Post #151
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Cherry Red Rallye .... On going OEM spec restoChina Blue GTi6 .... Weekend toy
Black 208 GTi .... Wife's car now
Silver BMW 550i.... The executive missile
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| Author | Subject: Red Rallye S529 OAN |
 Ben_W
Formerly gpm  Location: Lutterworth Registered: 01 Sep 2007 Posts: 2,941 Status: Offline |
China Blue GTi6 .... Weekend toy Black 208 GTi .... Wife's car now Silver BMW 550i.... The executive missile |
 Posted 16th Apr 2015 at 22:46
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rallyestyle
Seasoned Pro  Location: London Registered: 23 Jul 2003 Posts: 14,991 Status: Offline |
Post #152
3 days and no post! Stop slacking and get on with it! ;-)  ________________________________________ Just Drive It |
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Posted 19th Apr 2015 at 23:09
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Ben_W
Formerly gpm Location: Lutterworth Registered: 01 Sep 2007 Posts: 2,941 Status: Offline |
Post #153
Sorry dude. Progress has slowed significantly. Lost all interest at the mo. Very long story.....________________________________________ Cherry Red Rallye .... On going OEM spec restoChina Blue GTi6 .... Weekend toy Black 208 GTi .... Wife's car now Silver BMW 550i.... The executive missile |
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Posted 20th Apr 2015 at 12:19
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rallyestyle
Seasoned Pro Location: London Registered: 23 Jul 2003 Posts: 14,991 Status: Offline |
Post #154
Ben_W wrote: Sorry dude. Progress has slowed significantly. Lost all interest at the mo. Very long story..... No worries, was only joking with you ;-) I know the feeling though, it can get quite hard when the finish line seems so far away   Maybe take a break and then come back to it in a month or so's time. Hopefully the weather will be super warm by then and it will be fun doing what you need to do ________________________________________ Just Drive It |
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Posted 20th Apr 2015 at 14:47
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Ben_W
Formerly gpm Location: Lutterworth Registered: 01 Sep 2007 Posts: 2,941 Status: Offline |
Post #155
Right, today was not a very good mood day at all. Was all a bit dark.....Had to go somewhere near a Halfords so I picked up a can of Cherry Red and painted the bit I'd undersealed. Completely forgot to panel wipe it down first do there has been a little bit of reacting in a couple of places but, generally, it went down ok. I can rub back and redo any bad bits. The main thing however is the fact I think it looks ace!!!!!  Happy with the finish considering this is over stone chip....   ________________________________________ Cherry Red Rallye .... On going OEM spec restoChina Blue GTi6 .... Weekend toy Black 208 GTi .... Wife's car now Silver BMW 550i.... The executive missile |
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Posted 30th Apr 2015 at 16:17
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orta
Senior User  Location: East Mids Registered: 02 Sep 2006 Posts: 860 Status: Offline |
Post #156
Mate that came out great! It makes me think there is hope for mine! U going to any of the shows this year? Would love 2 see the work up close?? ________________________________________ CLUB BLACK RALLYE||B8s||60-70mm drop||Black Partner Steels||P1 VTS Rack||Refurbed Beam||Hybrid ARB||VTS Torsion Bar|| |
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Posted 3rd May 2015 at 08:40
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Ben_W
Formerly gpm Location: Lutterworth Registered: 01 Sep 2007 Posts: 2,941 Status: Offline |
Post #157
Tom, not sure if I'll get it to any shows this year.More than welcome to come and have a look if you wanted. ________________________________________ Cherry Red Rallye .... On going OEM spec restoChina Blue GTi6 .... Weekend toy Black 208 GTi .... Wife's car now Silver BMW 550i.... The executive missile |
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Posted 3rd May 2015 at 13:00
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Ben_W
Formerly gpm Location: Lutterworth Registered: 01 Sep 2007 Posts: 2,941 Status: Offline |
Post #158
Right,So I spent most of Saturday morning taking apart a beam. It had been at my mates unit since Thursday, having regular doses of releasing fluid. Hooked up the slide hammer expecting a right old battle and with just 3 hits, out the first one came. You could see where the fluid had penetrated. Ace. Flipped the beam round, set up the hammer and hit it. And hit it again. Hit it some more. Hit it lots more. Heated it. Hit it again. Stopped for a good cup of tea and a dose of releasing fluid plus more heat and got back to it and hit it again, lots. Didn't move a millimetre. s**t. Ended up at the lorry maintenance unit next door with an acetylene torch and a 20 ton press. Eventually gave up but took the plug that covers the end of the torsion bar with it. Need to order a new one. Just need to pop the bar out of the first trailing arm to come out and we are good. Bearings aren't bad but are getting replaced. Shafts look OK but I need to measure them, once I find out what they should measure. So after messing about with slide hammers and oxy torches and generally bashing about old beams, I opted for a slightly less strenuous afternoon and set about taking the rear seats from the interior I bought apart. I bought a spare interior mainly for spares really. It makes sense to have some spare material (and I mean the patterned stuff in the middle) available should I ever need it. I'd picked up the interior and beam Chiefton was selling. Absolutely no idea how, but we got a beam, 2 front seats, the 2 rear seat parts, a wife, a daughter and all the stuff for a weekend away into a Mondeo saloon.... So, onto the seats. I took apart the rear upright first as it seemed the easiest. Zips along the bottom and sides. Had to undo the fittings around the seat release to lie it down but no issue. The biggest issue was the 2 sections on each side with rods in them, attached via rings to rods mounted in the foam. I forgot to take any photos but ended up straightening one end of the rod to pull them out. I now know there is a better way having done the base too.....anyhow..... Eventually removed the cover and stuffed it into the washing machine.... The worst bits were removing the seat belt buckle fixings. The have a plastic part of the back with a one way fixing on them that goes through a separate part which was a swine to remove....I'll let the pics do the talking as it explains it far better than I can....    Straightened rod...  And finally removed...  After washing. Not impressed. Think I need to look at a different programme on the washing machine....  Not impressed with all the stuff left on it so wrapped some sellotape around my fingers with the sticky side out and went over it. Loads of pet hairs and stuff.... Looked a bit better afterwards...  Couple of marks...  Bit of bobbling...  Will compare it to the one in the car once dry and I'll choose the best. The seat base in still in the machine washing. Got I back onto the base those afternoon. Easiest way I found was to hook the rings round the rod in the material, then get them round the rod mounted in the seat foam, then pinch back together with a pair of pliers. Easier said than done, then a proper s**t when you realise you've put the seat cover on the wrong way around..... Hook rings...  In place...  Rod in the foam...  And finally one seat cover, back in place. This pic looks awful and makes it look like there are lots of marks on the seat. Either the mpic or the camera as they aren't there!!!  ________________________________________ Cherry Red Rallye .... On going OEM spec restoChina Blue GTi6 .... Weekend toy Black 208 GTi .... Wife's car now Silver BMW 550i.... The executive missile |
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Posted 31st May 2015 at 21:39
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Ben_W
Formerly gpm Location: Lutterworth Registered: 01 Sep 2007 Posts: 2,941 Status: Offline |
Post #159
Upright part of the seat back together. Still a couple of marks but a very reasonable spare. Washed it again at 50 degrees was as hot as I dare go! ________________________________________ Cherry Red Rallye .... On going OEM spec restoChina Blue GTi6 .... Weekend toy Black 208 GTi .... Wife's car now Silver BMW 550i.... The executive missile |
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Posted 2nd Jun 2015 at 15:26
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orta
Senior User Location: East Mids Registered: 02 Sep 2006 Posts: 860 Status: Offline |
Post #160
Looking good mate, I have massive love for the standard seats. What Nick is your drivers bolster in? ________________________________________ CLUB BLACK RALLYE||B8s||60-70mm drop||Black Partner Steels||P1 VTS Rack||Refurbed Beam||Hybrid ARB||VTS Torsion Bar|| |
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Posted 3rd Jun 2015 at 17:10
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Ben_W
Formerly gpm Location: Lutterworth Registered: 01 Sep 2007 Posts: 2,941 Status: Offline |
Post #161
On the seat in the car, very very good condition. On the spare set, it's toast......So, today, I had to get out of the house. Borrowed a mates blasting cabinet and made a start on all the bits for the rear beam. Got this far today....  Also got one of the trailing arms nearly done. Haven't got an after pic as its not finished but this is a before...  I'll be taking the hub off of it tomorrow to finish it properly. Finish wise, I think I'll be going powdercoat. Found a very cheap local place. The nuts and bolts and pipe brackets on the right of the first picture will all be getting zinc plated, with a yellow zinc plate finish. The rest will be powder coated black. Beam tune will be yellow and torsion bars red. All the nuts and bolts will be yellow zinc plated as well. ________________________________________ Cherry Red Rallye .... On going OEM spec restoChina Blue GTi6 .... Weekend toy Black 208 GTi .... Wife's car now Silver BMW 550i.... The executive missile |
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Posted 3rd Jun 2015 at 18:35
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Ben_W
Formerly gpm Location: Lutterworth Registered: 01 Sep 2007 Posts: 2,941 Status: Offline |
Post #162
Bit of today's progress then.Still had one torsion bar stuck in a trailing arm. Didnt mess about with this one and got it in the press. A few tonnes of pressure and eventually she gave in and popped out. Good. Straight into the sand blaster with that. In between doing some other bits and bobs, I also managed to get the bearings out of the beam tube and also get the beam tube blasted as well. Was fun doing that as half of it had to hang out of the door of the blasting cabinet. On top of that, it was VERY rusty in the middle, with perhaps 1/8" of crusty rust. Not any more. By the end of tomorrow I should have all the bits ready for powder coating. That's gonna have to wit until next month though as been an expensive month this month so far with daughters birthday and party etc..... So, the pics.... Blasted trailing arm from the other day...  Beam and torsion bar...  The stuff of dreams....non crusty, non rusty splines......they now slide together beautifully......gonna get a shed load of copper grease during rebuild!   Old outer bearing, still in reasonable shape and hasn't worn through..  Non worn bearing seat in the tube is always nice...  ________________________________________ Cherry Red Rallye .... On going OEM spec restoChina Blue GTi6 .... Weekend toy Black 208 GTi .... Wife's car now Silver BMW 550i.... The executive missile |
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Posted 4th Jun 2015 at 18:37
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rallyestyle
Seasoned Pro Location: London Registered: 23 Jul 2003 Posts: 14,991 Status: Offline |
Post #163
Awesome Fairly easy to blast then? Certainly seems the way to go if that's the finish you get ________________________________________ Just Drive It |
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Posted 4th Jun 2015 at 19:19
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Ben_W
Formerly gpm Location: Lutterworth Registered: 01 Sep 2007 Posts: 2,941 Status: Offline |
Post #164
Yeah, blasting is very easy. Very much a point and squirt type thing. Very, very effective at removing paint and rust etc. For oily and greasy parts, I try and clean them up as much as possible first. Makes it easier when blasting.The result is completely bare metal, ready for whatever you want to do next. Most of the bits above (tube, torsion bars, trailing arms etc) will be getting powder coated. The rest will be zinc plated. ________________________________________ Cherry Red Rallye .... On going OEM spec restoChina Blue GTi6 .... Weekend toy Black 208 GTi .... Wife's car now Silver BMW 550i.... The executive missile |
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Posted 4th Jun 2015 at 19:23
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Ben_W
Formerly gpm Location: Lutterworth Registered: 01 Sep 2007 Posts: 2,941 Status: Offline |
Post #165
Supposed to be taking it easy and not doing anything as been diagnosed with Supra Ventricular Tachycardia.....should be doing anything strenuous etc.....Going out of my mind with boredom. Sitting at home doing nothing gave my brain far, far too much time to focus on stuff it shouldn't be so..... Got out and got the sandblasting finished on the beam. Roughly mocked back up together on the bench. A long way from where it was...  Got to get that off to the powder coaters now... ________________________________________ Cherry Red Rallye .... On going OEM spec restoChina Blue GTi6 .... Weekend toy Black 208 GTi .... Wife's car now Silver BMW 550i.... The executive missile |
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Posted 10th Jun 2015 at 11:53
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Ben_W
Formerly gpm Location: Lutterworth Registered: 01 Sep 2007 Posts: 2,941 Status: Offline |
Post #166
Cleaned up a couple more bits tonight.Been meaning to do these for a while and at 9pm the wife put celebrity master chef on the TV (why do you want to watch a load of celebs, fresh from cookery lessons, cook something they've been trying to remember the recipe...) So outside I went to clean up the fuel tank and the fuel filler neck. Both were properly crusty having been in an exposed location under the car for all their lives so got busy with the Autosmart G101 and a good stiff detailing brush. No before pics I'm afraid as my phone was flat. The filler neck:   That came up very very well. Happy with that. Onto the fuel tank. Apologies for some of the pics:  The marks you can see on this pic are not dirt but the rub marks where it had been rubbing the body. I also removed the pump unit so I could clean that properly. That also gave me access to the tank to fill it with some water and give it damn good clean inside. Bit difficult trying to shake something that size with some water in it but I managed it!  There is no way these clips are going back on in this state. Might look at blasting and zinc plating, or buying new from Peugeot and going from there. Seem to think they changed the design of these.  Tonight, however, did see the return of an old nemesis......that horrible black underseal stuff.....aaaaaaarrrrrrrgggggggggghhhhhhhh!!  It's on the edges of the tank and despite me scrubbing with a nylon bristled floor scrubbing brush, it didn't want to move. I'm going to attack it with some green scouring pads tomorrow, see if that shifts it. Grinder and a brush might be a bit heavy duty and the physiological has only just finished sorting my back and still working on my neck and shoulder...... ________________________________________ Cherry Red Rallye .... On going OEM spec restoChina Blue GTi6 .... Weekend toy Black 208 GTi .... Wife's car now Silver BMW 550i.... The executive missile |
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Posted 18th Jun 2015 at 23:18
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Ben_W
Formerly gpm Location: Lutterworth Registered: 01 Sep 2007 Posts: 2,941 Status: Offline |
Post #167
Does anyone else wonder if, that during the early/mid 90's when they developed the 306, that they employed Einstein's offspring and the village idiots, at the same time? Clearly the brains got put into the engine and chassis departments whilst those without the grey matter got to design and decide on the fittings and fixtures.........yes, I have got the right royal hump. I mean, who on earth (other than said morons) designs a rivet with a hard steel centre and a soft aluminium head so that when you try and drill it out to remove the side skirt, the drill bit keeps slipping off the middle onto the soft aluminium, drilling anywhere and anything, other than the bit you want it to? The same idiots that decided a torx head screw would be ideal to live at the bottom of an exposed arch to hold the arch liner in, getting full of muck making it impossible to get a torx bit into it to be able to undo it.......aaaaaaarrrrrrrgggggggggghhhhhhhh!Rant over. I shall get onto this evenings activities, other than fighting with stupid, stupid French design! Was high time that the side skirt on the drivers side came off for me to get a better idea of how bad the damage to that from jacking point is and see if the rust has spread any further. Drilling out the rivets, as I might have mentioned earlier is a pain. I ended up drilling two or three holes in the head of each rivet. If you're lucky, the head comes off whilst drilling like this...  Most of the time, you end up prising it off with a screwdriver...anyway, the crushed sill was pushing up on the skirt and pushing it out of line/shape. This pic shows it quite well   Once the rivets were all drilled out, a little careful levering over the rivet stumps that were left and around the crushed section and the sill was off. The sill itself isnt in great shape. Bent out of shape and a couple of the mount mouldings broken...    So, the sill section......not as bad as I'd first feared in terms of the rust doesn't appear to have spread any further. Worse in the fact the sill section appears buckled in 3 places.....   Once washed down, the buckling became apparent..  It's gone in 3 places. Very hard to photo but I've circled them in one of the following pics   Bit of a dilema now. Not certain yet if the crushed section does need replacing or just straightening out. This buckled section is covered by the sill and won't be seen if I were to leave it but I'm not sure I'd ever be happy with it left like that. To be honest, if the crushed section does need replacing, I'll do the lot. It's just a slightly larger cut section I'll need from a donor. It has annoyed me though. As has some of the other poor finish paint bits and panel fit I've been noticing as I go. Clearly had the drivers quarter painted but they left the skirt on and did a crap job of the paint edges....  Paint on the passenger side wing. About 3 tonnes of it. Again, crap finish at the edge...  Poor panel fit on the front end. Very poor indeed.   I'm assuming it's been put back together poorly. Panels are all genuine Peugeot, no evidence of any front end crash damage (that I know of or have found yet....) The perfectionist is me has well and truely woken up. My wallet is busy hiding and shaking like a sh!tting dog and I'm worried now what else lurks below some of the fresh paint.......... Oh well, in for a penny........ ________________________________________ Cherry Red Rallye .... On going OEM spec restoChina Blue GTi6 .... Weekend toy Black 208 GTi .... Wife's car now Silver BMW 550i.... The executive missile |
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Posted 22nd Jun 2015 at 19:54
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Ben_W
Formerly gpm Location: Lutterworth Registered: 01 Sep 2007 Posts: 2,941 Status: Offline |
Post #168
And I just won this....http://m.ebay.co.uk/itm/161735537622?nav=WATCHING_ACTIVE Happy with that for £12.50....original new ditch finder too! ________________________________________ Cherry Red Rallye .... On going OEM spec restoChina Blue GTi6 .... Weekend toy Black 208 GTi .... Wife's car now Silver BMW 550i.... The executive missile |
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Posted 22nd Jun 2015 at 20:52
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walker_texasranger
Seasoned Pro  Location: Sunny Retford Registered: 26 Jan 2008 Posts: 2,502 Status: Offline |
Post #169
Just read this from start to finish, loving the attention that your are giving it mate! I'm the same as you, if its going to be done you might as well do it right. Only problem I have is lack of knowledge on what to do, so normally end up paying someone else to do it  Mine is in desperate need of some paint, it's done 167,000 miles now, skirts need re fitting, bumper needs painting, boot has been done badly in the past so needs re doing blah blah, you are inspiring me to delve in and have a look at the rest, bad times  Keep up the good work, will be awesome when it's done. Can't you foresake the OE spare thing and use a C5 Steelie? Loads lighter and looks nearly the same? ________________________________________ Almost standard 1999 Bianca RallyeHilux InvincibleX daily 306 No.13  Carp and specialist Anglers Click here |
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Posted 22nd Jun 2015 at 20:54
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Ben_W
Formerly gpm Location: Lutterworth Registered: 01 Sep 2007 Posts: 2,941 Status: Offline |
Post #170
John, be under no illusion that I'm any kind of 'expert' at this kind of stuff.I just figure if you are going to do it right, you start with bare metal again. I've spent a few hours researching and investigating and gone from there. Take your time and test stuff first and you won't go too wrong. If you are attempting then underside, either get it up on a two post lift or have the engine and fuel tank out and stick it on a rotisserie. Unless you fancy hours of expensive physio, don't put it up on axle stands on your drive and crawl under it for hours. Ultimately, I want this to be THE best, original spec Rallye there is left. For that reason alone, everything is going to be as it left the factory. The steel is only a spare anyway so not fussed. ________________________________________ Cherry Red Rallye .... On going OEM spec restoChina Blue GTi6 .... Weekend toy Black 208 GTi .... Wife's car now Silver BMW 550i.... The executive missile |
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Posted 22nd Jun 2015 at 21:18
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walker_texasranger
Seasoned Pro Location: Sunny Retford Registered: 26 Jan 2008 Posts: 2,502 Status: Offline |
Post #171
This gives me hope!! At the end of the day, whats the worst that could hapen  Fair play Ben, if OE is what you are after then OE it has to be  ________________________________________ Almost standard 1999 Bianca RallyeHilux InvincibleX daily 306 No.13 Carp and specialist Anglers Click here |
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Posted 22nd Jun 2015 at 22:01
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Ben_W
Formerly gpm Location: Lutterworth Registered: 01 Sep 2007 Posts: 2,941 Status: Offline |
Post #172
Deffo bud. Wouldn't be so fussed if it was a 6 but the Rallye was a rare enoguh beast to start with. There will be a market for them against some point....I can't do everything. Have a guy who is going to paint the bottom and engine bay for me. He will do a far, far better job than I ever will....A decent zinc primer with a good sealant layer over that will keep the chassis sweet for quite a while if you get rid of any rust first.....give me a shout if you need any advice. ________________________________________ Cherry Red Rallye .... On going OEM spec restoChina Blue GTi6 .... Weekend toy Black 208 GTi .... Wife's car now Silver BMW 550i.... The executive missile |
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Posted 22nd Jun 2015 at 22:12
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walker_texasranger
Seasoned Pro Location: Sunny Retford Registered: 26 Jan 2008 Posts: 2,502 Status: Offline |
Post #173
Thnaks mate, appreciated I know I have similar corrosion to sort underneath, I have only ever seen one of these cars thats not been abused by some tyre monkey and that was a minty Mc mint one owner moonstone six that I had in my posession a few years ago, the rest have been spanked  but what do we expect? These things are old now... ________________________________________ Almost standard 1999 Bianca RallyeHilux InvincibleX daily 306 No.13 Carp and specialist Anglers Click here |
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Posted 22nd Jun 2015 at 22:18
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tea boy
Senior User  Location: Market Rasen Registered: 27 Feb 2010 Posts: 632 Status: Offline |
Post #174
I've just read this from the beginning and I have to say that it is very impressive stuff.It has also shown me that I am wasting my time with mine so I am off outside now to set fire to it. ________________________________________ Make tea, not war.If it ain't broke......fix it until it is. |
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Posted 22nd Jun 2015 at 23:28
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Ben_W
Formerly gpm Location: Lutterworth Registered: 01 Sep 2007 Posts: 2,941 Status: Offline |
Post #175
First skim of filler on the beam tonight....I say skim in the loosest sense if the word. With it being so warm it went off far faster than I anticipated, despite me using a little less hardener to compensate...you live and learn.....some sanding to do then! ________________________________________ Cherry Red Rallye .... On going OEM spec restoChina Blue GTi6 .... Weekend toy Black 208 GTi .... Wife's car now Silver BMW 550i.... The executive missile |
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Posted 23rd Jun 2015 at 19:03
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