Red Rallye Resto

[Eddleston]

About time I put my project up for you lot.


Here it is when I took it over from Dad. (Dad owned it from 11months old to Aug '12) Mum was driving it when the cambelt snapped about 2009ish and it tapped for over 3yrs but my parents were exceedingly gentle on it doing about 3500miles a year. I took it for a year at work and it blew the day dad drove it home. A combo of a knackered rad and tapping and occasional over heating... well yeah. 




Decided it needed better rims while I was away at work




Then did the clutch with Mark. Old one was pretty knackered.


I had an almighty Hilux at the end of the year so the plan was that dad would take the car home.
Then a phonecall, "There was a loud bang and grinding noise, now I'm sat on the hard shoulder"
Oh dear. 

Start of me beginning the tear down.



First sign of problems - drain oil and coolant comes out lol


And here was the first tell-tale sign of death

[Eddleston]

Hub nuts attempted

Bugger

Eventually I did win though

Removed gear linkage


Then eventually after a long time struggling then finding stuff actually quite easy once someone had told or shown me how to do it...


f*cking nightmare for me, well pleased.


Rad probably didn't help the whole situation



Then thought I'd pop my box apart to see if the grinding noise was a gear. 5th and 6th were OK so stupidly I looked further down

And that's when the bearing on the lay shaft shattered. FML.
Turns out that's not how you take a box apart 

[Eddleston]

Ah feck. The photos aren't working

Edit: I've edited everything now 

[Eddleston]

Ah feck, no photos.

Admin, can I not [img] link them from FB?

[Dum-Dum]

You can and you can't img from FB, it doesn't work if your account is private.

If you use the "new reply" or "full edit" button and the upload button at the bottom then they'll work well here.

Anyway looking forward to seeing the pictures.

[7057sam]

Yeah look forward to seeing your photo's.

Interesting choose of wheels,did it come like that?

[Eddleston]

Yeah look forward to seeing your photo's.

Interesting choose of wheels,did it come like that?

Well dad had the cyclones on it, then it disappeared for 6 weeks for a vibration that the garage couldn't fix.

Turns out after a tiff with trading standards that the wheels hadn't been balanced. So he got them and the others were taken away. 
I didn't like them but he did weirdly. 
Sold them to some blokes in Bath for their 406. Glad to be rid of em.

---

Time to open up the dead engine. Everyone like destruction pictures! 

Something missing?










This was the hole out the front of the engine (blown through front AND back, big job!)

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Eventually opened up the gear box. Managed to snap one of those plastic bits that sits on the edge but that was sorted from Peugeot.
Luckily everything else was grand.




I was now left with this sight though.








My brain couldn't deal with that sight. Disgusting. The plan was only ever to put a replacement engine in but that just escalated quite a lot. 
Bit of a clean up but not nice.

[Eddleston]

And so it began 










Tried some oxygel stuff and that was grim. Tried all sorts of interesting shaped drill bits. Used quite a few rust remover wheels too. 



Red Oxide


Every bracket I came across got the same treatment.

Stripped right back and sprayed up


Same again

---

Decided going round each rust spot and attacking it was a silly idea


So did everything. Stripped it all back. 


Turns out this is the Paint code, hidden right under the wiper motor. Took aaages to find that.


Huzzah!

[Eddleston]

As you can imagine I was pretty pleased with that



Absolutely gutted when it ran under here but it's fairly well hidden


Then came the time to sort out the inlet manifold. 

What even is that spring!?

Then once you look inside the throttle body... Piston glitter!!



Loads of brake cleaner later


I then started on cleaning the inlet manifold. 
I was shown some stuff which fizzed on the dirt and I was told not to touch it. Then told again, seriously don't touch it. So I wore gloves.



Worked wonders though!

Everything nice and cleaned up!

[Paul_13]

Proper f*cking job on that engine, that's to my standard of engine destruction!

Not telling you to suck eggs but things to look out for when rebuilding it:

Don't use the phase 1 cam pulleys (3 x 10mm bolt heads) use the later phase 2/3 which has one 18mm head bolt

Don't use the oe bottom pulley when timing up the bottom end, it most likely would of slipped and would not time up correctly again.

Use the 136t cambelt setup, I don't trust the 137t one bit

Just put off preference but check the oil pump sprocket is the single piece keyed to the crank version. These can be bought from Peugeot for not that much and get a new chain while you're at it

[Matt]

Looking good, what stuff did you use to clean the inlet? I could do with some of that stuff!

[Eddleston]

Opened up a few more bits around the inlet. 


Sorted out the face of the brake cylinder mounting bit too. 


Once this was all under way it was time to order new bits!!




So nice when stuff gets put on the replacement engine (Big up Ryan!)


Also had to do a very slight modification to make the clutch kit fit on the new flywheel

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This was my old steering rack

Needed some work so may as well make it better

I then decided that as the engine was on the garage floor I'd do the head gasket too. 
Opened it up and found all this gunk round the cooling jacket holes. 

and started cleaning them up. Stanley blade and dad with a hoover nozzle hovering right above it. 

not bad eh!


All done


New HG

The head had the same stanley&hoover treatment too. 



This then turned out to be a right pain in the arse!! turn to set torque, now some more degrees, then some more then wait for jupiter to align with mars. 

---

Time for a few more extras. 
This was one of my greater achievements in the project. It was horrendous when I started.



Time to start working out where brackets and plastic were supposed to go. Obviously I forgot to take pics of the very last bits, taking them out. 


Then trying to remember where wires and stuff went


Then some more shiny stuff!!


This was followed with days of trying to get stuff to match up to old pictures I took on the strip down.

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NEVER BUY CHEAP TOOLS


Now, when I was aiming to get the replacement engine in I ran into an issue of getting it past the old one. My mate's polo sorted that for me.

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It was then finally time for the day I never thought would come


When your mates are more interested in playing games than actually helping you and then mum thinks it's funny to take a picture.


But wheeeey!


See the steering pipes running along the front?
They started like this:


So I got to this stage

and then went to NZ for 3.5months. 


The plan had been to get the car on its wheels to get it back in the garage for winter but unfortunately it didn't happen. 
So one of dad's mates popped over and popped everything back on that was needed for moving it. 

I returned home and immediately put the rad in and got the fans sitting in nicely.