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Old 01-01-2017, 01:41 PM   #1
LeeThr
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LeeThr's Moonstone Blue 106 GTi Track-Car/Road-Rally Project

Right, I think it's about time I get this up on here...

Firstly, all the pictures in this and many more will all be in an album on my flickr here: https://flic.kr/s/aHskKiXbuA

So back in September 2015 I picked this up for not much more than scrap money...
WP_20150907_13_19_24_Raw by LeeThr, on Flickr
[/url]WP_20150907_13_19_40_Raw by LeeThr, on Flickr

97 Plate 106 GTi in sunroof shell in Cherry Red with 155K on the clock, bought with the intention of turning into a track/road rally car.
These pictures are actually in a different album: https://flic.kr/s/aHskttxccY

Naturally with the price there was going to be a few issues lurking. A few I was aware of was the badly blowing exhaust, play in the steering, gearbox whining and im sure there was a couple of other things, but it's been that long and that much has happened inbetween i've forgotten. But anyway wasn't a huge issue as the first thing I was going to do was strip it down completely, all the issues could be resolved as and when. So a few nights in the garage resulted in this:
WP_20160321_18_06_14_Pro_LI by LeeThr, on Flickr
WP_20160325_00_48_18_Pro_LI by LeeThr, on Flickr

And this is where the real headache started... Up until now id had in my mind it was all mechanical jobs, how wrong was I....
[/url]WP_20160405_13_44_05_Pro_LI by LeeThr, on Flickr
WP_20160622_20_33_18_Pro by LeeThr, on Flickr
WP_20160622_22_53_23_Pro by LeeThr, on Flickr

Yup... it looked like I had a right rust bucket on my hands. So it was time to break the grinder out along with this attachment and find out just how bad it was.
WP_20160622_22_13_23_Pro by LeeThr, on Flickr

And the deeper I got the worse it was getting...
WP_20160405_13_44_18_Pro_LI by LeeThr, on Flickr
[/url]WP_20160413_02_23_49_Rich by LeeThr, on Flickr
WP_20160413_02_24_32_Rich by LeeThr, on Flickr
WP_20160413_02_24_39_Rich by LeeThr, on Flickr

All fairly straight forward repair work, time consuming yes, but still manageable as a long term project. But what really put a spanner in the works was when I got to the front floor stiffener plates and the chassis legs. What I found really wasn't good news.
WP_20160413_02_24_03_Rich by LeeThr, on Flickr
WP_20160413_02_24_12_Rich by LeeThr, on Flickr
WP_20160413_02_23_49_Rich by LeeThr, on Flickr
WP_20160413_02_23_41_Rich by LeeThr, on Flickr

This was clearly going to take a lot of work, and also a lot of new panels that are no longer available from Peugeot, foolishly however I decided I wasn't throwing in the towel and went off to buy this:
WP_20160713_18_50_31_Pro by LeeThr, on Flickr

A 2002 Cherry Red, Non-sunroof shell, with the intention of using as a donor car for the GTi, both body/chassis panels, and for the roof skin, as well as various trim pieces etc mine was missing which would need to go back in for road rallying. So I proceeded to tear this one to bits and cut cut out the panels I needed for the GTi.
WP_20160726_01_05_35_Pro by LeeThr, on Flickr
As well as the front chassis legs and a few other pieces, before what was left of the shell was sent on to car heaven.

And I got back to trying to work out a plan of how to get the GTi shell back together and rot free. But whilst in the middle of trying to work out a plan for this another factor came into the equation and after some more cutting and stripping this GTi shell sadly went bye bye also...
[/url]WP_20161018_14_15_30_Pro by LeeThr, on Flickr

More to follow.....
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Old 01-01-2017, 08:09 PM   #2
chatie1975
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Welcome along, they sure do rust!
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Old 01-01-2017, 10:40 PM   #3
Cris B
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Some rust in familiar places there...
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Old 02-01-2017, 05:49 PM   #4
LeeThr
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Indeed, think that shell had rust in every single place there known to go on. Been left that long as well it had just spread like wildfire.

I don't think the sunroof had been draining properly for some time either, under the carpet in the passenger footwell was underwater and had it's own little eco system going on. Also when I pulled the bungs out of the the front stiffener plates the amount of water that came out of there was shocking, especially considering the car had been sat inside a heated garage for 3 months prior to me to getting to that part.

The paperwork that came with the car suggested that at one point it did have an owner who did look after it and would get issues solved as and when they appeared. But it got sold on a few times since and the owners following were more the "typical boy racer" 106 owner, just ragged it around and threw budget parts on if they absolutly had too.

Also with it being such an early one having the analogue dash cluster, I think someone took the opportunity to play about with the millage counter. I found a sticker saying the timing belt had been done back in 2009 at 159K but yet when I bought the car September 15 the cluster was showing 155K. The most history also shows some discrepancies as well.
September 06 - 134,992
September 07 - 89,071
September 08 - 96,055
September 09 - 108,850
September 10 - 124,090

Something doesn't quite add up somewhere. But never mind always the chance you take with second hand cars and possible dishonest sellers etc, and this shell's long gone now.

So back in September whilst I was scratching my head about how to go about getting the Cherry shell sorted, I ended up going down to the midlands after winning a set of Newman PH3 Cams on the bay of E, and whilst there enquired as to why they were being sold. Turned out they'd come out of the sellers track car after the engine having thrown a rod out the side of the block and due to buying a Silvia as a replacement and getting into drifting, all the 106 related things were going, so of course asked what else he had. Que a trip down to the workshop where he had everything stored, to reveal he had this up for grabs....
2 by LeeThr, on Flickr
3 by LeeThr, on Flickr
4 by LeeThr, on Flickr
1 by LeeThr, on Flickr
WP_20161020_19_38_38_Pro by LeeThr, on Flickr

2002 Moonstone Blue Non-Sunroof GTi Shell (Bit of a rare combination) With 78K on the shell, 3 previous owners. And with it being sat as a rolling shell with no interior or engine/box it made it rather easy to check the obvious spots for rust. There was a few minor places that would need attention, but this was one that was just on the point of starting to rust. A point where catching and sorting it now would mean very very minor patching/treatment work rather than full on panel replacement. A very attractive prospect rather than the headache I had awaiting me back at home.

After a discussion about price etc, I went back home to have a think about the options available (including how I was going to get the shell up here should I buy it) and what to do with the cherry shell etc. But a decision was soon reached after an evening with an indepth discussion/poking around the cherry shell in the garage with a mate who's been helping me with the entire project. And a plan put in place and actioned, and once final arrangements had been made, work commenced to strip the cherry shell of the loom, and every last nut and bolt attached to it. End result was this:
WP_20161018_13_15_48_Pro by LeeThr, on Flickr
A few hours after this was taken I was greeted with this...
WP_20161018_13_30_50_Pro by LeeThr, on Flickr
WP_20161018_13_41_04_Pro by LeeThr, on Flickr

And then finally the cherry went off to car heaven...
WP_20161018_14_15_30_Pro by LeeThr, on Flickr

So another blank canvas, but a much stronger starting point....

Last edited by LeeThr; 02-01-2017 at 05:49 PM. Reason: Automerged Doublepost
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Old 02-01-2017, 06:45 PM   #5
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So with the new shell at home in the garage
WP_20161021_23_24_54_Pro by LeeThr, on Flickr

I had my first problem of getting a jack under a car sat on the floor...
WP_20161021_23_46_40_Pro by LeeThr, on Flickr
WP_20161021_23_51_17_Pro by LeeThr, on Flickr

But after this I spent a few hours dismantling everything ready to get stuck into getting the body sorted.
WP_20161025_02_55_52_Pro by LeeThr, on Flickr
WP_20161025_02_56_16_Pro by LeeThr, on Flickr
WP_20161107_22_52_15_Rich by LeeThr, on Flickr

Time to break out the grinder again and see what's lurking under the paint, pleased to say it was all rather healthy.
WP_20161111_00_56_32_Rich by LeeThr, on Flickr

X marks the spot of where needed to be cut out
WP_20161108_00_00_48_Rich by LeeThr, on Flickr
WP_20161116_02_52_34_Rich by LeeThr, on Flickr
WP_20161116_02_52_38_Rich by LeeThr, on Flickr

There was also a rather cowboy style hole in the bulkhead where the previous owner had made somewhere to run the loom for his standalone ECU through which would need to be patched up
WP_20161115_21_25_32_Rich by LeeThr, on Flickr

Time to break out the weld through primer and the mig at long last.
WP_20161115_23_46_24_Rich by LeeThr, on Flickr
WP_20161115_23_46_21_Rich by LeeThr, on Flickr
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Old 02-01-2017, 06:50 PM   #6
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That was a good find, when they come up in that condition you just have to grab them!
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Old 02-01-2017, 07:06 PM   #7
LeeThr
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As seen there was very little actual repair work to be done, but one thing I did have to do was change the panel containing the tow eye, and the loom connectors. The tow eye had had one of the bars to the eye cut to allow a bolt through for a tow strap, not the best idea seeing as half the strength was now gone. The other reason being this shell was original a 3 plug ECU loom, and was missing the engine loom, as well as what was left of the interior loom having been butcherd to tie into a standalone loom. I had two options, either find a 3plug engine loom & ECU and repair the interior loom, or use the single plug looms and ecu out of the cherry shell, and seeing as I already had all that in the garage and knowing it worked, it made more sense to use that rather than spending more money. But this became the second reason for changing the tow eye plate as most on here will know the 3 plug loom only has a single connector as this point where as the single plugs use two plugs.
So this happened.
WP_20161110_01_37_47_Rich by LeeThr, on Flickr
WP_20161110_01_37_19_Rich by LeeThr, on Flickr
WP_20161110_01_37_13_Rich by LeeThr, on Flickr
WP_20161111_00_56_16_Rich by LeeThr, on Flickr

Next thing was to add all the stitch welds as per the Peugeot Sport build manual
WP_20161115_21_25_35_Rich by LeeThr, on Flickr
Finally adding a set of strut top strengthining plates
WP_20161209_01_48_22_Rich by LeeThr, on Flickr

Finishing off all the welding work on the engine bay. So the grinder came back out to clean everything up, took it all back to bare metal and added rust treatment where it was needed.
4BF8831D-4A8E-4DA0-9BFD-D963F2DF5A89 by LeeThr, on Flickr
WP_20161123_17_32_06_Rich by LeeThr, on Flickr
WP_20161123_17_32_14_Rich by LeeThr, on Flickr

Finally built up a tempory spray booth in the garage
WP_20161206_22_08_40_Rich by LeeThr, on Flickr
WP_20161206_22_39_37_Rich by LeeThr, on Flickr
WP_20161208_01_42_00_Rich by LeeThr, on Flickr

Which ended up with this:
WP_20161210_22_37_24_Rich by LeeThr, on Flickr
WP_20161210_22_37_30_Rich by LeeThr, on Flickr
WP_20161210_22_37_38_Rich by LeeThr, on Flickr

Only in Epoxy primer for now, just to keep it all sealed up whilst I get everything else done. Once it's ready for it, it will be sprayed up in colour again.
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Old 02-01-2017, 07:21 PM   #8
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With the engine bay as finished as I could get it to at this point, time to turn it back into a rolling shell to get it facing the other way ready to sort the rear end out.
WP_20161212_22_36_27_Rich by LeeThr, on Flickr
WP_20161212_22_36_40_Rich by LeeThr, on Flickr
WP_20161212_22_43_46_Rich by LeeThr, on Flickr
WP_20161212_23_00_09_Rich by LeeThr, on Flickr
WP_20161212_23_00_34_Rich by LeeThr, on Flickr
WP_20161213_00_19_58_Rich by LeeThr, on Flickr
WP_20161213_01_48_48_Rich by LeeThr, on Flickr

Time to attack the rear end... Not that there's much work to be done really, just been a nightmare getting the underseal out of the rear arches. Inside the car there's this tiny patch to be sorted.
WP_20161213_00_20_11_Rich by LeeThr, on Flickr
And inside the arches themselves the only point of concern that needs work, is behind where the fuel filler neck sits flush against the arch, all the crap thats been thrown up into the arch that's been sat there has taken it's toll over time. Doesn't need a huge plate in however so I can't complain too much.

But that's pretty much where I got up to before christmas, I haven't touched it this last week or so at all, will be getting back to it soon however. I should also be expecting delivery of my cage either this week or next week as well all things being well, gone for the Safety Devices Weld-In Kit. Once that's in, and the rest of the welding works done including things such as seat rails, and also considering the Satchel wishbone rear mount strengthining kit, it will go off to have the interior and engine bay sprayed up in colour. Before it comes back to finally start going back together.

I should start to do something with this soon as well...
WP_20160629_22_17_17_Pro by LeeThr, on Flickr
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Old 02-01-2017, 08:38 PM   #9
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Nice work, keep it up
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Old 04-01-2017, 10:04 PM   #10
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I went to look at that shell..
It was in remarkable condition for a peugeot, I ended up with one in similar condition with a cage already welded in and painted ��.
Bonus for me as I can't weld or paint..
Good luck with it.
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Old 05-01-2017, 11:57 AM   #11
LeeThr
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Lucky for me you found that other shell then.
It really is in good condition overall, although it has still needed some work, it's nothing compared to what most of them do these days.

Thanks, good luck with yours as well
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Old 16-01-2017, 03:01 PM   #12
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Time for another update... Although nothing's really changed much, I haven't touched the car since before christmas due to work/uni commitments, last exam tomorrow though. But it doesn't mean that nothings happened on the car front.

Picked this up last week...
WP_20170111_19_50_13_Rich by LeeThr, on Flickr

Picasso BE4 with the TU bellhousing, and the driveshaft carrier with it as well. Need to clean that up and find the codes on it and see what final drive that's running. Also need to convert it from Cable to Rod linkages.

And then this morning I had a delivery....
WP_20170116_09_33_38_Rich by LeeThr, on Flickr
WP_20170116_09_53_00_Rich by LeeThr, on Flickr
WP_20170116_13_56_05_Rich by LeeThr, on Flickr
WP_20170116_13_56_10_Rich by LeeThr, on Flickr

Yes at long last my cage is here, very much in "kit" form. Arranged to have the windscreen taken out on Wednesday then the fun can begin on getting that fitted. I'd say the instructions are only a step above the one's you get with some Ikea flat pack
WP_20170116_13_56_16_Rich by LeeThr, on Flickr
WP_20170116_13_56_33_Rich by LeeThr, on Flickr
WP_20170116_13_56_40_Rich by LeeThr, on Flickr

And that's pretty much it for now. So only a small update.
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Old 16-01-2017, 04:16 PM   #13
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Crikey, not an easy job then... Lots of duct tape and swearing needed methinks.
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Old 16-01-2017, 09:37 PM   #14
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Indeed, I think the swear jar whilst fitting this would probably cover the cost of it haha
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Old 28-04-2017, 08:10 PM   #15
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I suppose it's about time I give this a bump. A few things have happened to the car,

Made a start on the rear arches, removing all the underseal etc to see what the state of play was there. Thankfully it's pretty healthy in there and just needed some small plates putting in at the bottom.
7DD40572-AAD0-4499-8860-1485EC0C8C44 by LeeThr, on Flickr
WP_20170209_22_56_52_Rich by LeeThr, on Flickr
WP_20170222_02_10_54_Rich by LeeThr, on Flickr
WP_20170222_02_11_02_Rich by LeeThr, on Flickr

Got a set of the rear wishbone mount strengthening plates from Satchel engineering, and got them in.
75C1D44F-68F0-4097-B350-C162968C39E1 by LeeThr, on Flickr
WP_20170215_22_12_32_Rich by LeeThr, on Flickr
WP_20170215_22_39_41_Rich by LeeThr, on Flickr

Also decided to have a look at what was lurking under the "spreader plates" put in by the previous owner for a roll cage... Horrified was an understatement...
WP_20170131_21_22_53_Rich by LeeThr, on Flickr
WP_20170227_21_48_08_Rich by LeeThr, on Flickr
WP_20170227_21_48_19_Rich by LeeThr, on Flickr

Then finally got the car packed up...
WP_20170222_01_36_00_Rich by LeeThr, on Flickr

And off it went....
WP_20170228_20_08_13_Rich by LeeThr, on Flickr
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Old 28-04-2017, 08:25 PM   #16
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I'm sure it won't take a rocket scientist to work out why it went.
Time had finally come to get the pile of scaffolding bar's I'd had in the garage for a few weeks fitted. Not been so straight forward and there has been some issues. But I won't go into detail until We've spoken to the suppliers properly and ironed everything out.

It's taken longer than expected due to issues etc, but it's nearly completed now. The plan was for it be coming back this evening, but sadly time just went against it today. So should see it back after the weekend. After which I can get get the rest of it ready for it to all be painted up and then start getting it back together.

But finally the cage is pretty much in bar a few final welds, door bar gussets etc. And the design looks rather good as well.
WP_20170308_20_50_18_Rich by LeeThr, on Flickr
WP_20170308_19_22_34_Rich by LeeThr, on Flickr
WP_20170308_19_25_10_Rich by LeeThr, on Flickr
WP_20170308_20_50_25_Rich by LeeThr, on Flickr
17440251_525105355889_118560661_n by LeeThr, on Flickr
17467881_525106892809_629979047_n by LeeThr, on Flickr
17888239_525331273149_1993799876_n by LeeThr, on Flickr
18155254_525542539769_1572141512_n by LeeThr, on Flickr
18175803_525542544759_1407580998_o by LeeThr, on Flickr


Pretty much there at last. And it's safe to say it's a rather stiff chassis now, jacked it up, and it looks as though there's going to be some 3 wheel cornering in the future...
WP_20170427_14_13_37_Pro by LeeThr, on Flickr

And that's where it's up to now, should be some more progress from next week as well.

The album for the cage fitting can be found here: https://flic.kr/s/aHskVXhSG9
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Old 22-06-2017, 04:55 AM   #17
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Has it really been another 2months since I last updated this? Wow where does the time go too.

So anyway after 2 months of having this...
IMG-20170428-WA0001 by LeeThr, on Flickr

At the start of May this re-appeared but looking a bit different to how it left...
IMG-20170503-WA0001 by LeeThr, on Flickr
WP_20170503_19_35_04_Rich by LeeThr, on Flickr
WP_20170503_19_35_13_Rich by LeeThr, on Flickr
WP_20170503_19_35_24_Rich by LeeThr, on Flickr
WP_20170503_19_35_30_Rich by LeeThr, on Flickr
WP_20170503_19_35_39_Rich by LeeThr, on Flickr
WP_20170503_19_35_55_Rich by LeeThr, on Flickr
WP_20170503_19_36_14_Rich by LeeThr, on Flickr


Threw the dash roughly at it to see just how much it's going to need to be butchered and it's a fair bit...
WP_20170505_17_09_11_Rich by LeeThr, on Flickr
WP_20170505_17_09_27_Rich by LeeThr, on Flickr

So finally back in my hands and I was raring to get back to work on it... unfortunately it came back just at the start of the month I had a 10,000 word thesis and my final year exams in uni to get through. Real life priorities had to take over and she's sat in the garage untouched for a month. But it did pay off as I found out last week as I've passed my degree with a 2.2.
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Old 22-06-2017, 05:19 AM   #18
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A long month later, I was finally able to start catching up with everything I wanted to do. The only other priority is a job search for something more permanent and get me on the right track career wise from where I am currently.

So back in the scruffs and hidden away in the man-cave I started to walk around the car and filled in the whiteboard as to what jobs I needed to undertake before I could send her off to be painted up. The rate at which it filled up was a bit alarming...
WP_20170603_02_05_15_Rich by LeeThr, on Flickr

Plenty to be getting on with, first job I tackled was test fitting the front end panels to see if anything had been disturbed by the inner wing strengthening panels being taken off and refitted. Down came the panels out of storage and the front end began to slowly resemble a 106 again...
WP_20170605_21_20_45_Rich by LeeThr, on Flickr

Dropping the slam panel back in quickly brought to light something had in fact moved...
WP_20170605_22_10_23_Rich by LeeThr, on Flickr

Passenger side seemed to line up quite nicely
WP_20170605_22_00_49_Rich by LeeThr, on Flickr

Drivers side not so much...
WP_20170605_22_03_29_Rich by LeeThr, on Flickr

Out came up a nice big ass ratchet strap.
987EA752-8DE7-4A26-A3F5-778A3321E658 by LeeThr, on Flickr

And with some playing about things slowly started to move back into line...
WP_20170607_19_13_37_Rich by LeeThr, on Flickr
WP_20170607_19_32_33_Rich by LeeThr, on Flickr
WP_20170607_19_20_08_Rich by LeeThr, on Flickr

I didn't spend too much time trying to make it all line up 100% perfect as it all had to come back off again. But once I got it to the stage where it was obvious just some minor adjustments with the bonnet hinges etc would get it spot on it all came back off again and back into storage.

Next up was time to start getting all the bits back in the car I needed to know where they sit to work around for things being moved and added. First up the interior loom...
88D78B80-21A7-4D4B-BF4F-3CA9D73A42B7 by LeeThr, on Flickr
Unraveled and slowly started to drop back into place along with a few other bits and pieces...
WP_20170609_01_14_30_Rich by LeeThr, on Flickr
WP_20170609_01_14_25_Rich by LeeThr, on Flickr
WP_20170609_01_14_34_Rich by LeeThr, on Flickr
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Old 22-06-2017, 05:54 AM   #19
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Need a seat?
So the rules of road-rallying dictate I have to have the back seats in somehow. At first glance with my cage that looked like a slightly daunting task. But after fetching them down from the loft and looking at exactly how the 106 rear seats are constructed things started to seem not so difficult. Only some minor cuts to be made to allow them to drop in around the cage. Just need to get some new hacksaw blades rather than taking the angle grinder to them and risk the hot sparks setting the sponge alight.
WP_20170609_01_14_14_Rich by LeeThr, on Flickr
WP_20170605_21_24_59_Rich by LeeThr, on Flickr
WP_20170605_21_25_05_Rich by LeeThr, on Flickr
IMG-20170605-WA0001 by LeeThr, on Flickr

Also noted the fuse box will need some minor trimming so it won't foul on the cage...
WP_20170606_00_34_47_Rich by LeeThr, on Flickr

Next up was making a start on getting the seat rails fitted and positioned...
WP_20170619_20_11_33_Rich by LeeThr, on Flickr
WP_20170619_22_11_50_Rich by LeeThr, on Flickr

This is where I started to run into a bit of an issue.. the brackets for the rails needed at least tacking on I have no experience with a welder, and my friend who's been helping me with the entire project and doing all the welding minus the cage in-house has been tied up with other work elsewhere recently and therefore unavailable
to assist me.

Not being one to give up and let a hurdle like this stop me, and isn't the whole point of a project to learn and develop new skills? I decided to put the welding mask on and even used the famous phrase "how hard can it be?"
WP_20170620_00_01_55_Rich by LeeThr, on Flickr

Well the reality was this pathetic little splatter of bird crap...
WP_20170620_00_09_15_Rich by LeeThr, on Flickr

Certainly not going to give anybody a run for their money at welding just yet.

Not being one to give up, and rather than damaging the seat rails and the bracket any more. I went back to this
WP_20170620_00_23_36_Rich by LeeThr, on Flickr

And got some scrap metal out where things did slowly start to improve
WP_20170620_21_36_52_Rich by LeeThr, on Flickr
WP_20170620_20_12_18_Rich by LeeThr, on Flickr

Then I had a go at joining two pieces together to see how well I could get them to hold..
WP_20170620_21_00_20_Rich by LeeThr, on Flickr
WP_20170620_21_36_18_Rich by LeeThr, on Flickr

Not the neatest but even with a 4lb lump hammer I couldn't get it to snap off.
With a bit more confidence that I might get a useful tack weld, I went back to the seat rails and got the brackets all tacked up, dropped the rails into a position to try and bolted the side mounts followed by finally the seat.
WP_20170621_02_36_19_Rich by LeeThr, on Flickr
WP_20170621_02_36_24_Rich by LeeThr, on Flickr


The rails are currently cut to a length where there just short enough that they will squeeze in between the sill and the tunnel but tight enough they won't move and take a fair bit of force to move them. They need shortening some more to go in permanently. But for now they work fine just to find the ideal position. Looks like the seat could be a tight fit up against the cage however.
[/url]WP_20170621_02_36_51_Rich by LeeThr, on Flickr
WP_20170621_02_37_08_Rich by LeeThr, on Flickr
WP_20170621_02_37_17_Rich by LeeThr, on Flickr


And lastly it looks like I have plenty of room behind the passenger seat to place the battery there like ive been planning too. A standard type battery sits nicely so one of the lightweight dry cells should have no issue at all.
WP_20170621_02_38_47_Rich by LeeThr, on Flickr

And that's where im at currently. I'll be back in there this evening and making a start on the rails for the drivers side.
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Old 25-06-2017, 11:12 PM   #20
Cris B
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You're making some good progress on this!
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Old 26-06-2017, 05:40 PM   #21
LeeThr
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You're making some good progress on this!
Cheers Cris Certainly won't be giving you a challenge for welding anytime soon yet though.

Good too see yours is still moving forward as well.
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Old 26-06-2017, 07:00 PM   #22
Dieseldave
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I missed these updates, nice work. The cage out to the inner wings is a better job than the
Custom Cage setup that fouls the wiper mech.
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Old 28-06-2017, 04:09 AM   #23
LeeThr
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I missed these updates, nice work. The cage out to the inner wings is a better job than the
Custom Cage setup that fouls the wiper mech.
Cheers Dave, the cage going out to the inner wing's caused a fair share of headaches. The instructions supplied really didn't give any clear indication on where in the bulkhead area the bars needed to pass through and what they were actually attaching to the other end. All we had was some rather useless line drawings with a very vague few lines of instruction. Which you can see above.

A call to Safety Devices UK didn't help matters either as they were unsure themselves (wasn't the first thing we'd had to call to them about either to which they were unsure about) What also led us astray is the picture on their website advertising the cage:
sd1 by LeeThr, on Flickr

If you look closely near to the air entry for the interior fan you can see the bar coming through straight to the back of the scuttle. As this was the only "fixed" information we could find on this cage it was assumed this was where the bar was supposed to go. But couldn't work out just how the two bars where supposed to meet up in this location or how they would both attach to add strength. Even after cutting out a hole in the scuttle and trying to position the bars we just couldn't work it out.

A call to west wales rally spares (the dealer I bought the cage through) finally shed some light, after they made a call to Safety Devices in Belgium, who very helpfully informed us the picture on the website was an installer supplied picture who had incorrectly installed the cage (Great way of advertising your products) But went off and did some digging and came across this picture for us:
17910810_10155170241942173_960893472_n by LeeThr, on Flickr


Oddly however the fitting instructions for the Saxo version of the same cage clearly show cutting the inner wing outer panels off and bringing the bars through as so. Not really sure why the supplied 106 instructions are so poor. But never the less it got there in the end.
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