Richies Project Rallye

[Rich306]

Hello all!
I have dreamt of owning one of these for many many years, it is by far my favourite car and the only one i want!
Soooo.... i bought myself one!
£1400 she cost me, 93k on the clock and she needed saving!





OK, now eagle eyed ones of you will notice that there are some stickers that do not belong on the Rallye....

So bring on the first part of the project :p

Early the next morning after buying her i got up, removed the incorrect stickers and gave her a bath.







I sat down and created a list of things that needed addressing. Many of which have since been completed.
Engine Bay:
- Take engine out and remove rust followed by treatment and respray of bay.
- Clean up and spray Engine removing corrosion
- Service and replace Cambelt
- Move Air Induction kit

Interior:
- Repair/Replace Radio head unit
- Sew Drivers seat up
- Move Amp and tidy up wiring
- Fix interior light

Exterior:
- Replace droplinks
- Find and sort exhaust leak
- Refurb Cyclones
- Remove rear Wiper
- Fix Trolley dent on N/s Door
- Push out dent on O/s door
- Damage on N/s Mirror
- Clean and paint 2 minor rust spots on Bonnet
- Replace morrettes with Crystals
- Replace Fog lights with Rallye Blanks
- T-cut 16v marks left on rear Quarter panels.
- Fit and paint new grill

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Some more Photo Whorage for you all!

Corey my son helping out (eventually had to take some of the tools off of him after he tried hammering in my Passenger door lock


Then kindly placing all the tools from the floor onto my engine

The wheels had to take a beating before they came off of the hubs!!! :o




So much rust!!!


I had to remove the engine which turned out to be a long old process, i had to angle grind through the Ball joint and a couple of other Bolts.

I also had to wire brush the rust off of my chassis minimising the corrosion that had occurred




Gained some more things to add to my shopping list
Droplinks
Ball joints
Driveshafts.
x1 Cyclone to use as a spare.

Well after a day of working on the shell, i finally cleaned up 80% of the rust and sprayed it black to protect it.
Some more pic Whorage

The Chassis before the work done

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After a majority of the work




The bits that still need wire brushing down


I have some photos of it all cleaned up...


And painted

I also did the Hubs today, cleaned all the rust up and hammerite'd them!



The suspension struts will be changed at some point so i left them for that reason.
I undersealed the wheel arches and bottom of the engine bay to give extra protection against rust. I don't think there is anywhere on the front of the car now that has rust on it lol!

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I found minimal rust under the engine mount which is amazing considering the state of the engine bay itself!!!! A wire brushing down followed by a hammeriting and the mount is like new!

Fitted new droplinks and balljoints, also cleaned up the wiring tying it away neatly.

Then moved onto working on the engine, which is in S**t state, after cutting myself twice with undoing the bolts. I snapped the bolt holding the tensioner onto the mounting bracket.



Also the Power steering pump is being held up by one bloody bolt that keeps slipping! Driving me up the wall to be honest!!
So i need to somehow remove it without getting the angle grinder out, and sort out that snapped bolt in the mount.

Managed to get the bolts in the end from a place in Portsmouth

A day or so later i worked on the engine to clean up all the rust and dirt that presented itself.
Had a few delays waiting for parts, i had the replace the PAS Pump after angle grinding through it to remove a seized bolt.

Here is a photo of the engine almost ready to go back into the bay.

[Eeyore]

Looks like some good work! What is the black paint? Hammerite?

This is exactly what I want to do to a gti6 or a rallye when i have a place of my own and a decent job!

[ginge191]

Aweosme project! What a bargain as well! keep it clean!

[Rich306]

After rebuilding the engine i put it back in the engine bay.



After all was put back together, i turned her over; Crapped myself when she wouldn't register anything on the dash and more so when she tapped to high heaven!
I turned her off and back on again, thankfully the dash had registered - must have somehow reconfigured herself completely.
After letting her get to temperature and bleeding the cooling system, she pumped out hot air, ran sweet as a nut and the tapping died down to the normal tick over.

The only annoying thing i am struggling with now is the bloody balljoint on the passenger side, i managed to drop a litre of Gearbox oil when the driveshaft popped out of place when moving the hub. And not content with that, i knocked over my only full bottle of G/B oil and then i had to buy some more.
Working by yourself on putting the balljoint into the hub is bloody difficult!!


Had a problem with the Passenger driveshaft, split the boot again and had to fit a new one. However the C shaped pin that holds the head on snapped.
Finding another one proved difficult and Peugeot would only sell one with a new kit at the fun price of £38!
So i had an ingenious idea of turning a Keyring into the new C shaped clip - which worked!! and now it's all back together .

Next bit that follows is putting a new track rod on the passenger side, cleaning up and spraying the callipers. Fitting the brake discs and pads.

The slam panel needs painting, but that will be done in time Also Front bumper needs replacing because of damage i found.

I finally got the car off of the Axle stands

After fitting a jubilee clip to the CV Boot to secure it, i then fitted both brakes (freshly painted):



And fitted some new Badges (from Custom Decals - Thank you very much buddy!)



After a quick move around on the drive, i gave her a bath to remove all the dirt and grime off of her i caused!




Got these off of Jo3HDi :p



Not telling price of them, all i can say is at mates rates

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It took a while for me to get out and work on the car again; mainly due to waiting for some parts to come through and also the time and motivation to do it!

So lets start with what goodies came through the post:


Yup, you guessed it, Rich's old strut brace from the poor beaten up 6'
2 hockey sticks in good condition thanks to Ash from the Club306 forum
and the two paint cans, well.... i picked them up Friday after getting some paint mixed (look below for the finished article).

On Friday i fitted the Hockey sticks


And Saturday pushed onto the wheels.
I've only done the one wheel for now, as the garage was closing when i chose to get the tyre pushed down.
Started with this:

Then the progression as shown:




Just so you get the idea of what the proper colour is, it's a red pearl mixed in with the black to give it this effect when in sunlight:



Soooo after Lacquering it up and s**tting myself when this happened :cry :

Thankfully disappears after a minute or two

I got bored in the end, and hungry... so i thought i'd stop indoors for lunch and a brew


My next task was to tackle rich's strut brace, now the paint was flaking quite badly from being on his Bianca, so i gave it a strip down and spray of paint..




Because i had to let that dry i thought i'd clean the car and give the paintwork a spruce up.
...... Which then turned into T-cutting because i scratched the entire bodywork in the process

I hope you can see the scratches in that photo :blink

I've had to 3000 grit sand the paint back to remove the scratches i created. and it's slowly started coming up.
However work had to stop as i wanted to bake the strut brace, and the only way to do that???


Yup... you guessed it.

What a better way to bake the paint on fully than to bolt it on to the car (carefully) and then turn the engine over into a sweet purr


That was pretty much it for that day... I had to wait for someone to drop off his Buffer machine so that it can remove the scratches better and with heat.
Then the bonnet should be shining like its meant to!

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Things went a little crap one week as when buffing the car up:


Yes, this person will be more careful next time!
Ordered another sticker and the bonnet is now 98% Scratch free! Amazing how many stone chips i have though


I worked on the other cyclones, but had to do one at a time as the preparation i did was so shocking, the primer cracked! :O

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It was about a week before i did any more work on her.

Waxed and polished
Exhaust rattle from the heat shield fixed and stopped.
Cleaned interior
Cyclones couldn't be finished as the weather got far too cold before i could finish them up. I'm going to have to try again later this year.

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Here is some more photos - I ended up repainting the Strut brace black:



I had the right amount of time off to work on the car, so i cracked on with the undersealing that has been begging me to do it!

Start with car on ramps



Followed by a brief insight to how much needs to be done:




I think they've rusted somewhat.


Question. Can i avoid putting the above heat shields back into place and be left with the one you see still sitting on the chassis?

After peeling back some more rubber coating, i found this :

Which eventually turned into this :o :


Gaaah More rust!!! Just a little more severe this time.

Don't you ever get that moment when you wish you hadn't poked anymore with the screwdriver and found more holes??
Looks like this might need welding at some point!!

Rust treatment doing its work:


I'm gonna have to wait a little while before i get it welded, might pay Daveyboy a visit in Southampton one weekend to get it sorted.
I will be keeping the car for as long as i can afford it, so it will need to be done.
This is a more temporary fix in order to preserve it a little longer until i can afford to get it cut out and welded.



Cleaned up the rear end, however i need to take off the Rear beam at some point due to rust on the mounts. Also enables me to completely respray the entire underneath. Probably will take down the Fuel tank as well.

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Ended up spending more money...

Found myself tempted by some mint condition Crystal headlights for £36 from a scrapyard.
I wanted to black mask them, so i did

Same colour as my Cyclones will be going




Photo of the old headlights with standard bulbs

Can tell the difference with the new Osram Nightbreaker bulbs, much better clearer headlights!!

Will get a better photo of the Black masked headlights tomorrow.

Not bad for a second time of doing this to headlights huh?

Just waiting on the cyclones being painted and put on the car now.
Used Autoglym products to clean and bring her up to a shine!
I also painted the Peugeot badge whilst i had the paint out from the previous night!
What do you think?





If anyone needs a set of Black masks doing, PM me with your interest and depending on the interest i will pop a thread up dedicated to doing these headlights.

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Whilst the car has been sitting there, the cold ruined the Battery, so i had to buy myself a new battery for her this week. A Bosch S4 Cold start battery.

Managed to get £20 off bringing the price down to £63 (roughly) from Euros!

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Looks like some good work! What is the black paint? Hammerite?

This is exactly what I want to do to a gti6 or a rallye when i have a place of my own and a decent job!

Thanks, the Black paint is something i got privately mixed up. I need to get more sometime soon to complete the work on the other Cyclones

[Tallguy_2]

Nice to meet you tonight mate!

[Ed Doe]

Great project thread matey good to see another black wallye saved!

You should defs come along to the summer meets when they get organised, I'd love to see this in the metal!

[Rich306]

I'm still awaiting my licence back, so when she is on the road then you'll be seeing me a lot more in the flesh.

She needed a lot of love and attention so i am prepared to give it to her.


Nice to meet you too Tall Guy. Will give you a PM when i find out how much i need to spend on the kit again for Black masking the headlights. Get thinking on any different colours you'd like them to be.

[Rich306]

So, went to a modified meet yesterday evening with Jo3 HDi and his Clio
Got a good chance to take some photos of the Rallye on the road!

We'll start with the photo of her in front of which i can only describe as the french theme here lol!






I'll put the rest in show and shine i think

[ozonehostile]

love the attention to detail in this thread

[Alee83]

Great looking Rallye, and a lot of work put into it... I take my hat off sir!!

[Rich306]

love the attention to detail in this thread

Thank you

Great looking Rallye, and a lot of work put into it... I take my hat off sir!!

I just love the way the paint reflects in the photos It's so nice having a clean car and drive something with a big poke!

I unfortunately turned a corner off of a gradient a bit too fast last night and snapped a droplink on the passenger side. So now need a new one lol, crappy ECP ones if you ask me.

[sam]

Looks really smart dude I might have a scorpion exhaust forsale soon if your interested

[Matt]

Looks sick, gives me inspiration to go sort mine ASAP

[Rich306]

Looks really smart dude I might have a scorpion exhaust forsale soon if your interested

Lol, erm i'm after a reasonably quiet aftermarket exhaust at some point, not just yet though. Money situation is a little bit low.

[Rich306]

So, been a busy weekend what with changing a Gearbox on a Rover and also paying Colin at Pug performance a visit; All whilst having my son for the Easter Weekend.

I had only intended to go up to PP to gain a second opinion on what to do about my engine mount, but ended up buying some goodies (as you do )

Got myself a Magnex Exhaust and a new Slam panel for a tidy sum!
I fitted it whilst i was there and she sounds brilliant now, thankfully not too loud but enough to give a nice grunt when putting the power down. I will be fitting the new Slam panel when it has been cleaned up and painted i think.
No pictures for this one i'm sorry.

I also made a visit to Brighton for a meet which turned out to be a bit crap, smiles all round however when i took the car for a blast through the A27 tunnel, and a massive grin when this photo was taken:


Makes me feel mighty proud owning a Rallye!

[Eeyore]

very tidy work

[7057sam]

The Brighton tunnel awsome got to do it twice this year.Also found some good tunnel sections in Birmingham city center on Thursday

I've now got black masks aswell, looks spot on.

[Alee83]

Rallye's and black masks FTW. It is very tidy, I would be proud too!

Need a bigger back box for mine, doesn't shout enough...!

[Rich306]

Thanks all she's getting there slowly, I need to sort out the engine movement so i need a 10mm plate welded in behind the Buffers at some point soon.
Also working on my Cyclones atm to get them ready soonish!! I want them on the car so that it will grip better (Suited and booted in Toyo Proxies).

Need to get hold of a Black ph3 bumper and N/s wing at some point, bad paint on these and also bumper is broken

[Pompey306mark]

Is that the engine mount I commented on when I was down yours a few months ago?

[Rich306]

Is that the engine mount I commented on when I was down yours a few months ago?

I cannot remember hence why i took it to Colin lol, if so then yes!
Exhaust kept coming loose due to the movement

[Rich306]

Right, I thought i'd paint my badge as i needed to break up the black bodywork at the front.

And here it is!!

I know it doesn't look it, but it is actually Red.

[Pompey306mark]

You that is pink so badly. Did you get the whole badge apart?

[Rich306]

You that is pink so badly. Did you get the whole badge apart?

It's a light Red, to match the Tow eye and Callipers.

I got the entire badge apart and glued it back on.

[vlj]

So, been a busy weekend what with changing a Gearbox on a Rover and also paying Colin at Pug performance a visit; All whilst having my son for the Easter Weekend.

I had only intended to go up to PP to gain a second opinion on what to do about my engine mount, but ended up buying some goodies (as you do )

Got myself a Magnex Exhaust and a new Slam panel for a tidy sum!
I fitted it whilst i was there and she sounds brilliant now, thankfully not too loud but enough to give a nice grunt when putting the power down. I will be fitting the new Slam panel when it has been cleaned up and painted i think.
No pictures for this one i'm sorry.

I also made a visit to Brighton for a meet which turned out to be a bit crap, smiles all round however when i took the car for a blast through the A27 tunnel, and a massive grin when this photo was taken:


Makes me feel mighty proud owning a Rallye!

Looking really really nice here!

[Rich306]

^^ Glad you like her :p She certainly smiles in this Photo!

[Alee83]

Badge looks much better! As you say, stands out from the black...

[Rich306]

And here we are! Looks miles better

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Alee88 - seems like you and i have a theme going on here hahaha! You got Red and Yellow, i have Red and Black

[Pompey306mark]

That's better looks much better in normal light and not as pink.

[Alee83]

Defo looks better Red!! What's next on your list?