S fronts
Standard rears
Mutant 4-channel amp
Mutant 12" sub fitted to custom enclosure
Bloody hell, took me ages to write all that and i'm now concerned about how much i've spent. That's a list of everything on the car at the minute, never mind the phase 1 stuff I got rid of!
My last update was two weeks ago now and the car only just got back on the road yesterday. To recap, this is what I posted last
quote:
Right, bit of f*ckery pokey means an update!
As it stood, the car needed a new beam or a refurb and I was planning on raising it, 60mm drop is a bit impractical for my liking at the car was bumpsteering thanks to mahoosive bump stops.
First on the list.. new struts. Well not new, but decent condition OE dampers and Spax 40mm springs. They were bought quite swiftly.
Then the problem of the rear beam. Upon inspection of mine, the shafts were a bit buggered and for the cost of parts to rebuild the beam I figured I could scavenge one already done. Up steps gota6again who ISN'T called Deepak (apparently
) with a 40mm lowered, recently rebuilt, shiny looking beam with working calipers, discs, pads, mounts, everything apart from dampers, for the bargain price of £200 + delivery. Hooray! Not hooray when I got f*cked over by Shitty Link for delivery though, more later.
Whilst the car was up on axle stands with the struts and rear beam removed I figured i'd get to work on some other jobs.
First up - ABS removal. I decided a while ago that I needed the space behind the headlight for my airbox plans and was waiting for the right time to remove the pump and lines. My original calipers had snapped nipples that I couldn't be arsed extracting, retapping and replacing so I couldn't do anything to do with bleeding the system. When I found out the beam came with working nipples I set to work stripping out all 60-odd feet of brake lines and 5kg or so of ABS pump.
New lines (35ft not including flexi's) were laid, the front brake split off one T and the rears off another T via a bias valve. Total cost? £25 for the lines to be made by a motorfactor inc fittings, £10 for brake fluid, £45 for the bias valve.. ah, not quite a cheap idea then. Oh well.
New lines..
No ABS pump or battery
Rear a little too long, had to loop it a bit to tidy it up
Excellent. Waiting for the bias valve to arrive, hopefully tomorrow, and can get the system bled once the beam is on.
Speaking of which..
Will probably underseal it to keep it fresh before it goes on, i've only got black though and i've already done this...
New shocks and springs and undersealed arches
Rear arches
Boot floor before
After
Tidying up nicely ready for its MOT next month.
As it stands at the minute...
Hopefully have her back on the road for the weekend so I can go for a drive, been without it 2 weeks now and it's starting to get annoying.
I hate being poor.
As it stood, the car needed a new beam or a refurb and I was planning on raising it, 60mm drop is a bit impractical for my liking at the car was bumpsteering thanks to mahoosive bump stops.
First on the list.. new struts. Well not new, but decent condition OE dampers and Spax 40mm springs. They were bought quite swiftly.
Then the problem of the rear beam. Upon inspection of mine, the shafts were a bit buggered and for the cost of parts to rebuild the beam I figured I could scavenge one already done. Up steps gota6again who ISN'T called Deepak (apparently
) with a 40mm lowered, recently rebuilt, shiny looking beam with working calipers, discs, pads, mounts, everything apart from dampers, for the bargain price of £200 + delivery. Hooray! Not hooray when I got f*cked over by Shitty Link for delivery though, more later.Whilst the car was up on axle stands with the struts and rear beam removed I figured i'd get to work on some other jobs.
First up - ABS removal. I decided a while ago that I needed the space behind the headlight for my airbox plans and was waiting for the right time to remove the pump and lines. My original calipers had snapped nipples that I couldn't be arsed extracting, retapping and replacing so I couldn't do anything to do with bleeding the system. When I found out the beam came with working nipples I set to work stripping out all 60-odd feet of brake lines and 5kg or so of ABS pump.
New lines (35ft not including flexi's) were laid, the front brake split off one T and the rears off another T via a bias valve. Total cost? £25 for the lines to be made by a motorfactor inc fittings, £10 for brake fluid, £45 for the bias valve.. ah, not quite a cheap idea then. Oh well.
New lines..
No ABS pump or battery
Rear a little too long, had to loop it a bit to tidy it up
Excellent. Waiting for the bias valve to arrive, hopefully tomorrow, and can get the system bled once the beam is on.
Speaking of which..
Will probably underseal it to keep it fresh before it goes on, i've only got black though and i've already done this...
New shocks and springs and undersealed arches
Rear arches
Boot floor before
After
Tidying up nicely ready for its MOT next month.
As it stands at the minute...
Hopefully have her back on the road for the weekend so I can go for a drive, been without it 2 weeks now and it's starting to get annoying.
I hate being poor.
I hated what happened next even more...
Rear - 40mm. Fronts? On the bumpstops. Turned out the sprigs were designed for 1.4's, 1.6's, 1.9's.. not the big lump of a GTI6 front end. So the -40mm struts were actually lower than the -60mm Gmax kit I had on with no play in the suspension at all. Couldn't drive it even down the drive! Back up it went then...
Whilst it was up I thought i'd better investigate a clunking noise coming from the front N/S. Had a poke around and noticed a bit of play in the wishbone bushes so I got the 18mm out and found the front bolt didn't want to come out, just spin and spin. The diagnosis? A sheared bolt in the middle of the bush. It had sheared in such a way the the half bolt couldn't be withdrawn and was trying to take the inner metal casing of the bush with it. That was NEVER going to come out. New subframe needed then, great.
Tried to remove the old wishbones with a view to replacing the damaged bushes and using the Meyle heavy duty P-bushes I got off Kris B. Unfortunately they'd disintegrated after less than 12 months, hardly heavy duty. So I had a choice. New bushes and **** about fitting them to the old wishbones, or new wishbones with bushes pressed on. Yeah, I took the easy option. Taking advantage of a 30% discount on the ECP website these turned up a couple of days later
and I went about fitting the month old ball joints from the old wishbones. All neatly built up, I just needed a new subframe. A trip to the scrappies revealed a 306 that had been lovingly raised up to have the engine removed and not dropped back down, so half and hour removing the wishbones and steering rack, a couple of hours cleaning up and several lashings of black underseal left me with this
Hooray! Time to put the car back together along with the -40mm struts actually designed for the GTI6.
Ooh here's the bias valve for anyone interested. Tapped to M10 so no need for 3/8" to M10 adapters.
And also the phase 3 boot badge I stole from the scrappies. Wound out the boot spacers too to stop the really annoying rattle I was getting from the boot lid. *shuts boot* Sounds like a Golf now
:
That's all for now, car feels brand new with no play in anything. Also the tracking has gone WAY out now, compared new and old wishbones and the N/S was bent like hell! Must have been during the winter when it took a whack, probably what sheared the bolt too. Had it tracked and it's lined up properly now, thank god. Steering feels brand new.
Still not finished though. Will post a *wish list* when my fingers have had a rest :laug:
________________________________________
Bye bye Sundance Kid
Posted 8th Sep 2011 at 16:29
low speed fans for the first time since i've owned the car!!
