ZX 16v

[welshpug]

Right then, seeing as the 6 forum keeps going down I thought I might as well post this thread over here off the 205 forum, this started back in 2012.

[quote name="welshpug" post="1257105" timestamp="1338577015"]
Following on from my previous ZX thread which ended abruptly on a slippery roundabout with a Sill+post interface, the search was on for a replacement shell, 6 months on I found a Silver 16v on a K plate which was being broken for spares, ended up getting this for free!

No pics as yet as it was Dark when I first saw the car, my friend AdamB did the road trip with his P2 Volvo V70 T5 spitting flames and using lots of fuel at the moment its parked up at Goliath's in Gloucester as I haven't space here in the valleys.

Also had good news last Wednesday in that the insurance claim against the Micra driver that took out the offside front corner by turning right across me has finally been settled in full, 18 months on!! I think I will be getting around £900 all in, which isn't bad.


Had a spare hour this afternoon after work, so dug out some bits I have collected recently, and took some pics of just how much space there is up front in a ZX, and weighing up whether I will use the cut down inlet I bought, or cut another one I have spare and make it even longer....

As it was before taking it apart



Space between bumper and fans, rad and fan cowling removed, epic amount of space...



Inlet stripped off....







BWARP....



stuck the bonnet down and tried to get a pic of how much vertical space I have to play with



enough to get a filter on easily! but looks like I have a ton of space to get more length....
[/quote]


[quote name="welshpug" post="1257110" timestamp="1338579260"]
few more pics...







current inlet length from the head face




Not sure what rad I could use to gain the space, maybe a BBM/Radtec shortened large capacity unit.
[/quote]


[quote name="welshpug" post="1258696" timestamp="1339252198"]
Take one spare inlet manifold:



Attack it with an angle grinder...



try it in the engine bay...



Pointing down a little too far on their longest point, but a little further back from that will give a nice angle, yet to measure what total length will be.
[/quote]


[quote name="welshpug" post="1258707" timestamp="1339254297"]
Standard inlet centreline length from the head face is 330mm, makes total length roughly 380mm.




[/quote]


[quote name="welshpug" post="1294725" timestamp="1346254082"]
so, err, yeah...




Oh and Goliath dragged this over today, cheers George!

it has a remodelled drivers door courtesy of a brick wall somewhere, a rusty drivers arch, knackered rear bumper and a smashed rear screen :blink: oh and a cracked windscreen! :wacko: But it was free.



Apparently the HG or bottom end has gone on this engine, not that it matters, as I have my RFS lump to drop in.

Obviously will clean the bay, maybe a lick of paint if required.


[/quote]

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September 2012 -

[quote name="welshpug" post="1295480" timestamp="1346616443"]
Made a start on getting the silver shell ready yesterday in between helping my mate Richard (Spannerman) change the clutch on a Mk7 Transit crewcab tipper twinwheel 100 PS.

Previous owner had somehow managed to break the rear screen, I can only imagine in attempting to remove the rear spoiler :wacko:



less of the street diamonds to hurt myself on! and a pile of trim bits...



from pulling out the seats dash heater box, to get at the carpet which was torn and flthy....




and to get at the heater matrix which was donald ducked.


then this morning Helped Rich sort his garage out and move stuff around, and got the donor in the dry ready to crack on.


[/quote]


[quote name="welshpug" post="1295501" timestamp="1346621881"]
Later on today after lunch and the F1 GP, thought I may as well get more done and start tearing the black bent car apart, this one similarly had the street diamonds scattered everywhere and a pretty damp carpet, but most importantly it was in once piece, the heater matrix in this car is under a year old as well, 2 hours later and all the seats carpet dash and heater box is out.



Jetwashed the carpet off in the back yard and put it on the workshop roof to dry out, is now hanging over the bannisters waiting for the bath to be free....
[/quote]


[quote name="welshpug" post="1295973" timestamp="1346835510"]
Didn't do anything Monday night after work, faffed about for an hour last night, front bumper was half off as can be seen in previous pics, but as usual the cage nut things were seized across the bottom lip, so had to take the angle grinder up.

Whilst I was fiddling at the front I took the slam panel off and unplugged the engine loom and drained the PAS res, wont take long at all now to get it out as there's no exhaust or coolant pipes left, just shafts and 3 bolts!!



Also swapped the wheels that Adam had put on to move the car as it came without any, he'll need them back soon as they're his winter tyres for his 406 Bus, comedy size difference, 65 to 55 profile!!




Oh and 3 days on the carpet is still hanging up in the house still damp in places! so interior progress is a bit slow still, but hope to get to a scrappy later on today and get some sound deadening as I don't work on Wednesday
[/quote]


[quote name="welshpug" post="1296584" timestamp="1347054910"]


Carpet finally dry, so dysoned it.



Popped down the sound deadening I alleviated from a ZX in Harry bucklands on Wednesday.



Carpet in



Fitted my shiny heater matrix into the heater box.



Then fitted heater box in the car, this one is so much easier than the 306 as there's a plastic plate and a foam gasket that sits over the pipes, then the pipes poke through the bulkhead and another rubber gasket and a steel plate is screwed down on the top, no faffing and cursing for ages trying to squeeze the grommit in place!

Two nuts on studs with fibre washers on the engine side of the bulkhead and a bolt to a bracket on the exhaust tunnel and that's it, wiring sits in a channel and screwed onto a few tabs across the top.



underside of the dash (which weighs bugger all) steel parts on the left are for the fuse box drivers side air ducting and general stiffness, on the right side is for the glovebox with an additional piece across the bottom, couple of in built ducts in the middle and brackets for the heater controls.



All done for the evening, no bad for 2 hours work




one of the other bits I got from the scrapyard was a two speed relayed fan control loom from a 1.9 N-A diesel ZX, as standard the 16v has a single speed single fan, the diesel has a single two speed fan as well but in a double cowling, the TD uses twin fans, a nicely self contained loom, I've used one of these on my 205 now, plugged straight in, just needed to splice in the fan connector


[/quote]

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[quote name="welshpug" post="1296781" timestamp="1347190831"]
Spent most of the day yesterday at Castle Come watching now not to go around a track fast :lol

My mate Richard (spannerman) has said that I should get the interior done first, then body then mechanicals afterwards, that way nothing will be left when it finally gets on the road.

After taking the front interior apart in fairly swift time, I thought I'd crack on with the rear and get that swapped over today, or at least it all removed ready, crikey what a difference, there's so many bloody screws its not surprising it feels so much different to a 306, took me an hour and a half to get all the trim off, seats were already out!

The bag on the light cluster is half full of all the screws that hold everything down from the B-pillars back.



A big box of trim panels! Going to grab some autoglym engine and machine cleaner and go over the plastics.



This little piece that sits under the rear seats you don't get on lower spec ZX's.



More coffee and time for F1...
[/quote]


[quote name="welshpug" post="1296815" timestamp="1347206157"]
F1 done, got some Autoglym engine&machine cleaner and washed the interior plastics, then had a look at how to get the sunroof cover off, as its broken on the donor, looked to be easier to take the roof lining down to do this so remove all 4 grab handles, roof lining is only stuck across the very rear edge with a tiny bead of sealant type stuff, the rest is velcro'd in place!

Only comes out through the boot if you want to keep it in one piece, then I had a look up at the mechanism, AHA!!! that'll be why you don't see any ZX's with rusty roofs like you do 306's, clever buggers at Citroen used a plastic frame and bolted it not like Peugeot that spot welded the sunroof frame up....


[/quote]


[quote name="welshpug" post="1298495" timestamp="1347829642"]
tbh most of it is compatible, heater box is the same, steering column and switches, but everything body wise indeed quite different, I think the front seat frames are the same.

sod all progress the last week as my mate Rich is having some building work done, and they found how the garage was getting its electrickery, the garage is across the lane with some armoured cable between two posts and into the shed at the end of his back yard, we found the cable simply goes into a junction box as you'd find for a lighting circuit :blink: then carries on to the house another 30 feet or so in some standard 2.5mm[sup]2[/sup] cable spurred off a socket next to the boiler!! :wacko:

given the roof is off the shed and the wiring exposed Rich doesn't want to leave the power on whilst he's not there in case it trips, he'll have a defrosted freezer and dead fishies!



Dan (DCC) popped up yesterday to have a fudged locking wheelbolt sorted on his C2, and dropped these off :ph34r:


[/quote]

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[quote name="welshpug" post="1298993" timestamp="1348080018"]
A bit more progress finally!

Rich managed to get the wiring sorted so its safe again, and I sorted the Strut swap to complete his PAS conversion on his 1.5 diesel 106 runabout as he's injured his arm, then after a very late lunch did some work in the garage.

Continuing with the bodywork+interior, unplugged the tailgate which is a doddle as the wiring just sits under the seal and goes into the car through decent sized holes behind the rear light clusters.



Pop the struts off, Knock/pull the hinge pins out as an able assistant (my brother Osian) holds on to the tailgate.



Pulled down the headlining,



undid two plugs and 8 nuts, and out the sunroof mechanism came.



Naughty thoughts of leaving the bugger off :ph34r:




Undid the 4 13mm bolts in the boot for the bumper, cut off the two 10mm's underneath, caged nuts, say no more! A good yank and off it came.



Gave this a little prod, and it fell off




And that's it for this evening
[/quote]


[quote name="welshpug" post="1300918" timestamp="1348926932"]
Got my brother to give me a hand fitting the sunroof mechanism and vacuum a few bits.



Stuck the strengthening piece back down onto the headlining, then lifted it up into place.




Went to remove the seatbelt clasps that sit under the seat seat.



OH COCK.

so I just carried on with fitting the rest of the trim, dozens of different bloody screw types! nightmare trying to remember where they all go :wacko:



got it all done, fitted rear light clusters, then popped the parcel shelf in, cool rear sunblind integrated into it.




Dropped the rear seat back in, simply drops into two brackets welded on either side, has a bar running across the bottom of the seat.



that was yesterday...
[/quote]


[quote name="welshpug" post="1300919" timestamp="1348927027"]
Today, finished assembling the dash and fitted the passenger seat.




Had a quick peek underneath, the bottom of the seatbelt bolts are visible, hence why they are rusty and seized :angry:

will have a go at drilling and tapping, but if all else fails they are the same thread as a standard harness backplate, 7/16 UNF x 20TPI.

---

All the brakelines underneath look rotty as hell, this one is actually damp!



I did re-pipe the old black car some 18 months ago from the base of the buklhead back, so should be able to salvage them.

Pushed it all the way back in the garage, then jacked the front up, will tinker along a bit more later.


[/quote]


[quote name="welshpug" post="1300923" timestamp="1348931976"]
It's a bit crusty up front, thankfully not the body, 16mm socket just slipped straight around the balljoint pinch bolt :blink:



not to worry, as the stuff on the other car was painted when I had it apart last time.
[/quote]



[quote name="welshpug" post="1301141" timestamp="1349025733"]
Today's progress:

Seeing as I wont be using this lot and it was looking to want to put up a fight, I did it the easy way, 4 bolts two nuts each side, chop the brake lines as they looked grotty as hell and unplug the ABS Leads.



Removed the alternator and unbolted the AUX bracket from the block, remove the two nuts from the hard pipe bracket on the bellhousing.



Drained the oil and whipped the shafts out, history of the engine is unknown, other than the shell has 120k on it, I think its safe to assume the HG had gone!


[/quote]


[quote name="welshpug" post="1301146" timestamp="1349026230"]
Sling a Towrope around the engine+box, take up the slack with the trusty manual engine crane, remove the last nut from the transmission end...





Jack the car up slightly, remove axle stands, and drop the car down.



SO much easier than trying to wind that crane up and down!

Pull the engine out and push the car back into the garage on the jack.





One emptier engine bay.




Going to extend these cables and relocate them across the top of the bulkhead, as they run across the bulkhead stiffener along with the 3 brake pipes, having seen how hot the RFS exhaust manifold gets when I was down at Alvin Powells with Dan and Sandy for Mapping in his 205,and having the wiring loom grommet melt and smoke away, I think it'll be a wise move to replicate the 306 here!




[/quote]

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[quote name="welshpug" post="1301150" timestamp="1349026957"]
Having thought that'll do for today, went back to the house for some coffee and late lunch, got a call from Dan (DCC) asking where I was, as he was outside

He had a present for me

Pete (MadScientist) had mentioned a few weeks ago that he had a Satchel DCOE pattern inlet that he wasn't using due to the angle not suiting a 205, however as the ZX is somewhat longer in the bonnet department may be of use, conveniently Pete was in Cardiff on a Stag weekend and Dan was passing and picked the inlet up from Pete who had kindly bought it along as Dan now works down west Wales he hadn't had a chance to pop up for a few weeks, and given it was raining today wasn't going to work on his 205.

Slung a couple of bolts in quickly and popped it in place on the old Black car.



looks great....

AH.....





DOH! the bonnet does close if I slacken the nuts and let the manifold tilt downards a little, but no chance of getting a filter on



Tons of space around them though, and I think this might work in a 306.



HMMMM



[/quote]


[quote name="welshpug" post="1301273" timestamp="1349040593"]
Now then, this is what me and my brother have been up to this evening, he was piloting the computer, I did the measuring.



Bonnet angle hasn't been measured yet, but we know the trumpets touch at the moment.



rough guesstimate so far is that the flange needs to be at about 155mm, its currently at 95mm.

Valve to head flange short side is roughly 70mm, inlet is roughly 300mm total.
[/quote]

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[quote name="welshpug" post="1301848" timestamp="1349280467"]
got the scrubbing brushed Autoglym engine+machine cleaner, and brake cleaner out this morning, but to no avail on the drivers side wheelarch, I don't know if its some feeble attempt at protecting the paint or just a massive buildup of oil and general s*ite, but it was Black, and its a silver car.



Black arches are a massive pet hate of mine on many builds, why go to all the effort of paining the body a lovely colour, then making the arches look like you couldn't give a toss and make the whole build look lazy, I'd much rather a body colour clean arch (or white even)

So I took a wire brush attachment in a drill and gently went at it to remove the blackness, and any loose surface rust on some sections, treated said rust areas with some Bilt Hamber product, that's the light blue areas.



I'd love to strip the whole underneath down, but I haven't the time or money so its going to be the areas that need attention only.
[/quote]


[quote name="welshpug" post="1301858" timestamp="1349287804"]
Popped back up to the garage, laid some primer in the arches, ran out, gave upon that.

Decided to strip the old engine down ot make it easier to move around, spent a while cursing whichever pug/citroen designer used T30 bolts on the front of the intake manifold, as half od them were fudged from rust, not to worry though as 10 and 11mm 12 point sockets hammered on worked a treat.

Found a nice remanufactured starter motor.



and a comedy speedo cable pin location.



as well as lots of oily rusty grubbyness, and some comedy cooling pipework.
[/quote]


[quote name="welshpug" post="1306192" timestamp="1351092337"]
Apologies to anyone mildly interested, been trying to get hold of the brake pipes and bulkhead heatshield and not feeling great for a while, motivation levels almost non-existant.

About a week ago I did some grinding away with the wire brush and applied some rust eater, had a poke a few days later and found a hole crap pic, but its right next to the subframe mounting section, as time is sparse I got some 2mm plate and extended that section down covering the hole, bit tricky and not the best welds, but its on and stuck



then gave it a shot of primer and some crappy white paint I Had lying about.



then dug out the tubing I bought off ebay to sort the engine bay brake pipe re-routing, as weel as sort the rotten bits.



I quite enjoy doing this actually, I'd love some more tooling to make it easier as its very satisfying getting it looking as it should from the factory, nearly.




will do more tomorrow hopefully as Dan (chipstick) has posted me a load of bits which should be at work by now.
[/quote]


[quote name="welshpug" post="1306480" timestamp="1351193470"]
Done a bit more!! Dan's parcel had indeed arrived, thanks Dan

Stuck the heatshield in place to see what I needed to do to get it secured.




the lower stud is already there and secures the upper exhaust tunnel heatshield, the two holes further to the right on the strengthening section are already there, leaving only one fresh hole to be drilled! I have a rivnut Gun and some Stainless steel caphead screws, the upper most stud is already present.

onto the brake lines, and here's the DOH! moment, I couldn't figure out how they were meant to sit, then it dawned on me that Dan's xsara must have been a fairly early car prior to PSA deciding top shift the brake lines up the bulkhead!

Still, there were a few unions and clips I can re-use, so cracked on with a brake line, now I remember why I wanted to buy a Decent Sykes-Pickavant flaring tool, you have to wind this thing pretty tight for Copper-Nickel tube to stay put as you wind the die down!

Mostly bent up and placed in the clips to get an idea of where to route it.



Also fitted the Servo vacuum hose Dan sent and bent the original pipes up roughly where I will stick the new ones


[/quote]


[quote name="welshpug" post="1307558" timestamp="1351632973"]
just got these....




8x15 ET0, so not sure if they'll fit under the 205's arches.

but there's this very useful web page here called Will they fit.com and it looks like there's a slim chance, the ZX arches are a little roomier though
[/quote]

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OCTOBER 2012




[quote name="welshpug" post="1307698" timestamp="1351692033"]
up and over Dan.

Got more done today, drilled the two holes to 9mm and added the third one, popped some rivnuts in.



Then started the faffage with the brake pipes, found my el-cheapo flaring tool really doesn't work on Copper-nickel tubing so gave up on that and used my Copper pipe, I can;t afford a proper Sykes tool at the moment but the most awkward pipe to replace I have managed to sort in copper-nickel so if I really want to I can do the rest again at a later date.

Popped a pair of 7mm holes in the scuttle and added some clips.




Heatshield in place, looking good


[/quote]


[quote name="welshpug" post="1307754" timestamp="1351704082"]
Got the heater pipes clipped in, what a doddle with no engine in the way

Bolted the heatshield down properly, and stripped some ancillaries off the old lump.



Need to sweep the floor out under the car then drop my engine in.


[/quote]


[quote name="welshpug" post="1309349" timestamp="1352304997"]
Done naff all for a little while again, but today got a fair chunk achieved.

I'd removed the driveshaft nuts a few weeks back, so to get the shafts out was easy enough, wheel off bottom balljoint removed and shaft pulled out, drained the oil whilst faffing about supporting the RHS of the car (it's on a slight slope which makes everything a PITA, and a bit dodgy :ninja ) undid the two 11mm nuts on the Intermediate driveshaft bearing carrier and whipped that shaft out, oh the wonders of working on a car you've already had apart, no seized bolts!

Bought some ratchet straps, only girly ghey ass skinny ones, but they were all I could find and be bothered to hunt for, slung a 2" dia bar resting on some wood across the bay and popped both straps around the engine.



Undid the downpipe to manifold 10mm's, then removed the LHS engine/transmission mounting and cradle.

Marked up the clutch arm+shaft, removed the wiring support bracket, popped the clutch arm off then the starter motor.



removed the remaining bolts, pulled the box off the engine.





So at the mo its sat on a trolley jack and two engine mountings with a T-bar stopping it swinging forwards, waiting to be whipped out which I might do later with a hand off my brother.
[/quote]


[quote name="welshpug" post="1309415" timestamp="1352322431"]
Engine oot!



nearly the end for the black car
[/quote]


[quote name="welshpug" post="1309431" timestamp="1352325014"]
yeah, the car is on quite an angle, so trying to get the engine and box out in one go is pretty difficult as its very heavy so shifting the crane about is very hard work, dropping 40 kilos off the weight of the lump helps a lot.

If I jack the car up where it is it just that little bit too high with the jack pointing the wrong way it just slides sideways!

this is from 4.5 years ago when I swapped the original engine, same crane as it happens.






[/quote]

[welshpug]

[quote name="welshpug" post="1310138" timestamp="1352569086"]
More done today.

One engine in the back of the trusty 405, its been in here before, about 5 years ago!




Set the height roughly on the crane, reverse the car up to it, pop a bolt through the D-shackle



Take up the tension with a ratchet, drive the car forwards!




Shift it into the garage out of the way, pop the gearbox on.



Lower the car on the jack, swing+shove the engine into the bay, jack the car up enough to get the LH mounting bracket on the chassis leg.



Take the car back up with the jack, fit the LH rubber mounting, wind the crane down till the RH arm is sitting over the mounting and taking the weight of the engine, shift the crane out of the way and pop the car back on the axle stands.

Dropped the slam panel on out of the way.



Got the RH driveshaft in and secure, main long gear rod from the base of the stick in (its different on the RS engine to clear the cat+downpipe) fitted the gear rods, starter motor in place, PAS pump and alternator bolted on, for some reason the AUX belt sems too short, but I haven't tried the one from the black car, might be that the RFS crank pulley is larger, forgot to check this.
[/quote]


[quote name="welshpug" post="1310926" timestamp="1352899071"]
Seeing as I need to get it rolling fairly soon, thought I'd get some suspension back on it.

Quite pleased with how these look after 2 years, springs are only cheapo's not the top dollar Eibach's AST use on their competition stuff, but the bodies are pretty much as they were bar one bit where they must have been scratched. (Yes they are VERY dirty...)



Got my Wishbones off too, one side is all bolted up, having lunch then cracking on with the other side shortly.


[/quote]


[quote name="welshpug" post="1310986" timestamp="1352914833"]
Found that the n/s f brake pipe was also a little crusty, so did that whilst fiddling with the suspension on that corner, also got the o/s built up.



Re-taped a few bits on the loom and got it fitted and clipped in to anything available, only the ECU and anything on the inlet to go.


[/quote]


[quote name="welshpug" post="1314040" timestamp="1354121308"]
Car is now at the back of the house with the old shell gone, wasn't a great deal left on it, subframe struts wishbones 2x tailgates passenger door, 15 tin roof sheets a dozen brake discs a few clutches, the old dash + heater box, came to 580 kilos.

The ZX non aircon only used a single speed single fan, but last time I was over at a decent scrappy near Cheltenham there was a TD ZX in there, also single fan but two speed so I got the loom off it, I couldn't take the fan cowling as it had forklift damage :lol :doh but its the same as a 306 twinfan housing which I already have.



Swapped the fan over and fitted the wiring, just need the box and a relay, and a clip for the low speed resistor.



Got the radiator and the cowling in, headlamp/slam panel on.



Bolted the air box on, slowly filling that bay up with clutter!



Stroke of genius, needed to sort a few flares that the £10 heapos**te flaring tool had made a mess of, take one Sykes vice mounted Flaring tool, and a large pair of stilsons.



No more jobs to do with the inlet off, so Bolted that on to get it out of the way in the workshop



then got p**sed off with catching my overalls knees/thighs on the pointy wing ends, so fitted the bumper and lights.


[/quote]

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[quote name="welshpug" post="1314675" timestamp="1354386723"]
Beam stripdown day, I knew this needed doing at some point and already had bearings in stock, picked a pair of shafts up from Neat Autos

Quite nicely finished, no branding at all on them.



felt pretty light which I don't remember them being so previously, maybe all the ones I've had before have been the smaller bore ones? I know the Febi spec is large bore, and these came out at a similar price but my local motorfactor never got back to me after I asked them to order a pair, so sod them, they might even be on the shelf for all I know :lmao



Take one beam, weighs a fair bit as is there! Fat torsion bars too, not the original 21's



Got to use part of my recent tool kit purchase.




Still don't know what half of these are meant to be used for!



But this one was ruddy obvious

Set it so I didn't have to faff remembering to measure when I re-assemble.



Pulled the dampers and torsion bars brake calipers etc off, then pulled the trailing arms out.



Left this pile of dust from one side!



So yeah, it was dead but not seized!
[/quote]


[quote name="welshpug" post="1314702" timestamp="1354394051"]
Avert your eyes, bright shiny thing!



Got this from Rich Walker some time ago, already powdercoated and unused since.
[/quote]


[quote name="welshpug" post="1343979" timestamp="1365006408"]
Has been some time since I last touched this!

Progress finally, got the trailing arm shafts swapped at Area52 back at the end of January.



Built the beam up, can't remember now what I set the damper bolt distance to, other than it the same both sides :wacko:

but then browsing my pictures I see I had the great idea to take a pic !

yep, 300mm, but its 23mm bars so no its not a 50mm drop





Front beam mounts are o.e peugeot, rear ones have done little mileage as they were replaced by the previous owner.

Dropped the fuel tank off fitted the front to rear brake lines, made up two from the compensators to the beam flexi's and bled up the brakes with an Eezibleed.

Sorted the two snapped seatbelt bolts by removing the captive nuts and using harness nut plates as they're the same thread.

As soon as a little welding is sorted on the outer sills at the rear the fuel tank can go back on then tidy the bodywork, fit the inlet an save up for an MOT.

Dropped a donor inlet and my Jenveys with Sandy Brown too...
[/quote]

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[quote name="welshpug" post="1354103" timestamp="1370004035"]
I think this will do the job.







Playing around with my 50mm lens, got this one on a half second exposure.





Big thanks to Sandy Colin and Dave.
[/quote]


this is just about the end of may 2013.

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June 2013.

[quote name="welshpug" post="1354320" timestamp="1370113970"]
I dun stuff!

as I need to get it in the garage to jack it up properly and do the welding, and that is up a fair slope I thought I;d see about making it drive, so stuck the radiator in, spent an hour hunting fruitlessly for the bottom hose wire clip, bolted the inlet manifold on.

Emptied 15 litres of fuel from the fuel tank that's been sat in the back garden a few months! bolted the tank on, then got the exhaust hung and clamped up.


tank on (only 3 from 4 fixings, 4th is in o/s sill right by the rust and has a snapped bolt) -



Exhaust on, not a bad job apart from faffing with the downpipe to manifold, only the rear box has hangers, though does have three, so fit the centre loosely to the rear and hang the rear up, offer the centre up to the cat and pull together and clamp up, I'm using genuine peugeot/citroen single piece clamps.



wire brushed the tailpipe yeah, the box looks crusty, and has a little condensation inside, but doesn't rattle...


[/quote]


[quote name="welshpug" post="1354442" timestamp="1370193480"]
Bunged a battery on, Radio still works



Filled the engine with water, left the bleed points open so it doesn't build pressure as I haven't got hold of a clip for the top hose yet.

Fitted a lambda sensor, removed the coils and plugs, spun over and got 2 bar oil pressure on the dash.

Plugs back in and cranked it, but wouldn't fire, couldn't hear the fuel pump going, primed the pump with a power probe and swapped the fuel pump relay, it fired up and swung straight up to 4k rpm and a great load of hissing!

Obviously quite an air leak, resonator intact, inlet bolted down securely on a PhillipM PTFE gasket, so the only thing left was the idle valve and sure enough it was stuck, I had a spare thankfully




There's an ABS sensor unplugged on the drivers side, and no aux belt as I haven't got any PAS fluid yet.


A good day, the engine hasn't run in 18 months, very happy with how it sounds
[/quote]


[quote name="welshpug" post="1355191" timestamp="1370465156"]
Today, I bought PAS fluid and an AUX belt, dug out some track rod ends form the shed, fitted the radiator hose clip and radiator securing clips, swapped a few wheels about so I could get the summer tyres on the 205.

Clipped the Clutch cable on, adjusted it vaguely, bolted the drivers seat in, bolted the drivers door mirror on.


Then I only bloody drove it up and down the back lane still air in the brakes somewhere :o good thing the handbrake works
[/quote]


[quote name="welshpug" post="1355221" timestamp="1370470156"]
Tea Power, it is the future



New AUX belt, I didn't realise there was two options, depending on which alternator was used, presumably they have different offset or pulley size, a longer belt for the higher power units, I did swap the alternator as it was noisy but didn't think anything of it, its only 9mm longer!

(actual spec is meant to be 1076, but the factors list a 1078, guess more vehicles use that size and this will take that up ion the adjuster fine)



£1.20 of clip, off the shelf, quite surprised they had one as they (peugeot/citroen) haven't been using a 16v XU for some time and they are stainless so don't need replacing unless lost!...


[/quote]


[quote name="welshpug" post="1355537" timestamp="1370601450"]
Tidied the tools and nuts and bolts in the Workshop last night.

Moved the ZX




Swept out.




Squeezed in, found it was still a bit long, took the bumper off.





Toight!


[/url]

peekaboo.


[/quote]

[Chris_90]

Read that all, really interesting read, and an amazing amount of work! Well done like to see it finished

[zx_volcane]

Some project there

What's the current status of it?

Do you know if it is possible to get hold of 16v front wings?

[welshpug]

current status to be clarified shortly, loads more pics to come!

sorry for the massive pic content, but this forum seems to lump consecutive posts all into one even though when posting there is a 20 pic limit, so I can't even go back and edit

16v wings have been NLA for quite some time, however standard wings can be trimmed back and the arch trims stuck on, if you have some bent/damaged 16v wings you could transfer over the stiffening piece over and use clips which are still available as they were used on the Berlingo/partner trim as well.

I did exactly that for the RH wing that's on the car and also have a spare genuine New non 16v wing, the front bumper is also a non 16v item but from a sport model that didn't use a trim stripe, possibly a late reflex or similar, only difference was the lack of slots on the corners for the wheelarch trims to clip into but they got broken off a long time ago!

[welshpug]

Right then, last picture of the ZX being bunged in the garage was taken back in June 2013, fast forward to July 2014 where progress starts up once more.

[quote name="welshpug" post="1426254" timestamp="1406490999"]
whoah, time flies!

its been sat outside the garage for a few months again as I stuck the 205 inside, not dome much to it really, I sorted the weeping brake unions and bled the brakes again, and more recently just been waiting for a friend to have some spare time to weld it up for me, we did think of making a start on it today but he has a house he's painting for his dad which is dragging on a bit unfortunately, so I took it to bits again...




Unplugged the engine loom...



Faffed about with the auxillary loom adding a few plugs and wrapping it in tape, then added the DTA loom I had made, made up the last few connections to mate it to the car temporarily, then bolted the bodies on...



yes, I do have a rusty looking rad, but it doesnt leak, AND I have an alloy ordonez rad spare I can fit to it if needs be.

I then thought, errr, all I need is to bung a coilpack on and it "should" run....

so I did! https://flic.kr/p/ocNe87 (video link)



[/quote]


[quote name="welshpug" post="1426659" timestamp="1406806035"]
Progress!

borrowed Antons trailer!



though when I pulled up Anton was making funny faces looking at the trailer, I hadn't realised the nearside rear wheel was steaming away, what with Dan sticking his arm in the way of the mirror all the time, and Diesel smoke going down that side of the car too



looks like a lining had detached itself and got wedged, cooking all the grease from the wheel bearing too!

in the workshop jacked up already

---

[quote name="welshpug" post="1429174" timestamp="1408655845"]
A few weeks have passed, Anton has waved his weldy torch over the grotty bits, a new windscreen fitted, and finally this evening he dragged it back for me, he'd lashed up a quick throttle cable bracket from some wire to aid moving it

Thought I'd best make a proper bracket and see if I could get full travel without lifting the pedal too far, or having to bury it in the carpet.

a bit of steel angle, a rivnut, a threaded adjuster barrel and a 90deg v-brake noodle and I have myself a £90 saving on a Jenvey linkage kit.

20140821_204632 by WELSHPUG, on Flickr

20140821_205738 by WELSHPUG, on Flickr

20140821_205802 by WELSHPUG, on Flickr
[/quote]


[quote name="welshpug" post="1429235" timestamp="1408736891"]
more progress after work this evening, as my bodies are short and I have long trumpets, and normal length Weber gti6 injectors I needed a stepped backplate, these are usually over the £50 mark, but inspired by Kristian (Black_Mi16) who had made his own stepped backplate from some sheet steel, I cracked on with some C.A.B.A.D*

20140822_174904 by WELSHPUG, on Flickr

(*Cardboard And Beer Aided Design)

20140822_181739 by WELSHPUG, on Flickr

20140822_183116 by WELSHPUG, on Flickr

20140822_183507 by WELSHPUG, on Flickr


Bolted the centre piece under the trumpets to figure out where the injector securing bolt reliefs needed to be.

20140822_190223 by WELSHPUG, on Flickr


Transferred the design onto some steel sheet.

20140822_191317 by WELSHPUG, on Flickr

chopped it out.

20140822_194531 by WELSHPUG, on Flickr

carried on chopping and a bit of holesaw action, had nothing to hand to do the radius cut unfortunately, but it wont hurt to have some flat edges instead of curve.

20140822_202131 by WELSHPUG, on Flickr
[/quote]

---

[quote name="welshpug" post="1431124" timestamp="1410353193"]
I did finish off the airbox, not 100%^ happy with it, I haven't much experience of welding tin and I put a bit too much heat into some parts so its not as flat or pretty as I'd like it to be.

[url=https://flic.kr/p/oQgZzG]
20140823_084153 by WELSHPUG, on Flickr


20140823_121759 by WELSHPUG, on Flickr

You'll notice it now has more black panels on it now, I am thinking of making the whole car black as with the old shell.


20140823_134811 by WELSHPUG, on Flickr

Found a few of my trim clip bags though I still need a few more, some parts will need sticking on with some structural automotive adhesive.


20140909_183209 by WELSHPUG, on Flickr

moved the radiator fan across to the left side and fitted an Alloy Ordonez radiator I'd got hold of, then had a fiddle about with an oil cooler to see if I could make it fit without spending loads on new pipes, gentle persuasion of the steel hard pipe and shifting some brackets on it means that no longer fouls, but the low pressure feed from the reservoir needs re-routing a little so its not rubbing on them constantly (I plan to retain the standard heat exchanger as it aids warmup, and using the thermostatic control on the oil cooler to stop it over cooling at the same time as adding extra cooling capacity)


20140903_190109 by WELSHPUG, on Flickr


20140903_194332 by WELSHPUG, on Flickr



rear seats and cards fitted.


20140905_163733 by WELSHPUG, on Flickr
[/quote]


[quote name="welshpug" post="1431125" timestamp="1410353769"]
got hold of some Clio 182 Weber Pico IWP 042 injectors, flow 250cc/min @ 3bar, decent spray pattern I hear, and most importantly shorter than the IW204 gti6 units.


20140905_171609 by WELSHPUG, on Flickr

which means this fits


20140905_171915 by WELSHPUG, on Flickr


20140905_171931 by WELSHPUG, on Flickr


though with the trumpets I have the filter doesn't fit, so I still need a stepped backplate, or if possible some Satchell trumpets with the backplate bolted to the back of the radius of the trumpets.


20140905_173035 by WELSHPUG, on Flickr

then I took the inlet and loom off, made up an extra bit of loom for the other injectors, seeing as the ecu and the bodies have capacity for twin injector's why not?



20140907_150538 by WELSHPUG, on Flickr



Stuck the standard loom ecu and inlet back on for now, as I want to get it MOT'd, looks a bit like this.


20140907_170047 by WELSHPUG, on Flickr



got my set of part worn Michelin PE2's and C5 wheels fitted up with new valves and balanced.


20140910_113539 by WELSHPUG, on Flickr
[/quote]


[quote name="welshpug" post="1433163" timestamp="1411930933"]
progress since the last post has been that I fitted a standard 24mm rear arb, and stuck on the drivers side front arch trim, also got hold of an 075 battery off a mate scrapping a mk4 golf in exchange for one of my dead batteries.

and the V5 finally turned up, so its off for an MOT on wednesday (1st of october)
[/quote]

---

so, Wednesday came...

this happened....












20141001_131837 by WELSHPUG, on Flickr

[Damian.H]

Great project, loving this! Always liked the ZX 16v. Well done, keep it up!

[zx_volcane]

great, so its officially road worthy now

[welshpug]

yup, drove it to work today, went mountain biking yesterday, does need more front spring or less rear spring rate.

im going to add more front camber by adding 306/xsara balljoints as they are longer

[zx_volcane]

yup, drove it to work today, went mountain biking yesterday, does need more front spring or less rear spring rate.

im going to add more front camber by adding 306/xsara balljoints as they are longer

306 ball joints add a ridiculous amount of camber - put a 306 wishbone on mine once by accident, result was hilarious

[Matt-Rallye]

yup, drove it to work today, went mountain biking yesterday, does need more front spring or less rear spring rate.

im going to add more front camber by adding 306/xsara balljoints as they are longer

306 ball joints add a ridiculous amount of camber - put a 306 wishbone on mine once by accident, result was hilarious

So do 306's have a wider front track? or just more suspension travel as standard?

Cracking project you have on the go here i'll have to take a trek down to you sometime for a proper nosey.

[welshpug]

just a marginally wider track, not much, ill measure and post the difference soon, the top mount spacing is closer together, how much camber did they add?

will need to check non pas 306 balljoints, as they are shorter than pas.

part numbers for the coil spring and dampers are the same as a phase 1 xsara.

[Matt-Rallye]

Also didnt realise you knew 'goliath' i remember george (and unfortunately his brother henry) from the golden days on clio16valver.co.uk!

[welshpug]

yeah known George for years, helped him build many of his cars

[welshpug]

600 miles down in two weeks, no issues at all other than central locking playing up.

got hold of some kw springs from a 306 coilover kit courtesy of AdamB, to replace the 30nm 250mm lomg ast springs, awkward sods are metric.

kw's are 170mm and I believe 50nm, so gone from 180 to 285 ish lbs, wound the spring pans up so there was no flapping about, hopefully they dont go coilbound before the bumpstop as its low enough already, might need to try a 200mm spring.

[mattsrallye]

Great project! When are the bodies going back on? We'll be needing videos when they do...

[welshpug]

when I have money, skint at the moment, so if you fancy some wheels or a shiny exhaust feel free to buy them so I can go mapping!!

[adam b]

The kw springs are 315s - I dropped to 270ish as I'd lost so much weight from the front end.

[welshpug]

I see, they seem to work with the torsion bars well, need to up the damping a few clicks.

[welshpug]

no updates of late, didn't use it at all in January but I bought a massive air filter from Tom so I don't need to get an expensive backplate, I've got shorter Pico injectors in the bodies now so clearance there isn't a problem.


I've got a few lengths of -6 Teflon Braided hose, probably enough to do the engine bay but I haven't got any fittings, I need about £80 or so of them and get two adapters welded to the fuel rail.

[zx_volcane]

Need to see some vids of the sound of those bodies in action

[welshpug]

oh yeah, I forgot about the RR day I attended.




and made this noise.

https://flic.kr/p/ps62f5

---

I did have it running on the bodies last year.

https://flic.kr/p/ocNe87

[welshpug]

Friday after work I decided to faff about with the throttle bodies instead of watching youtube videos and drinking beer all night.

 
inlet off.


 
gti6 wiring loom off.
 


 
 
got a bit dark by then even with the awesome £9 LED floodlamp from Screwfix, and it started raining.


Saturday morning I got the loom laid out, inlet and filter fitted, decided to just run the standard fuel rail till I get the AN fittings.
 

 
Got the Tablet hooked up after feeding the wideband wires through a handy grommet behind the glovebox and the sensor fitted into the downpipe.
 

 
Today I made a bracket for the coil, need to find some bolts and get some Vauxhall plug leads.
 

 
Then went for a quick spin up the road.

https://flic.kr/p/rcr5Pf
 
 
OHMYGODTHENOISE!!!!        :wub:

[procta]

I tell you welshpug that's a reshell!

[welshpug]

Brief update from last weeks faffing, bought a jiffy bag full of bits from Alex at Torques (on here as Powers)  thanks very much to them for the quick postage and decent prices, I'd already been donated and picked up a few lengths of AN -6 teflon hose already.


quickly boshed the ends on as practice.


20150219_215233 by WELSHPUG, on Flickr

Then on Friday after work set about taking the rubber stuff on ready to fit the shiny stuff, chopped the flare off the original steel return pipe and found it was not 8mm as I was expecting, but 8.4mm, checked the feed and that was 10.2mm FRENCH BASTARDS!!!

Annoyed and starting to get rained on I gave up at that point.

Saturday morning, went on a mission to find some 8mm o.d tubing, ended up at Screwfix in Newport buying their only 25metre roll, B&Q's website showed stock but had none on the shelf, not a bad thing as it was about a third more expensive, though came in a shorter reel, so I have lots spare!

see, fits!


20150221_110343 by WELSHPUG, on Flickr

I've used one of those compression fittings before on a 205's steel tubing and it fitted fine, so it made sense to use them again here.

and here's the nearly finished setup, the two short lengths of rubber will be replaced by welded or brazed fittings as soon as I find someone to do that for me.


20150221_162151 by WELSHPUG, on Flickr


And for some as yet unknown reason, it wont bloody start!   Fuel pump is ireggularly priming all the time, which it should only do once when the ignition is turned on, however I can connect to the ecu just fine, so I think I have a noise or damaged wiring issue in my home made loom

[adam b]

Cotswold hydraulics in Tewkesbury

[welshpug]

aha, will take a look thanks, might need a couple more fittings

[adam b]

They brazed my PAS pipes for the V6 conversion

[welshpug]

ahhhh! I see, did they charge much? Might be able to feed Anton biscuits and lesbian tea in exchange for them being attached in some way

[welshpug]

I do wish this forum didn't auto merge posts, its made this first page load so slowly!!

update:

made up another loom, I had already made one up with an ecunplug, just needed the relays addimg, a few more termonals and some wire lengths adjusting, and the plugs for the second set of injectors.

gave it another try but found a flat battery, and really black plugs so packed up for the night, fresh charge on the battery and new plugs, and still nothing, ecu talking fine to laptop and no noise on the crank sensor, however did have pops and flames!

popped a short vid up on Facebook and a friend suggested incorrect firing order, so swapped the pairs on the coil and bingo, splutters farts then barks into life

need to tidy the loom up then head for mapping I think!