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Old 06-11-2006, 09:34 PM   #1
Ian E
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Ian E's Car Blog

Name: Ian
Location: Bucks
Age: 33
Occupation: BMW Mechanic at www.birdsauto.com
Forum Name: Ian E
Car: 106 Rallye S2
Purchased: Oct 2006

Engine / Exhaust / Transmission

- Fully rebuilt 16v j4
- New oil pump, shells, rings, block rehoned, etc.
- Catcam 708s
- JP4 Cam Covers (soon)
- 100 Cell CAT with Powerflow "stealth" system
- K+N Panel Air filter
- Raceland Exhaust Manifold - heat wrapped
- Cam covers powder coatedin Anthracite
- Powerflex lower engine mount
- Uprated driveshafts

Suspension

- Front Lowered on Eibach Sportline springs (-50mm)
- Rear Torsion Bars Adjusted To Match
- Bilstein B8 shocks
- OMP lower strut brace
- All bushes replaced for genuine items

Brakes

- 266mm 206 GTi Fronts
- Std rear discs
- Wilwood brake bias valve

Interior

- Safety Devices 12 point cage
- Sparco Evo2 Plus x2
- Sparco Harnesses
- Rear of car stripped
- Momo Tuner steering wheel
- Carbon Fibre track day kit (door cards,etc)


Wheels + Tyres

- Road - 14" Steelies with 185/55/14 Conti Sport Contact
- Track - 14" Steelies with 185/55/14 Yoko A048s -Soft

ICE

- Panasonic CD head unit
- Sony front door card speakers only

Future Mods

- Quiafe ATB diff

Some pic's when i first bought her...

One from the Autotrader...



New steelies were bought straight away...





I have already changed the radiator due to a leak. (also fitted new cap!)
Also changed the cam belt and tensioner as there was no record of this being done!
I am currently reading up on lowering the torsion bar so that should be done soon.
Bought some new steelies from Peugeot as the old ones were rusty and discoloured. See the pic's!!!
Fitted the 3" Pugsport decat system on fri thanks to 106parts.com! So I'll get some new pics up soon. But have to say the engine is much happier to rev now as the old system was a Bosal cheapy job.

Looking forward to doing more mods, all in keeping with the Rallye theme of course as I am very anti-chav.



Also have this modded M3...



And this '79 e12...

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Old 11-11-2006, 11:53 AM   #2
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Pic of the 3" Pugsport Decat system as promised...



Pops and bangs like a gooden but find it very noisy between 2000-3000rpm. Otherwise I bloody love it! Nice and quite on the motorway aswell.

I do need to change the rear wiper arm for a more modern one. Any suggestions?
I like the wiper on the white Euro 106 Ralllye featured in PGTI. Any ideas what that is?
Many thanks, Ian.

Also picked up a spare wheel, jack and brace last weekend from a forum member Tyler.
Cheers dude.

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Old 11-11-2006, 12:04 PM   #3
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1) a nice 206 rear wiper looks pretty cool mate.
2) other option is to remove it and put a rubber bung in it. gives the car a more smooth rear end.

either one looks great
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Old 11-11-2006, 03:48 PM   #4
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clio wiper arms a popula one aswell isnt it?
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Old 10-05-2007, 01:18 PM   #5
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Quick update on the Pug.

She's now done 100,000miles!!!

And I've changed the rear wiper arm for a late model 106 version. Much nicer.

New tyres are next on the list but might go for 185's this time.

Still loving it!

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Old 27-05-2007, 03:25 PM   #6
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New steering wheel.

Momo Tuner (black version)...





I'll take some pics on Tues once its fitted.
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Old 29-05-2007, 05:22 PM   #7
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Now fitted...



Much better than the Airbag jobbie! I'm off for a drive.
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Old 21-07-2007, 04:38 PM   #8
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Now lowered on Eibach pro-kit springs with torsion bar lowered to match...



Took 6 hours to unseize the beam. Looked like it had never been touched!
Also changed the gearbox output shaft seal which was leaking and changed the gear oil using Peugeot 75w80 gear oil.

Outer ball joint has play so will need doing soon as well as an engine oil change.

One pic from FCS 2007...



Thanks for looking
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Old 01-10-2007, 09:40 PM   #9
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Outer ball joint and oil change now done. (thanks to 106parts.com)

4 new tyres on order. Yoko S-drives in 185/55/14

Then MOT on sat.
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Old 23-02-2008, 09:28 PM   #10
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Little update @ 106,000m



Rear beam was knocking, so after much searching on this forum I found a thread where someone mentioned welding a washer over the ARB plate. So on sat I did this little mod and its done the job. Might weld the 13mm bolt in place at a later date cos it still comes loose! So thanks to all on this forum.

Changed the sparkplugs for some genuine Pug items and changed the oil and filter.
Also did a brake fluid change.

Yoko's are pretty good all rounder. Been on there a while now.

Next mod is a set of shocks and rear brakes are getting low.

Cheers, Ian.
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Old 13-03-2008, 11:07 PM   #11
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New seats. Got them cheap...



I made the brackets from some unequal angle aluminum that was lying around at work. These seats are only temporary, whilst I save up for some proper bucket seats and harnesses.
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Old 16-03-2008, 11:26 AM   #12
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looks good mate.

silly question but if your a BMW mechanic then how comes your not into your BMW's? or is it a case of you work on them all week so the last thing you want is to work on one of your own?lol
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Old 17-03-2008, 10:33 PM   #13
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Quote:
Originally Posted by saxo_ro View Post
looks good mate.

silly question but if your a BMW mechanic then how comes your not into your BMW's? or is it a case of you work on them all week so the last thing you want is to work on one of your own?lol
I do have a BMW which rarely gets driven...




But I really love my hot hatchs. Its an illness!!!

Small update : Rear seats and shelf removed. And yet further work into why the rear antirollbar makes so much noise!!!
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Old 14-05-2008, 09:06 PM   #14
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Sparco Harnesses...



Rear beam update - I tried drilling the holes out larger and using an M10 bolt but that didn't work. Its not the ping noise you get if the Antiroll bar plates are loose but a metallic bang over bumps. So I've given up with rear beam noises, so might try and find a low milage 2nd hand one. Let me know if anyone has one.
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Old 26-06-2008, 10:38 PM   #15
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I've replaced the antiroll bar plates on both sides now to cure the knocking noise. The antiroll bar was loose in the old plates, causing a noise. New plates were stiff to slide on to the antiroll bar. Been ok for a few weeks now. Result!!!
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Old 20-09-2008, 07:55 PM   #16
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New seats.

Sparco Evo2 plus...



Drove all the way to Wigan to buy them this morning. Got home and stuck them in!!! Went for a drive... bloody awsome!!! Removed rear door cards and front seatbelts at the same time.

Also did another oil change at 110,200miles.
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Old 20-09-2008, 09:27 PM   #17
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The new seats look lovely!

Some good progress being made on the car!
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Old 20-09-2008, 10:16 PM   #18
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I have a set of OMP one's from Anniversarallye that you can have for a fiver or so? I think they're blue. Oh and welcome to the Sparco Evo club!
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Old 25-10-2008, 08:05 PM   #19
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Thanks to Ponk for the OMP harness pads!

Car is now off the road for a bit so I can do some work on it at (111,111mls)

Todays progress...

Remove seats and carpet to fit Wilwood bias valve and pipes.
Weld harness points to floor and paint.



Will be refitting the carpet when all the brake pipes are in as I use the car everyday.

Whilst its at work I'll be removing the rear beam to treat the surface rust around that area.
New rear beam mounts.
Should be ordering some B8 shocks but have yet to do that.
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Old 25-10-2008, 08:08 PM   #20
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Ooooo very nice! Better make sure we don't park next to each other at any shows, wont be able to tell them apart!
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Old 25-10-2008, 08:16 PM   #21
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Quote:
Originally Posted by Ponk View Post
Ooooo very nice! Better make sure we don't park next to each other at any shows, wont be able to tell them apart!
I was just thinking that when I was reading your blog. But its easy... you have red seatbelts!
Car is looking good Pete.
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Old 08-11-2008, 06:20 PM   #22
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Update. Damn I've been busy!!! Car nearly back on road. Pics will tell the story...



Rust needed sorting...



So I removed the beam...



Cleaned all the rust off adn sanded down. Treated the metalwork then primered it...



Then painted blue...



Billie B8s arrived...



Rear beam painted, 4x new mounts fitted then refitted...





Seats and carpet now back in...



Not driven it yet. Still need to change front dampers. Also had to weld the pug sport due to a crack. Painted the brake calipers black. Removed a load of dodgy stereo wiring from previous owners. And general tidying up.

Let me know what you think. Cheers.
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Old 10-11-2008, 09:49 AM   #23
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Very nice, what's next on the list then?
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Old 10-11-2008, 12:17 PM   #24
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Quote:
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Very nice, what's next on the list then?
Cheers.

Need to change the front discs and pads. Any recommendations??? What you using Pete?
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Old 10-11-2008, 02:42 PM   #25
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I'm running 266mm 306 S16 brakes, just standard Bendix discs and pads at the mo. Although as soon as I can be bothered i'll be fitting some DS25000 pads.
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Old 17-11-2008, 10:43 PM   #26
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Been driving it for a week now. Played about with the bias valve for a bit. Brakes are now working as they should!!! No more rears locking up!!!

Bilstiens are great. Thought they would be hard but you'd hardly notice them. Much more postive through corners and more grip from the tyres.

Need some rear door card covers asap as well.
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Old 17-11-2008, 11:03 PM   #27
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realy nice car, keep it up
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Old 18-11-2008, 09:27 AM   #28
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Quote:
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Been driving it for a week now. Played about with the bias valve for a bit. Braked are now working as they should!!! No more rears locking up!!!

Bilstiens are great. Thought they would be hard but you'd hardly notice them. Much more postive through corners and more grip from the tyres.

Need some rear door card covers asap as well.
Strange isn't it? When I fitted mine I was expecting it to be teeth rattlingly bad. The only time I find the B8's harder to live with than standard is if I hit a pot hole.
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Old 24-01-2009, 05:11 PM   #29
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Lowered the rear a little more and polished her up...





Pics from meet...



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Old 25-01-2009, 11:56 PM   #30
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Good read mate
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Old 30-03-2009, 06:26 PM   #31
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New Pug front discs and pads. Old ones were finished...



Also just picked up this evening a brand new set of steelies ready for some A048s and new boot lid stickers as the old ones were peeling off. And a new fuel filter!
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Old 04-04-2009, 12:09 PM   #32
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Yoko A048 185/55/14 (soft) on my new set of steelies. These tyres are amazing!!! The level of grip is miles better than the Yoko S-Drives that I have been using. I will be keeping these as my track day tyres but I can see its going to be difficult to not have them on all the time!!! I've only driven 20 miles so far!!!





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Old 18-04-2009, 04:40 PM   #33
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Replaced the bearings on the torsion beam that hold the trailing arm. There was alot of play in the left hand wheel!!! Wasnt a bad job. Luckly nothing was seized...



Probably wasnt helping my issue of pulling to the left on hard braking. Also plumbed the brake bias valve to use all ports from the master cylinder instead of just one. And now have the bias valve wound fully in.
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Old 31-07-2009, 10:19 AM   #34
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One pic from Mallory Park (PPC Magazine day)...



Just fitted a brand new rear beam...



Old beam was worn badly...



New and old Pug beam...



Carpet and roof lining now removed. Looking for a cage soon.
Thanks for looking.
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Old 31-07-2009, 10:24 AM   #35
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good progress dude. im sure at some point im going to have to bite the bullet and buy a new rear beam. mine is too full or suprises! The other 16v engine will be having some headwork done to it too if your still interested
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Old 05-11-2009, 10:55 PM   #36
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Some pics from the year...

Trax in Sept...







Castle Combe Rally Day...





Cars been running really well lately. Coming up on 120,000miles. I had to weld in a CAT for the MOT last month so performance is down slightly. One advisory reference slight play in rear wheels caused by rear beam bearings. So took the arms off and really packed out the bearings with LOADS of grease. Seems to of done the job.

Looking for a 16v engine, loom and ecu at the min. PM me if you have one for sale!

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Old 06-11-2009, 09:01 AM   #37
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I'll have an ecu unlocked by Bluehawk for sale soon dude, probably after xmas I think.
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Old 06-11-2009, 11:02 AM   #38
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oooh my old ecu

they get about a bit lol

good to see its goin to another good home
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Old 06-11-2009, 02:31 PM   #39
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I think we should make it the official London + SE 16v ecu
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Old 09-01-2010, 04:24 PM   #40
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A couple of pics in the snow before it got too dark...





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Old 09-01-2010, 05:39 PM   #41
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Very nice rallye you have Ian
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Old 10-01-2010, 12:13 PM   #42
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Seeing those photos of it in the snow is making me want to go out in mine
Looking very nice
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Old 05-02-2010, 09:10 PM   #43
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Quick update on the Rallye,

1. Bought a 16v engine (TU5J4) which I've striped and am currently rebuilding.
2. Fitted some 4 point, 3inch Sparco harnesses. Much better!
3. More soundproofing removed and Grip Tape added to both footwells. Really loving that!
4. Fitted a set of Eibach Sportline springs -50mm. Dont hate me too much!!!lol

Need to get some new pics up as soon as the weather improves and once I have some of the parking dents removed!

Looking for a set of cams for the 16v and a 4branch manifold in the near future.
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Old 17-03-2010, 08:33 PM   #44
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Parking dents now all done! Happy days!

16v engine is totally striped at the min. Engine block is currently away being re-honed and cleaned.

All new parts from Peugeot arrived today :

Headgasket + headbolts
Waterpump + oil pump
Big end shells + piston rings
Cambelt kit
Various o-rings and seals
Sump bolts, etc.

And also ariving today a lovley set of CATCAMS 708s. They look massive next to the standard cams!

Started lapping in the valves to the head yesterday but got bored. Only did 4 valves!
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Old 17-03-2010, 09:08 PM   #45
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I hate lapping in valves lol

I got some omega pistons f/s you could whack in there while its apart
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Old 20-03-2010, 01:33 PM   #46
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Quote:
Originally Posted by Cyb3r View Post
I hate lapping in valves lol

I got some omega pistons f/s you could whack in there while its apart
Thanks for the offer but I've spent enough at the min on her!!!
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Old 22-03-2010, 12:08 AM   #47
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Some new pics whilst the sun was out ...





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Old 25-03-2010, 10:57 PM   #48
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Never read before, will deffo keep an eye now! Nice work!
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Old 26-03-2010, 10:02 PM   #49
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same here thats a bloody nice rallye
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Old 29-04-2010, 07:52 PM   #50
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A little update. 16v engine now fully rebuilt with Catcam's 708 and Raceland manifold.

Engine when bought..



Block stripped and rehoned...



Catcams fitted with clearance issue. Had to grind a bit off the head...



Engine as it stands tonight, with Powder coated cam covers in Anthercite...



Waiting for an engine loom (Pete!!!!!!!!!) then it will go in asap.
Maybe with a Quiafe.
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