106 Rallye Prep and Restoration

[PhillipM]

Better than all these dodgy welsh ******s, every time I go to Wales there's more of 'em, they're breeding like sheep...

Anyway Cris, I've got another firm looking at sorting the bearings at one end now, if they don't come through I'll fab some adaptor brackets up so you can use the 306-type units.

 

[davenport]

^^^

did i send you my spare S1 drop links??? i`m sure i wrapped them up but cant remember sending them???

 

[PhillipM]

Sent me one to work from, don't know what you've done with your other one

 

[Cris B]

Cheers Phillip, lets get these back on track

For those bored with looking at metal work photos here's something different... I organised a group buy to get the rear beam refurbished by a specialist company near Grantham. Here it is having just come back with the 23mm torsion bars and polybushes fitted. I also mounted up the AST adjustable rear shocks for the photos.

 

[Coo]

You'll be cursing them for setting the standard the rest must be as clean as !

 

[dboy]

Thats a very nice looking beam to go with a very nice 106..

I spent 2 summers ago restoring my old supercharged saxo vts but luckily it did not have that much rust on it,,
Good job btw..

 

[Cris B]

Did a few bits and pieces over the weekend, but not a huge amount on the car. I finally finished fabricating up a pair of bumper mounts to be welded onto the inner wings. The old ones were rusty and caked in filler.

Despite quite a lot of effort working on the cardboard templates, I'd misaligned the wing mounting hole with the nut welded to the back and also the lower bumper securing hole. This meant when they were tacked on they didn't align correctly. Rather than start from scratch I jiggled the positions around on the existing brackets and they're now done ready for fitting.

Finally took some pictures of my work-in-progress modified top mounts to facilitate easy camber adjustment of the AST top mounts. These are the mark two version with the top mounts in primer until I get around to repainting the whole engine bay. Every time I walk past the car in the garage I look at them and think that I can do better so they're likely to change again. Probably just need me to get the files out and even up the edges.

Non Power Steering Position.

Power Steering Position.

Also seam sealed the O/S wheel arch so some good progress has been made... Had enough of working on cars and missing out on the weather and family time, so I'm taking a couple of weeks off.

 

[SamT]

looking excellent mate!

i was just wondering if you know how to separte the trailing arm off the beam, to replace the bearing section??

 

[agc]

looking excellent mate!

i was just wondering if you know how to separte the trailing arm off the beam, to replace the bearing section??

SamT you have pm to save cluttering up the thread.



Alan

 

[Cris B]

Been on hols but back on the case now and onto the nearside inner wing. No where near as bad as the off side, but still needs some love. Can you see the swiss cheese?

This is why.

Chopped out and started repairing - simple patches first and filling in unnecessary holes.

Ground down the welds. Tomorrow we start on the more complex bigger patch.

 

[Cris B]

Finished the repair on the nearside inner wheel arch. I need to grind down and finish up these welds then seam weld this side of the engine bay. Then there’s the repairs on the section where it joins onto the chassis rail, but the chassis rail shouldn’t need any work.

 

[Cris B]

This weekend I thought that I had finished the N/S inner arch repairs but as I welded on the last repair patch it has become obvious that part of the chassis rail was pretty rotten. What was supposed to be 1.6mm thick steel melted away under the tip like it was paper. It's a gutting discovery as there's no point ignoring it so now I will have to undo some of the most recent work I have just done and repair the chassis rail. It looked okay externally so it has gone from the inside out. So so so frustrating. Bit behind it taking photos, but will post some up next time I get working on the car. Really busy with work so progress has really slowed.

 

[Cris B]

Here’s how far I had reached before the true state of the chassis rail rot became clear:

<p>So chopped out the estimated rotten section based on the O/S repair:

_b.jpg[/img]

Chassis rail top was in a bad way:

Internal gusset out:

 

[andyxxxx]

Very nice project mate. Love the motor.

I have to confess I'm a huge '90s Peugeot fanatic

That is some serious rot though! Certainly have your work cut out there.

 

[Cris B]

Thanks for the comment. Yes it seems pretty bad

I spent an hour in the garage last night and managed to cardboard template for the chassis rail side cut out above, but spent most of my time sitting looking at it and trying to work out the plan of attack. The gearbox mount needs to come off to be able to repair the other side of the N/S rail which on close inspection seems to be equally rotten. It might just be surface rot, but I figure I've gone so far with this project now I might as well do it all properly.

 

[davenport]

stick with it fella... if you do have to cut the gearbox mount off make a jig up first that picks up off somewhere solid on the bottom of the bulkhead/opposite side engine mount firts so when it does go back it remains in the correct place...

 

[Cris B]

Yeah thought a jig might be the way ahead. Made a bit of progress tonight, hoping to forge ahead this weekend...

 

[Cris B]

Some progress from last night:

Outside of the chassis rail now has the repair panel firmly tacked in place. This will have to come off in the long run so I can fit the chassis rail gusset back inside. In the interim it gives the rail some structural strength and rigidity whilst I do other repairs.

Once that was in I could remove the rotten section of chassis rail top. Some tidying up work is now needed before I can fabricate a repair section to replace this. The route taken here has negated a need for a jig so far and allowed me to make soe good progress in teh time I had last night. I will need to make one up before doing much else to the engine bay side of the rail and the gearbox mount located on it.

 

[Cris B]

So after some careful planning, I chopped the engine bay side of the N/S chassis rail, carefully doing so to allow repairs without needing to setup a jig. There was plenty of structural rigidity in the sections of rail left and the rotten sections simply lifted out once they were cut out – once the spot welds were drilled out, most of the work was done with a 1mm slit disc and then some careful work with a disc on the Dremel.

Made up a repair panel and fitted it after I had pressed in some creases to match the original section.

Most of it could be welded from the engine bay side, but some work had to be done from inside the rail.

Then fabricated up a repair section for the gearbox mount support. Slightly more complex as this has a M6 nut welded on to act as an earthing point. It was also an excuse to get a hole swager out…

Dressed down the welds with a combination of grinding disc, flap disc and carbide burrs.

Next job is to fabricate the internal gusset and the chassis rail top and get them fitted.

 

[Chipper]

Good stuff, keep it up!