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Author Subject: Black Rallye Ongoing Project
hbomb1905

Newbie

Location: Alfreton

Registered: 15 Jul 2014

Posts: 40

Status: Offline

Post #1
Hello, debut post!
Quick bit of history, i've now had 5 306's and 9 Peugeot's in total. A mixture of TU's, XUD's and two XU7 306's.
Been a member on 'pug306.net' since 2006 and more recently '306oc.co.uk' but never dipped my toe over here due to a lack of XU10'age... anyway after 2 years 306less i've bought my first XU10! (and hopefully a keeper)
It all started on the 13th July when I made the fatal mistake of taking my 1.1 205 to Pugfest. By Wednesday night i'd seen a Rallye advertised on here and been over to Stoke and picked it up from john1989. Link to For Sale thread
It needs bits doing and as such I got it for a fair price.
I'm going to use this thread as means of asking questions and keeping track of where I am with it, as well as hopefully entertaining you internetists.

It's a nice clean car with 114k and full service history. Cambelt done at 79k according to the book so it's ready for another belt. Has a Cat 1 Alarm which seems pretty good, it's decatted, has a foamy cone filter thing, 16" Comp MO5's, group N lower engine mount, quick shift selectors, black masks, Goodridge hoses and Bilstein struts on the back, 1 braided hose on the front and what look like Bilstein's (see pic below and advise if you know please!) also apparently it has Skip Brown springs but all I can tell from looking at them is that they are lower than standard, I think 30-40mm.

A few phone pics on the way back from Stoke:













Another phone pic with my 205 (now For Sale) No



The car desperately needed tracking as it was all over the place so the next day I got it on the ramps at a friends place and fitted two fresh track rod ends (lots of heat required to get bolts undone). Quickly got the tape measure out and 'tracked' it ourselves to get me to a garage - needless to say it was absolutely horrendous to drive! Tried four different places and didn't manage to get it done so it had to wait til next morning - during all of this I was stuck in traffic around town and the car was getting really hot... had to stop and let it cool and a nice man came and told me all about his Almera GTi which had 260bhp from the factory. Needless to say made a quick exit... Next morning came tracking



Car had two locking nuts on the back and no key so out came the lump hammer..



Just a nice pic...



Then over the last week or so i've not spent much time on it. Cleaned it a couple of times and managed half an hour of claying, removed the nurburgring sticker and fitted a new rad fan switch to somewhat cure the 'hotness'



Had chance to jack her up and have a look round today and make a to-do list.





Fifty shades of Hammerite... LOL



That'll be why the alarm siren doesn't work then!



Both outer joints need replacement



Surprise surprise, grinding, treating and undersealing to be done where it's been jacked up by chimps over the years
(not a great pic sorry)



The 'bay



Slow power steering leak



More work required on either side but doesn't look too bad



Bilstein or something else??



Beam refurbishment required and boot floor needs a good clean and paint. Pretty sure the load sensors are seized as the back end feels very twitchy under enthusiastic braking Big grin



Exhaust is leaking and pretty horrible looking so need to find a stainless replacement!



Contrary to popular belief, this is not an aerial shot of the sahara desert with giant snakes on it, it is a very scruffy bit of sound deadening with evidence of a subwoofer having been fitted. Wiring will be removed.



I have to say, this steering wheel makes for a brilliant drive but it looks fairly rancid so I could do with changing that as well!
Please excuse the muck I haven't touched the interior yet (it was quite clean when I bought it mind you)




Final pics for today, whilst the front wheels were off I gave them a good scrub inside and out and a polish and wax - rears still to do. Look so much better and i've grown to love the yellow but they will still be painted a more subtle colour







Thanks for reading Smile

To-Do List

Done:
Radiator Fan Switch
Track Rod Ends
Remove lockers
Buy Cyclones
New wiper blades
Headlight rear dust caps
Wind deflectors
Smoked side repeaters
Grease up front calipers
Thorough interior clean including removing old wiring


Not Done:
New top-mounts (n/s heavily cambered)
Lower front suspension to match rear
Locking wheel nuts
Paint wing mirror caps
Paint front bumper
New Rallye blank N/S - Bought
Paint towing eye black
Rear view mirror
Full service - Bought
Cambelt and tensioners
Weld, Rust treat and underseal under footwells
Rust treat and paint front end
Rebuild a rear beam
New alarm siren
O/S and N/S outer cv boots
Matching brake hoses on front
Paint brake calipers and grease up rears
New n/s driveshaft seal
New exhaust and radiator urgently!
Thermostat
Posted 3rd Nov 2014 at 19:36
Day666

Seasoned Pro

Location: Bristol

Registered: 20 Apr 2013

Posts: 5,214

Status: Offline

Post #2
Should I say welcome or Hello

It was up for sale for a very long time Thomas.....hope you didn't pay the asking price ?

Looking good what your doing ...
Defo needs TLC ....

Anyway ....The wheels are worth 400-500 & are very rare being ET15 no spacers direct fit 16s not many made.

Hope you get handling sorted
Loads of knowledge on here & I'm sure they are more than willing to share it .......Thumbs up
Posted 1st Aug 2014 at 06:47
jimmyrallye

Seasoned Pro

Location: portsmouth

Registered: 19 Apr 2008

Posts: 3,144

Status: Offline

Post #3
Looks a great car with like anything these cars are getting on a bit now there's plenty on your list to get your teeth in to Smile

________________________________________


"Police arrested two kids yesterday, one was drinking battery acid, the other was eating fireworks. They charged one and let the other one off."
Posted 1st Aug 2014 at 08:10
orta

Senior User

Location: East Mids

Registered: 02 Sep 2006

Posts: 860

Status: Offline

Post #4
Mate I was toying with buying this but decided against it and regret it. I'm still searching for a blCk rallye. Chesterfield isn't far from me so we should meet up sumtime to share the pain of 306 ownership haha. This forum is a huge source of knowledge, I've been on here ages just without posting much. The FAQ section alone is worth the £5!

________________________________________

CLUB BLACK RALLYE


||B8s||60-70mm drop||Black Partner Steels||P1 VTS Rack||Refurbed Beam||Hybrid ARB||VTS Torsion Bar||
Posted 1st Aug 2014 at 10:11
hbomb1905

Newbie

Location: Alfreton

Registered: 15 Jul 2014

Posts: 40

Status: Offline

Post #5
Thanks for the replies chaps, no I didn't pay the asking price! And as you say the value of the wheels makes this a very reasonably priced Rallye.
I'm looking forward to getting stuck in and getting it up to standard - clean and well maintained with a few mods - mostly just improving the mods that have already been done to it.
Orta i'd imagine the forum will come in very handy as time progresses! and nice to know you're local! Smile
Posted 1st Aug 2014 at 10:48
walker_texasranger

Seasoned Pro

Location: Sunny Retford

Registered: 26 Jan 2008

Posts: 2,502

Status: Offline

Post #6
Where abouts in Chezvegas are you then? I was living in Hasland for a bit but back in Sheff now

________________________________________

Almost standard 1999 Bianca Rallye
Hilux InvincibleX daily

306 No.13 Doh

Carp and specialist Anglers Click here
Posted 1st Aug 2014 at 12:12
chiefton

Seasoned Pro

Location: cranleigh

Registered: 09 Dec 2012

Posts: 1,195

Status: Offline

Post #7
lovely rallye and love those wheels they look awesome, gotta love comp mo's.

I wanted a black one when I was looking,but mine came up for sale less than a mile from my house so had to get it,and it was hanging too!!

seeing stuff like this makes me want to keep mine lol

plenty of info/inspiration on here, be keeping an eye on this Thumbs up

good luck

________________________________________

cherry rallye daily (the money pit)
Posted 1st Aug 2014 at 12:35
mik

Seasoned Pro

Location: Kent

Registered: 17 Feb 2011

Posts: 2,100

Status: Offline

Post #8
Looking forward to seeing how you get on with this, I've had my Rallye over 3 years and still love it. A few people have done the underbody tidy-up and written it up in threads. Coskevs is excellent, it's what I based my project thread on.

Regarding being jacked up by chimps, I've paid a few quid to get those cross-members redone and a sill section replaced for that reason and I have regular rants about it. I now tell every garage I go to to only jack it on subframe, sill jacking points or rear axle tube. Not on the cross members behind the front wheels! Despite this still been damaged slightly since I fixed it.

Really satisfying getting the underbody done, and these cars are actually quite rust resistant compared to similar age BMWs and Fords in particular.

Nice car, looking forward to updates.

________________________________________

Cherry Rallye SOLD

Posted 1st Aug 2014 at 16:41
hbomb1905

Newbie

Location: Alfreton

Registered: 15 Jul 2014

Posts: 40

Status: Offline

Post #9
Long overdue update!


Walker - Over in Holymoorside mate! Do you regularly drive up and down Derby Road (A61)? A couple of mates have mentioned they keep seeing a White Rallye over that way although given their car knowledge it could be a 106! ha

mik - Underside is worse than I thought having had a proper look, just waiting on funds to get it booked in to a fabricators then the underside will be getting a good going over. Had a look at coskev's thread, very inspiring but I doubt mine will be that good any time soon, its my only car!

Right, gonna struggle to remember every detail now as I haven't updated for ages but i'll do my best!

Not long after I had it, stripped the seats out as it was fairly grim and gave it a good clean

Before:







After:







Much nicer place to be!

Then it got a good claying and its first polish and wax, paintwork is still fairly rubbish but its getting better with time









Obviously it rained, hard! The day after haha



Took the brake calipers off one evening to paint them, realised the carrier pin was seized so put them back together before it got dark (without painting them because I was p**sed off haha)
Couple of days later went up to my mates workshop to 'unseize' it - snapped it... thanks to pug_306 for sending me a carrier as fast as he could! No pics apart from one of the car looking sorry for itself!



**WARNING** Rusty Rallye images ahead!!!!

Ok so got it on the ramps for a proper look! Seems the o/s outrigger has been done (badly) and the n/s isn't really there anymore. Whole underside needs tlc! Need to get it booked in for welding! Any very good fabricators recommended within Derbyshire and surrounding counties?









Picked some Cyclones up and decided I prefer them so the Comp's are available - need to get some pics of them but if anyone's interested send me a PM.

The Cherry is a friends very early Notts reg'd Dturbo which he picked up for £150 as a winter car - bargain! (and much less rusty than the Rallye!)







Couple of stragglers

New smoked side repeaters and an obligatory 'outside the dealer' shot







So, at the moment i'm looking for

  • a good welder/fabricator
  • a radiator (mines bent) so I can change the coolant ready for icy mornings - need to pick up a thermostat too
  • once i've picked up a d/shaft seal I can do the full service as well which will put my mind at ease a bit (got the rest of the stuff)
  • a cat-back full stainless desperately as this is dropping to bits!

  • also got some new fog blanks and paint ready to take the front end off, paint the bumper, paint the towing eye and rust proof and paint the inner wings, oh and give the engine bay a good clean!! have updated my to do list on the original post though!

    Getting there slowly Smile
    Posted 3rd Nov 2014 at 21:56
    rallyeash

    Seasoned Pro

    Location: Devizes

    Registered: 11 Dec 2006

    Posts: 4,424

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    Post #10
    Smart Rallye

    ________________________________________

    230 hp 2.1 16v XU 205 rallye on jenveysHyper Project thread here
    309 3dr K20 Type R
    Posted 3rd Nov 2014 at 22:06
    orta

    Senior User

    Location: East Mids

    Registered: 02 Sep 2006

    Posts: 860

    Status: Offline

    Post #11
    I was only just re-reading this thread last night and here we are with an update spooky. Mine looks worse underneath than that mate. Just can't get it up in the air like that for decent pics of it. I liked the comps a lot but not in yellow. Black cyclones look spot on tho

    ________________________________________

    CLUB BLACK RALLYE


    ||B8s||60-70mm drop||Black Partner Steels||P1 VTS Rack||Refurbed Beam||Hybrid ARB||VTS Torsion Bar||
    Posted 4th Nov 2014 at 07:15
    orta

    Senior User

    Location: East Mids

    Registered: 02 Sep 2006

    Posts: 860

    Status: Offline

    Post #12
    Ps if you find a good fabricator Derby way let me know as I need work doing and would rather use somewhere recommended even if I do have to travel!

    ________________________________________

    CLUB BLACK RALLYE


    ||B8s||60-70mm drop||Black Partner Steels||P1 VTS Rack||Refurbed Beam||Hybrid ARB||VTS Torsion Bar||
    Posted 4th Nov 2014 at 07:14
    walker_texasranger

    Seasoned Pro

    Location: Sunny Retford

    Registered: 26 Jan 2008

    Posts: 2,502

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    Post #13
    Car looks mean on those Cyclones!! That looks like a Jetex exhaust to me Hmm and could well be worth fixing?

    I drive up and down the A61 all the time mate, mainly between Sheffield and Frankie and Bennys roundabout but do occasionally venture out through clay cross. The car wasn't stickered up though so looked like a lesser model from the outside. They would spot me now though as it's got full livery Thumbs up

    I have a mate in Sheffield that can sort the welding out for you by the way, drop me a PM and I'll get his details if you so wish.

    ________________________________________

    Almost standard 1999 Bianca Rallye
    Hilux InvincibleX daily

    306 No.13 Doh

    Carp and specialist Anglers Click here
    Posted 4th Nov 2014 at 08:36
    hbomb1905

    Newbie

    Location: Alfreton

    Registered: 15 Jul 2014

    Posts: 40

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    Post #14
    Cheers guys, I was a bit apprehensive about putting the underside pics up so it's good to hear there's others with the same woes LOL:
    Next time you're doing a black rallye meet up orta give us a shout Smile

    I've no idea what the exhaust is, its leaking at the backbox though and generally looks pretty eaten away!
    Main problem is its loose where the de-cat meets the downpipe as its been fitted pikey style with random bolts. Really need to get it sorted as it sounds dreadful at the mo haha

    Ahh might not have been you then although he assures me it was defo a 306! lol
    Posted 5th Nov 2014 at 18:08
    mik

    Seasoned Pro

    Location: Kent

    Registered: 17 Feb 2011

    Posts: 2,100

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    Post #15
    Good update. It is a ball-ache getting the underside sorted but well worth it. These cars are getting to an age when TLC is needed, but they are basically sound. Yours is by no means the worst pre-TLC Rallye on here. You should get the sill covers off and clean up under there - if it is like mine it will be fine unless damaged by muppets. I bought new heat shields instead of cleaning old ones up.

    The 306 Rallye is still a great steer - even when compared to a new 208 (non-GTI though) I had as a hire car last week which felt very dull. The electric steering was lifeless, especially around the straight-ahead, and as a result was hard to judge along twisty A-roads. Not particularly confidence-inspiring. It was an OK car but nothing special, not too different-feeling from the Nissan Quashqai I had the next week.

    Black Rallyes have got to be quite rare now, so well worth looking after.

    ________________________________________

    Cherry Rallye SOLD

    Posted 5th Nov 2014 at 23:18
    hbomb1905

    Newbie

    Location: Alfreton

    Registered: 15 Jul 2014

    Posts: 40

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    Post #16
    mik wrote:
    Good update. It is a ball-ache getting the underside sorted but well worth it. These cars are getting to an age when TLC is needed, but they are basically sound. Yours is by no means the worst pre-TLC Rallye on here. You should get the sill covers off and clean up under there - if it is like mine it will be fine unless damaged by muppets. I bought new heat shields instead of cleaning old ones up.

    The 306 Rallye is still a great steer - even when compared to a new 208 (non-GTI though) I had as a hire car last week which felt very dull. The electric steering was lifeless, especially around the straight-ahead, and as a result was hard to judge along twisty A-roads. Not particularly confidence-inspiring. It was an OK car but nothing special, not too different-feeling from the Nissan Quashqai I had the next week.

    Black Rallyes have got to be quite rare now, so well worth looking after.


    Thanks mate, that's cheered me up! Once the main welding is done and the 'front' of the floorpan is painted/sealed nicely i'll be looking at sorting the boot floor (hopefully have a refurbed axle ready to go on if I time it right) and then sideskirts off and front end for touching up those areas. Then I shall be happy Smile

    Not driven a Pug newer than a 207 but I can imagine it's not the same sort of experience at all! Although having said that i've sat in a 208 GTi and it seems from the surface that they're upping their game... thoroughly looking forward to the 308R as I think the new 308 is a great looking car.

    Got her on the ramps again today and stuck new downpipe to de-cat gasket and bolts/springs on so she's not quite so antisocial again now! Should be fine now it's fitted properly!

    Also managed to bodge a clifford alarm speaker into my 'hornet' siren box so it makes a noise again but its about as loud as a fast moving slug so it's not going to scare anyone. Might need to invest in a new siren box.
    Posted 6th Nov 2014 at 19:28
    hbomb1905

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    Location: Alfreton

    Registered: 15 Jul 2014

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    Post #17
    Went to my first PSCUK meet yesterday at John Harrison Peugeot dealer in Lowdham, Notts

    Had a good time, nice bunch of chaps - pretty much all 205 owners though from what I could gather - I was the only one reppin' the 306!

    Quickly jet washed the motor on the way there but still looked crap as it was p**sing it down (also the reason hardly any older cars turned up)

    Anyway, took a few pics - the RCZ R is a beautiful car! Peugeot have really upped their game IMO.









    and managed to blur the one with my car on... haha

    Posted 9th Nov 2014 at 12:51
    walker_texasranger

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    Location: Sunny Retford

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    Post #18
    Ah nah, I would have turned up if I had known about this...

    ________________________________________

    Almost standard 1999 Bianca Rallye
    Hilux InvincibleX daily

    306 No.13 Doh

    Carp and specialist Anglers Click here
    Posted 9th Nov 2014 at 13:23
    orta

    Senior User

    Location: East Mids

    Registered: 02 Sep 2006

    Posts: 860

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    Post #19
    Likewise I drive thru lowdham everyday on my commute!

    ________________________________________

    CLUB BLACK RALLYE


    ||B8s||60-70mm drop||Black Partner Steels||P1 VTS Rack||Refurbed Beam||Hybrid ARB||VTS Torsion Bar||
    Posted 9th Nov 2014 at 15:28
    hbomb1905

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    Location: Alfreton

    Registered: 15 Jul 2014

    Posts: 40

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    Post #20
    Ahh sorry chaps, like I said it was my first PSC meet and didn't really know what to expect. Was a bit of a wash out because of the terrible weather! I'll make sure to post something up if there's another!
    Posted 10th Nov 2014 at 00:09
    hbomb1905

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    Location: Alfreton

    Registered: 15 Jul 2014

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    Post #21
    So, didn't get much done for a few weeks and then sorted loads of stuff over the last few days so feeling good. Constantly thinking 'I need a BMW' and my watch list is full of 530i Sport E39's but then I get on with the Rallye and the feeling subsides for a few more weeks. Can't justify having both and don't want to get rid of the Rallye so i'll just have to put up with it Big grin


    Serviced the old girl a few weeks ago having built up a parts pile. Got Peugeot filters and Mobil oil so should be operating nicely now! Unfortunately after putting the NGK's in I knicked coil pack no.4 wire meaning she didn't want to go! I rougharse diagnosed it to be the fuel pump relay and as I found it hanging behind the battery box with a smashed casing I waited for a replacement (thanks to pug306). Whilst waiting I noticed the loom that i'd damaged and found it had been done before and simply twisted together and electrical taped back together!! Soldered it all back up and heatshrinked/weatherproofed appropriately. Was worried the solder might melt but it seems to be going ok at the moment. Tried it with the smashed up old relay and voila she started. New relay fitted now though anyway and bolted where it should be!
    Pics of my damage/previous owners bodge







    Arsing about pic


    Shortly after, walker came over to have a look at my Comps and brought the Rallye-R of braymond fame - Love
    First time since owning my Rallye it's been next to another Smile

    Decided to finish the service yesterday and went to get a driveshaft seal ready for changing the gearbox oil! Suddenly remember the need for CV boots so got a couple of those as well! and another seal being as the shaft would be out anyway!

    Nasty old boot and seal




    This is an awkward daft design!



    Progress pics and a time-lapse just for fun (and can put it in as part of my coursework - i'm back at college studying Auto Engineering)







    **Can't seem to upload time-lapse**


    Ash J spotted an OMP stainless and very kindly sent me a heads up message on Wednesday so I quickly contacted the seller and it was delivered yesterday! Fitted it last night and very chuffed. Car now only has a backbox but is surprisingly reserved when milling about but lovely and raspy up the revs.. and it gets rid of the Jetex tailpipe which I really didnt like! Needs adjustment as it sticks out a bit too far and hangs to the left (was ok when I fitted it but then moved about a bit for some reason!)











    Today decided to give the car a good clean, polish and wax. Ofcourse I was just finishing drying it and it p**sed it down for 4 minutes (exactly long enough to soak the entire car) then dried up again. At this point I decided to clean the interior instead! Nice rainbow pic to finish off though Smile (crystals back in as masks need re-sealing)





    Update to To-Do List



    Done:

    Radiator Fan Switch

    Track Rod Ends

    Remove lockers

    Buy Cyclones

    New wiper blades

    Headlight rear dust caps

    Wind deflectors

    Smoked side repeaters

    Grease up front calipers

    Thorough interior clean including removing old wiring

    Rear view mirror

    Full service

    O/S and N/S outer cv boots

    New n/s driveshaft seal

    New exhaust




    Not Done:

    New top-mounts (n/s heavily cambered)

    Lower front suspension to match rear

    Locking wheel nuts

    Paint wing mirror caps

    Paint front bumper

    New Rallye blank N/S - Bought

    Paint towing eye black
    Cambelt and tensioners

    Weld, Rust treat and underseal under footwells

    Rust treat and paint front end

    Rebuild a rear beam

    New alarm siren - done but too quiet!
    Matching brake hoses on front

    Paint brake calipers and grease up rears
    New radiator urgently!

    Thermostat
    Posted 6th Dec 2014 at 00:41
    walker_texasranger

    Seasoned Pro

    Location: Sunny Retford

    Registered: 26 Jan 2008

    Posts: 2,502

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    Post #22
    Nice update that mate! When we going for a spin? Need to wash all the conifer off mine first though, oops Blush

    New exhaust looks nice Cool

    ________________________________________

    Almost standard 1999 Bianca Rallye
    Hilux InvincibleX daily

    306 No.13 Doh

    Carp and specialist Anglers Click here
    Posted 6th Dec 2014 at 00:56
    hbomb1905

    Newbie

    Location: Alfreton

    Registered: 15 Jul 2014

    Posts: 40

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    Post #23
    Thanks man! Poor white rallye! haha

    I'm working at the weekends which doesn't help but I finish college for christmas week after next! Should go for a christmas drive at some point! Also, usually free Fridays regardless!
    Posted 6th Dec 2014 at 00:59
    orta

    Senior User

    Location: East Mids

    Registered: 02 Sep 2006

    Posts: 860

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    Post #24
    Thought Andy broke braymonds Rallye? Would like to see it again if it's in my neck of the wood.

    ________________________________________

    CLUB BLACK RALLYE


    ||B8s||60-70mm drop||Black Partner Steels||P1 VTS Rack||Refurbed Beam||Hybrid ARB||VTS Torsion Bar||
    Posted 7th Dec 2014 at 21:20
    ash j

    Regular

    Location: Fareham

    Registered: 02 Mar 2011

    Posts: 415

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    Post #25
    Nope.

    If you read the for sale/breaking thread, then you'll see at the end that Walker confesses to having bought the car complete and not letting it be broken.

    Good to see it wasn't broken.
    Posted 7th Dec 2014 at 21:38

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