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Author Subject: Rusty Rallye
af1-gti

Senior User

Location: avoiding my pug

Registered: 08 Nov 2010

Posts: 807

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Post #1
Hi, I suppose i should start a project thread.

Mostly so i can ask advice and also a reference for other people who may also run into the problems I will inevitably run into during my ownership.

This Rallye was bought in 2014 as a replacement for a 2006 BMW 330D SE. I fancied an older car and something with a bit of a cult status. Also the BMW was not at all me! modern new and refined. I did have the DPF removed and a AMD remap for 280bhp and I'm sure my BMW ownership time will come again in the future as it was a brilliant car.

Anyway...

I bought it off Ebay, I think a thread came up on here about it before I purchased it. Intergalactic mileage, and obviously has a smack but I'm a bit of an idiot and it suited me perfectly.

Had a great time getting the train to Wales and was confronted with this


Front bumper sprayed badly, whilst still on car and the wrong shade of white and the black grille? well its white.

The car had been polished and looked great regardless! despite there being polish all over the black rubber seals of the screen and on the mudguards and spoiler.

I took it home and what with it being a car and all that, I drove it!
trouble free motoring



Bit juicy on fuel and leaving a few spots on the driveway but bless it.. its a T reg car with 167000 miles, you wouldn't put your Nan down for leaking a bit would you.

I then took it to Pugfest and did a few Hill Climbs



I quite like the rear wheel in that picture, kind of looks like its on lions!

Anyway then it was MOT time



CARBULANCE to the rescue (no really)



who did a great job at fixing this hole and he did a little bit of welding on my Series 1 Rallye as well



He also sold me a Mig Welder so I am going to get practising and maybe get myself on a course so i can solve the rest of the rust.

I have also fitted new Lemforder Track rod ends for good measure..

The MOT tester missed a severely split N/S steering gaiter so i stuck a new one on for good measure! (I'm not sure how i feel about the MOT tester missing out on a fault! id rather a car failed for something dangerous as opposed to it being ignored.

I stuck 2 Toyo Proxes on the car too, i can't fault them as Tyres and have used them for years, good price and seem capable enough, much better then the Yokohama Prada Spec 2s that were on the front and supplied 0 grip in the wet (95% of the time in britain)

Im currently waiting on a OE exhaust to be delivered (2nd hand) to help with emissions and to reduce the irritating boom that comes with a Decat and missing middle box. I doubt that big exhausts do much to aid performance on a standard car anyway and at least i will be able to pass the emissions test!

I have found a couple of other holes in the wheel arch so will have to tickle them with a welder once i become competent.

The gearbox seems to be leaking from two places.

one of them is here.



can this part be removed once the oil is removed and sorted with a silicone gasket seal?

and here



Im pretty sure that there should be a dust boot here next to the bearing?

advice would be great.

the o/s driveshaft also has a slight split and is leaking a bit of grease, so for simples i may as well replace the whole driveshaft rather than replace boots seeing as the driveshaft is going to have to come out to sort the leak Sad

Any comments or criticisms or compliments are welcome

Alan



________________________________________

Rich E wrote:

With the 306 Rallye the goal wasn't to make a purer or more focussed car. It was to make a cheaper car, and then cynically use Peugeot's motorsport heritage to make it appeal to enthusiasts.
Posted 2nd Aug 2014 at 21:06
pebbles167

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Location: Melksham. Wiltshire.

Registered: 08 Dec 2009

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Post #2
Saw this at Prescot, as you say, looked nice. Good project, best of Luck Thumbs up

________________________________________

2005 Peugeot 206 GTI 180

2008 BMW K1200R
Posted 2nd Aug 2014 at 21:11
af1-gti

Senior User

Location: avoiding my pug

Registered: 08 Nov 2010

Posts: 807

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Post #3
were you the guy who walked up to me and said "your front bumper is wrong" and then walked off like you were about to puke up? cause after that point i decided i wasn't much fussed on socialising!

oh and..

NEED LESS PROJECTS!

________________________________________

Rich E wrote:

With the 306 Rallye the goal wasn't to make a purer or more focussed car. It was to make a cheaper car, and then cynically use Peugeot's motorsport heritage to make it appeal to enthusiasts.
Posted 2nd Aug 2014 at 21:15
rikky 🦔

Location: cheshire

Registered: 28 Feb 2004

Posts: 26,795

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Post #4
af1-gti wrote:
were you the guy who walked up to me and said "your front bumper is wrong" and then walked off like you were about to puke up? cause after that point i decided i wasn't much fussed on socialising!


LOL

________________________________________

306 rallye reproduction decals (full sets/individual decals) | 306 b-pillar textured vinyl weatherstrips
306 slam panel esso stickers | 306 yellow / orange / pension fund red side door badges
gti6 inlet manifold badges | 306 rear boot badges (p2/p3)
winner of Extraction of toys from prams with outstanding vigour award 2009 [source: gti6 owners club]
Posted 2nd Aug 2014 at 21:44
jimmyrallye

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Location: portsmouth

Registered: 19 Apr 2008

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Post #5
Haha ... Awesome pic of it on hill with a few quid spent on this will look good

________________________________________


"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 2nd Aug 2014 at 22:15
af1-gti

Senior User

Location: avoiding my pug

Registered: 08 Nov 2010

Posts: 807

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Post #6
I realise that the seal on the gearbox where the driveshaft goes is an old type pug one. I bought the new rubber type part today so hopefully when i get a new shaft i can stick it in!

You know something that does annoy me though?

BMW and VW both have a heritage parts line to cater for enthusiasts that are restoring their old cars where as Peugeot seem to think i'd prefer to be financed up on a 208 feline or something... umm no

________________________________________

Rich E wrote:

With the 306 Rallye the goal wasn't to make a purer or more focussed car. It was to make a cheaper car, and then cynically use Peugeot's motorsport heritage to make it appeal to enthusiasts.
Posted 2nd Aug 2014 at 22:22
mik

Seasoned Pro

Location: Kent

Registered: 17 Feb 2011

Posts: 2,100

Status: Offline

Post #7
Nice car, good to see someone's sorting it. A Bianca White Rallye is an excellent choice, as you don't have to put up with the Cherry Red fading!

________________________________________

Cherry Rallye SOLD

Posted 3rd Aug 2014 at 19:39
Niall

Seasoned Pro

Location: Epsom

Registered: 06 Jun 2012

Posts: 1,941

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Post #8
Don't let mileage worry you. These are bullet proof engines when looked after properly.

Like Jimmy said, few quid spent on it and it will be back to its once former glory!
Posted 3rd Aug 2014 at 19:48
pebbles167

Seasoned Pro

Location: Melksham. Wiltshire.

Registered: 08 Dec 2009

Posts: 2,516

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Post #9
af1-gti wrote:
were you the guy who walked up to me and said "your front bumper is wrong" and then walked off like you were about to puke up? cause after that point i decided i wasn't much fussed on socialising!


No I was not! Angry I was polite to everyone I met and gave you a thumbsup out of my window.

________________________________________

2005 Peugeot 206 GTI 180

2008 BMW K1200R
Posted 3rd Aug 2014 at 20:31
jamiek_uk2000

Seasoned Pro

Location: Llanelli

Registered: 18 Apr 2009

Posts: 1,925

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Post #10
T'was you I saw the other day then.

It seems like there are as many Rallyes as GTi6s on here nowadays.

Another persons spending money saving a 15 year old french car. At least I'm not alone!

________________________________________

205 GTi Red - G939 RTU - Died!
306 GTi 6 Diablo - Being resurrected! Project Thread

Looking for:
VTS P1 Rack
PR1.2 16"
Posted 3rd Aug 2014 at 20:36
Tarmac terror

Regular

Location: Southampton

Registered: 20 Mar 2014

Posts: 458

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Post #11
jamiek_uk2000 wrote:
T'was you I saw the other day then.

It seems like there are as many Rallyes as GTi6s on here nowadays.

Another persons spending money saving a 15 year old french car. At least I'm not alone!



Nope...I'm there too!!

Thumbs up

TT
Posted 4th Aug 2014 at 15:54
Castor_Troy

Regular

Location: Forfar

Registered: 25 Jul 2013

Posts: 282

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Post #12
tarmac terror wrote:
jamiek_uk2000 wrote:
T'was you I saw the other day then.

It seems like there are as many Rallyes as GTi6s on here nowadays.

Another persons spending money saving a 15 year old french car. At least I'm not alone!



Nope...I'm there too!!

Thumbs up

TT


And me Crazy
Posted 4th Aug 2014 at 16:31
Nose

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Location: Birmingham

Registered: 23 Jun 2013

Posts: 994

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Post #13
quote:
Another persons spending money saving a 15 year old french car. At least I'm not alone!













And another, £££££££££££££££££££££££££££££Shock LOL

________________________________________

Bianca 306 Rallye.
Mondeo Titanium X.
Posted 4th Aug 2014 at 20:17
cully

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Location: Cullompton

Registered: 12 Jun 2013

Posts: 1,093

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Post #14
Castor_Troy wrote:
tarmac terror wrote:
jamiek_uk2000 wrote:
T'was you I saw the other day then.

It seems like there are as many Rallyes as GTi6s on here nowadays.

Another persons spending money saving a 15 year old french car. At least I'm not alone!



Nope...I'm there too!!

Thumbs up

TT


And me Crazy


Ill add my name to this list too
Posted 4th Aug 2014 at 20:34
mik

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Location: Kent

Registered: 17 Feb 2011

Posts: 2,100

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Post #15
...and me as well. I've just put in another order to the dealer for some bits. I've got all the parts invoices but have never added them up.

________________________________________

Cherry Rallye SOLD

Posted 5th Aug 2014 at 01:34
af1-gti

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Registered: 08 Nov 2010

Posts: 807

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Post #16
Got a run about which has bought me a bit of time to work on the rallye as opposed to rushing bits, driving it all week and fixing it at weekends



The temptation to tidy up the rust on it and apply a PTS decal set for rallye replica goodness a strong with this one, but for now I'm enjoying all 45hp of urgent ness

Any way

Exhaust needed changing due to mot failure on emissions
The plan was a swap over at mot time each year but the more I think about it, the more irritating a big boomy exhaust is

Managed to get a complete system for £60 delivered from
Some pug breakers (was called pug performance iirc)

Took the exhaust off, noticed it has a big dent in the back box


Also, a peek at the decat reveals this...

Is this a good thing?

________________________________________

Rich E wrote:

With the 306 Rallye the goal wasn't to make a purer or more focussed car. It was to make a cheaper car, and then cynically use Peugeot's motorsport heritage to make it appeal to enthusiasts.
Posted 12th Aug 2014 at 18:09
welshpug!

Capt Pedantic

Location: Bigend, Wales.

Registered: 27 Mar 2007

Posts: 25,838

Status: Offline

Post #17
looks like a twin tybe group a thing? backbox looks like longlife, pipe where mid box should be appears to be a bit narrow.

________________________________________

need a part number? get on here - http://public.servicebox.peugeot.com

Bring on the Trumpets.

Posted 12th Aug 2014 at 18:26
af1-gti

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Location: avoiding my pug

Registered: 08 Nov 2010

Posts: 807

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Post #18
Well just unwrapped my new (old) standard exhaust
And I see a big problem with the catalytic converter...





No lambda hole!!?

________________________________________

Rich E wrote:

With the 306 Rallye the goal wasn't to make a purer or more focussed car. It was to make a cheaper car, and then cynically use Peugeot's motorsport heritage to make it appeal to enthusiasts.
Posted 12th Aug 2014 at 18:29
welshpug!

Capt Pedantic

Location: Bigend, Wales.

Registered: 27 Mar 2007

Posts: 25,838

Status: Offline

Post #19
LOL

that'll be off a diesel then.

________________________________________

need a part number? get on here - http://public.servicebox.peugeot.com

Bring on the Trumpets.

Posted 12th Aug 2014 at 18:49
af1-gti

Senior User

Location: avoiding my pug

Registered: 08 Nov 2010

Posts: 807

Status: Offline

Post #20
Mother fudgers

________________________________________

Rich E wrote:

With the 306 Rallye the goal wasn't to make a purer or more focussed car. It was to make a cheaper car, and then cynically use Peugeot's motorsport heritage to make it appeal to enthusiasts.
Posted 12th Aug 2014 at 18:54
af1-gti

Senior User

Location: avoiding my pug

Registered: 08 Nov 2010

Posts: 807

Status: Offline

Post #21
I'm going to the pub

________________________________________

Rich E wrote:

With the 306 Rallye the goal wasn't to make a purer or more focussed car. It was to make a cheaper car, and then cynically use Peugeot's motorsport heritage to make it appeal to enthusiasts.
Posted 12th Aug 2014 at 18:56
Niall

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Location: Epsom

Registered: 06 Jun 2012

Posts: 1,941

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Post #22
Yeah that isn't a standard cat from a gti. They are huge in comparison to that!
Posted 12th Aug 2014 at 18:58
af1-gti

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Location: avoiding my pug

Registered: 08 Nov 2010

Posts: 807

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Post #23
Oh well I have already unintentionally name dropped the seller

________________________________________

Rich E wrote:

With the 306 Rallye the goal wasn't to make a purer or more focussed car. It was to make a cheaper car, and then cynically use Peugeot's motorsport heritage to make it appeal to enthusiasts.
Posted 12th Aug 2014 at 19:16
af1-gti

Senior User

Location: avoiding my pug

Registered: 08 Nov 2010

Posts: 807

Status: Offline

Post #24
So I had the welding 'done' and it failed it's mot again
On more rust

Rear sill


Front inner wheel arch



Pretty sure this car has been kept under the ocean most of it's life

________________________________________

Rich E wrote:

With the 306 Rallye the goal wasn't to make a purer or more focussed car. It was to make a cheaper car, and then cynically use Peugeot's motorsport heritage to make it appeal to enthusiasts.
Posted 11th Sep 2014 at 12:10
af1-gti

Senior User

Location: avoiding my pug

Registered: 08 Nov 2010

Posts: 807

Status: Offline

Post #25
Oh yeah and this is the second fail sheet

I'm
A bit concerned the first tester missed the rear rust

________________________________________

Rich E wrote:

With the 306 Rallye the goal wasn't to make a purer or more focussed car. It was to make a cheaper car, and then cynically use Peugeot's motorsport heritage to make it appeal to enthusiasts.
Posted 11th Sep 2014 at 12:11

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