Once back at mine (Jan 2016) I started with the most important job of the build, getting rid of the rear lights. These got a great reception during Wayne’s build thread. Some kind soul took them off my hands via ebay and a replacement set was found at the local scrappy.





I then proceeded to empty the car and had the joys of finding a home for all the removed parts. These became a pain in the arse for the next 18 months with tripping over them, having to empty the shed every time I wanted to get anything from it and the Mrs constantly moaning about the front and rear bumpers not making a good garden feature!
Once the car was stripped back to nothing I set about removing the remaining sound deadening from inside the car and the under seal from underneath. It was at this point work slowed down for various reasons. One being the cage installation. For some reason it bugged me. Nothing against the job that had been done, but I was not happy with it. The cage came out and I set about digging further into it. I also looked into some of the previous rust treatment that had not worked that well. A good nine months passed…

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At this point I was fed up with lying on the floor in the winter and I had both front floor cross members to repair due to the common rot. So I dug out the spit I bought a couple of years back for a bargain £52 on ebay. I knocked up a couple of mounts and cracked on lifting the car to mount it. It was daunting the first time it got spun over but the points seemed to be in the right place as the car could be handled by one person and rotated. It would not go fully over to the left due to the front towing eye but it was ample for what I wanted. The floor pan was cleaned back, treated and protected. The arches and engine bay received the same treatment. I have to say that was the best £52 I have ever spent! At this point the rallying bug had really bitten so racing the car was long in the past. The dash had been cut right back to make it as light as possible for the track and the heater box was missing so I set about finding some replacements. After taking trusted advice from people who had used various aftermarket heater solutions in the bid to save weight it soon became apparent to fit the original heater box. There is nothing worse rallying in the middle of the night when it is p**sing it down and having the windows steamed up. No matter how much weight you save you won’t be any quicker if you can’t see!

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I now had the joys of refitting the cage, what a c$nt of a job as it is such a tight fit and everything seems miles out of alignment. However once you start tightening things up I is amazing how it all comes together and lines up. With this you have the joys of trying not to scratch the new paint and trimming and fitting the internal trim to miss the cage. The carpet went in and I trimmed that around the cage and I am pleased with how it fits. One thing that annoyed me with my 205 is the lack of adjustment on the navigators foot rest. I found a pair of aluminium bars that were threaded every 25mm. These bolted to the floor nicely and the foot rest bolts to these allowing adjustment of the foot rest. They also allow the footrest to clear the carpet which makes fitting easier. The carpet was the take back out so I could fit the fuel lines. So a large order from Torques (which made my eyes water) arrived and I cracked on installing them. I decided to retain the standard fuel tank and pump set up so I ordered some 5/16” quick release fittings for the PTFE lined AN-6 pipes. This allowed me to connect it up to the standard pipes that come from the pump to the filter and then start the nw pipes through the car and into the engine bay. Allan Allan kindly sorted my fuel rail out by welding on a pair of 9/16” fittings. It annoys me that all I could find is steel weld on fittings that have no flats to allow the use of a spanner whilst fitting / removing the pipes – don’t like the idea of twisting the existing fuel rail pipes. So I found a solution and ended up with what I wanted for a fraction of the price.
The brake pipes were also made up and installed ready for the carpet to be refitted.

















Although the car is going to be used for road rallying I plan to get it log booked by the MSA so it can be used on stage rallies. There is a good selection of rallies that have a road rally class. This will also help as the engine has to retain the standard injection system for road rallying. I plan on running a standard engine for the time being so this helps keep the costs down and means I don’t get put in a class with escorts with £20k+ engines. The aim of the game here is to go out and have some fun!

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Lovely work buddy!

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1997 ph1 bianca GTI6 - The looker
1996 ph1 Sigma GTI6 - Dead
1999 Red Rallye - The Daily
2005 Nissan Navara D40 - Family car
1968 Mustang Coupe - The dirty little secret
Put ya foot down, put ya foot down we'll loose em easy!

Is this your post-photobucket solution? If so let me know what it is so I can replace pics in my project thread.

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Cherry Rallye SOLD

The rear beam has been apart and rebuilt with new genuine bearings and seals. A new pair of trailing arm shafts were also pressed in and the beam located on the car with a set of solid mounts. Whilst it was apart a set of VTS 21mm torsion bars found their way on. The beam has been set slightly above the standard ride height to give clearance on some of the rough Lancashire and Derbyshire tracks. A pair of 306 Group A tarmac Billies were also installed. The hubs will be converted to studs further on in the build along with a set of standard GTI6 brakes.



As said before the engine is going to remain standard for the time being. It has received a cam belt, water pump and a set of plugs along with a new clutch. The inlet manifold was treated to a session in the blast cabinet along with the fuel rail. Both had a quick lick of paint. Various sensors / senders have been fitted to the engine for the additional Stack gauges. The gearbox was fitted which houses a 4.4 CWP and Gripper diff. Having ripped apart my garage and shed during the week I came to conclusion I had lost the RH engine mount that bolts to the rubber mount on the inner wing. Fortunately Anthony from the 205 forum has come to the rescue and it landed on my doorstep last Friday morning ready for fitting the engine on the Saturday morning. Stew Baker at BBM has kindly sorted me out with a set of uprated engine mounts to keep this firmly in place.






Whilst the dash was out the loom ended up having a good trim removing many wires, relays and plugs that will not be used. Additional wires for the shift light were added to the rev counter feed and a wire for the spot lights added to the back of the indicator stalk. This will then be run through a switch so the spots can be isolated from the main beam as per the regs. Fitting the loom was a nightmare due to the cage front strut triangulation bars which made it very tight to fit the dash loom to engine bay loom connector. It managed to fit though without having to re locate the hole in the bulkhead. I stole a cracking idea from Mile’s to use the hole for the lighter to stash the T pull for the fire extinguisher and I also trimmed out where the standard clock sits to allow the fitment of a few switches including the battery cut off switch. This weekend I had power back on for the first time in years and started connecting the additional switches and gauges up. Ryan (Pug_306) has also been a legend in supplying loads of missing parts. Some bit bits and also loads of niff naff and s**te – top bloke cheers!! The OMP wheel has been fitted with a quick release Lifeline boss.







The fuel tank straps were blasted and had a quick lick of paint. I came across some heavy duty heat shrink so decided to cover each strap for added protection. Getting rally specific parts for the 306 is a bit of a pain in the arse. For 205s bits are everywhere. I struggled to find a suitable sump guard until I came across a virtually new Nova one on Facebook. A short drive to Chester had it held in position confirming it would do the job. A few mounts have been added to the subframe and front cross member and it fits a treat. Last Monday the car was also treated to a make over. I guy came round and spent the day removing all the years of s**te from being stored in a barn and all the grinding particles that had found there way on to the paintwork.

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It has been a very busy few weeks after I set a deadline of this Tuesday to have the car mot’d. It has been rather stressful to say the least what with wondering if parts are going to turn up on time and if there is enough hours in the day.

First beauties were the new discs from Godspeed. These suit the non 106 Cup Car hubs which allow me to use the AP 4 pots.




Next up was to fit the oil cooler from Radtec. Now I buggered up here and ordered one which is slightly to small but I will see how I get on with it.



Then there were the Aero catches. These were a bit of a twat to fit but more to the point to get right. I started by back drilling from under the slam panel through the inner bonnet skin before going through the outer skin. I used a 90 degree windy drill here with a drill block to ensure the pin would sit square to the slam panel. I then marked round the catch before chain drilling the outer skin, filing it to the correct size and shape and drilling off the holes. II trimmed the inner skin to suit. They were installed with a smidge of black RTV.











Brackets for the Cibies were made and fitted before the lights were installed.



A few pics of the car completed ready for the MOT and the passenger seat to be installed.

















Door cards ready to be fixed on





But on Tuesday after an eventful MOT where the ECU shat itself mid MOT it passed

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Looking Great a credit to you
Keep the posts coming Mark

By the way, the gear knob is temporary! Satchshift will be fitted soon but I had to prioritise

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Thanks!

Not yet. I am going to look into using a standard tank and chopping the bottom of a second one. A w**k load of tiger seal and space out the braces to accommodate. I spoke with a few people at the prom stages who had done this.

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Prom stages was a good do. Yeah a few 306s out which did ok. I was in the silly seat in a type r which was a right laugh

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Really well done Mark