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Old 13-11-2017, 01:26 PM   #101
Cris B
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Quote:
Originally Posted by shenparbitch View Post
Rad mounting technique looks familiar ����
Ha ha! I knew you’d done something similar.

I looked for your photos but couldn’t find them on Photobucket so freestyled it
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Old 18-11-2017, 09:53 PM   #102
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Satchshift fitting

Back in 2012(!) when I bought Danny's Quaife'd BE box off him it came with a Satchshift. At which point I sold my MA version and cracked on with the then project car which was the 16v White S2 Rallye. The thing was that in doing this car, I'd welded in a trimmed down version of the stick gator mounting plate so I didn't have one and I'd forgotten that. So the starting point for fitting the Satchshift to this car was to make a bit of tube.

I'd not made a tube out of flat sheet before but I found a paint tin that was the right diameter so used that as a form to bend the steel around. Ended up with this - it's pretty much round



Did the necessary prep, which included blanking the original gear lever hole and welded bit of formed tube in.



Now having fitted a number of Satchshifts over the years any one who has also done it will know that it is enough of a faff to bolt the bits onto the bulkhead with the interior stripped and an empty bay, but it's really a two person job with the car assembled. To remedy that I welded nuts onto the bulkhead so no spanners are needed - just a hex key

I also don't know how the shell was used previously as it had the cutout and drilled holes for the upper pushrod gator, but the other holes weren't drilled which was a bit weird



All fitted:



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Old 19-11-2017, 11:12 AM   #103
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Good work.
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Old 19-11-2017, 07:44 PM   #104
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Did the S1 shell not have the 2 captive nuts for that pedal box brace? They are in my 106 & Saxo.
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Old 19-11-2017, 08:13 PM   #105
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only one captive nut there on an S1.

been helping to do some very similar work on a Red S1 rallye too.
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Old 19-11-2017, 10:39 PM   #106
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Pedals

Bought some Motamec pedal covers, but they weren't a great fit and being thinner alloy that say a set of Sparco's decided that they needed to be modified:



Bit of time shaping them:



Did all three:



Drilled the pedals and welded nuts onto the back to simplify fitting. Bit of matt black to tidy them up...



Mounted

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Old 23-11-2017, 11:13 PM   #107
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Finally managed to get the paperwork sorted and it arrived back from the DVLA this week.



14(!) registered previous keepers which means that there's some significant gaps in my knowledge
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Old 25-11-2017, 10:35 PM   #108
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So suspensions on, steering is connected up. Question has anyone else had any issues with getting the tracking right with Tommy's steering arm kits? I've basically zero'd all of the adjustment out of them and I still have quite a bit of toe in. Without shortening the arms I'm going to have to use thinner lock nuts or something similar to make these work Any one else have any issues?



Chucked the wheels back on and rolled it outside for a wash, it was very dirty but it's given me a chance to clean up some of the mud off the bits I need to tidy up. It's clearly been run without wheel arch liners for quite a long time and now the dirt is gone, it's clear that there is tar residue all over the place.

Rear beam on this car has been properly slammed, too low for my liking...

Any way the reason for getting it rolling was to turn it around so I can do the engine swap out of the Maxi into the Rallye more simply. Once the engine and box are in I can letterbox the bulkhead into the scuttle.
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Old 26-11-2017, 03:54 PM   #109
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Never had an issue on Mike's with the arms. I'd imagine once weight of the front end is in the arms will pinch in and a true toe setting can be set.
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Old 26-11-2017, 10:02 PM   #110
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Quote:
Originally Posted by dunc View Post
Never had an issue on Mike's with the arms. I'd imagine once weight of the front end is in the arms will pinch in and a true toe setting can be set.
Cheers Dunc. I think I need shorter springs so maybe with a completely different setup I'll get it dialled in right...

Before I scrapped the silver GTI I chopped this out:



This was because I had realised the I'd was going to put the EW back in the Maxi so I'd need to repair the cut out I'd put into the chassis and I'd need a donor section. Now when I've been working on the Rallye, I'd come to need to buy a pair of the chassis reinforcement plates.

Turns out this is the last one that 106 Parts had for sale:



By sheer luck I have a pair:



Drilled the four spot welds and with some careful work with the slit disc on the welds and we have two ready to fit...

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Old 08-12-2017, 06:53 PM   #111
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Footrest is in. It was a mission, but second time lucky on the welded in captive nut mountings. Should make it nice and easy if I decide to run carpet and gives me more confidence than the threaded rivet inserts.

Powder coat is bolloxed. Cracked and peeled off as it was bent to shape to fit the footwell. I’ll get it blasted to key it in and then either epoxy it or get it powder coated again.
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Old 09-12-2017, 08:53 PM   #112
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Fantastic progress pal! What is the end intention for the car? I thought initially it was a daily, but there's some pretty fancy parts going in!
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Old 10-12-2017, 07:52 AM   #113
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It’s supposed to be a run about

Just a fancy one
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Old 11-12-2017, 12:36 PM   #114
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Thumbs up

Going to be doing the same for a passenger footrest in mine.

Will you be mounting a small dry cell battery to the rear of the footrest?
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Old 11-12-2017, 03:35 PM   #115
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Quote:
Originally Posted by westwell_22 View Post
Going to be doing the same for a passenger footrest in mine.

Will you be mounting a small dry cell battery to the rear of the footrest?
Yes that's the plan. I did that on my white s2 previously but wanted a more secure mounting this time around. The s1 and s2 floor pans are different shapes too.



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Old 11-12-2017, 05:26 PM   #116
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Whats the plan for the car long-term? Anything MSA related? As there clamping down on putting the battery behind the footrest. If it's not in the rules yet it will be soon but it will need to be behind the back of the occupants not in front.
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Old 12-12-2017, 06:20 AM   #117
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Thanks for the heads up. In that case I will likely put it on the bulkhead behind the passenger seat... I intend to allow an interior to be refitted to road rally rules. Liverpool Motor Club just sent out an email to members about a new version coming out for some light festive reading so I might take a look over the holidays.

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Old 15-12-2017, 10:15 PM   #118
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Engine's swapped over time to cut the scuttle...



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Old 16-12-2017, 09:13 PM   #119
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Chopped the scuttle to create a letterbox for the bodies:





The bulkhead face of the scuttle is shaped and for what I want to do I needed to smooth it so a bit of chopping and welding needed. With the trumpets in I need to chop another 10mm out of the side nearest the middle and it'll be spot on.



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Old 18-12-2017, 04:57 PM   #120
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You need a kit car airbox.
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Old 18-12-2017, 07:47 PM   #121
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You need a kit car airbox.
I bet you've got a good idea where there's a couple for sale currently as well?
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Old 18-12-2017, 09:11 PM   #122
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is the gearbox sat a bit low?
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Old 19-12-2017, 06:43 AM   #123
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Quote:
Originally Posted by Dieseldave View Post
You need a kit car airbox.
All will be revealed

Quote:
Originally Posted by welshpug View Post
is the gearbox sat a bit low?
Donít think so might be a camera illusion
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Old 05-01-2018, 11:01 PM   #124
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Passenger door has always had check strap issues so decided to do something about that and treated the car to a brand new part



Comparison of old vs new and there are a few subtle differences...



The result...

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Old 14-01-2018, 10:45 PM   #125
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Wanted to find a way to get the oil catch tank in. Spoke with Sandy to confirm positioning. Didn't want to do something conventional above the gearbox mount so made this instead.











Just needs a lick of paint...
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Old 21-01-2018, 10:14 PM   #126
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Other projects around the house and workshop keeping me busy but did manage a bit of progress...

Painted up the catch tank and the coil pack brackets.



Fitted those and then put in an insulated bulkhead fitting for the battery cable.





In doing this came to the conclusion that the stainless rivnuts I pressed in for the steering column were not the way forwards. As they're not flush fitting the column was wobbling even with a third bolt added in for stability. So I cut the rivnuts out and welded in some captive nuts. Those combined with the third fixing means it's solid now.
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Old 21-01-2018, 11:20 PM   #127
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have you checked if you can go lock to lock without anything touching yet? found that bolt on the middle rubbed on the bulkhead!
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Old 22-01-2018, 09:31 AM   #128
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Yes that is on full lock in the photo.
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Old 22-01-2018, 10:09 AM   #129
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yeah we found that the bolt rubbed around the middle of the bulkhead, classic french tolerances!
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Old 20-02-2018, 04:55 PM   #130
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Not updated much recently as I’ve had a few woodworking projects around the house. In the garage I have started work on the biggest job on the Rallye - the passenger side sill. I had one chopped out of a solid shell at a local breakers yard. Once the under seal was off and it was split open it turned out to be less solid.



Currently working my way through the rotten bits and fabricating repair panels for the repair panel. It’s tedious and to make matters more exciting I ran out of gas for the MIG at the weekend.

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Old 22-02-2018, 07:11 AM   #131
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well, that's a fairly daunting looking task. its a shame no one has done a replacement sill. i spoke to a guy in Holland who makes 205 and R5 parts but he doesn't see enough of a market for 106 panels.
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Old 12-11-2018, 05:51 PM   #132
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I am back!

Decided to take a bit of a break from cars and focus on other things for a bit. What did I miss
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Old 14-11-2018, 11:21 AM   #133
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I am back!

Decided to take a bit of a break from cars and focus on other things for a bit. What did I miss

Very little......
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Old 19-11-2018, 08:22 AM   #134
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Quote:
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Very little......
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Old 13-01-2019, 11:06 PM   #135
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After near to a full year off I am getting back on this project next month. Just sourcing some parts...
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Old 14-01-2019, 02:53 PM   #136
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Old 31-01-2019, 01:33 PM   #137
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Looking forward to seeing the progress!
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Old 11-03-2019, 03:22 PM   #138
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So true to my word last month I started the project again after 12 months off doing DIY jobs around the house. Rock and roll. First things first, gassing up. The once local-ish supplier in Rochdale is now less so, but two refills get's the MIG back in action.



That's meant I can crack on with the TIG Trolley which has been a mild distraction, but is now nearly finished:



The next job on the Rallye is still the sills. I'd made some good progress on these before I ran out of gas, so I have been pressing on with these. The replacement sill I picked up to replace the crusty one on the car was, err, crusty:



New sections fab'd up and ready to go in once I sort out the jacking point plate. That's currently sitting in a chemical bath but may well end up getting a new part made up. It will need to go between these two sections the top one of which replaces the rusty bit that was in the photo above:



Then this bit can get welded in and tidied up



The other end of this half of the sill sits on the inside of the rear arch and a complex 3d curve which my rudimentary panel beating failed to replicate despite several attempts. I'm not 100% happy with what I ended up with so clearly the answer was to go back to basics.

Buy another 106!

Well mostly, I didn't much enjoy the process of chopping up the silver GTI on the drive so decided to go hunting. Turns out they are a rarity in the local breaker yards in the NW, but I did find a good late model one in a yard in the North East where I work. Thinking ahead I marked up both sills and the boot floor to be liberated by two experts with a STIHL saw. What could possible go wrong?

Hmm. Well I did not quite get all of what I was expecting





Sigh

Oh well, at least the full sill is the other side I didn't have and needed and that the bit of the side I am currently working on is actually the bit I need. They're in pretty good shape too.

My boot floor looks like it was attacked with a ball peen hammer. I may replace the whole panel when I re do the boot floor seams.









Had a chat with @Slammed106 about tackling spot welds and decided to try some of these after trying and breaking some Rotabroach minicutters last time:



So much spot weld drilling to come next!
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Old 16-03-2019, 07:42 PM   #139
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Corr that’s some effort. Keep up the good work.
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Old 17-03-2019, 09:01 AM   #140
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Glad to see the action recommencing! Hope the spot welds are easy going.
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Old 18-03-2019, 11:45 AM   #141
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Thanks chaps. aiming to make some progress with weekly updates from now on...

So took the smaller section of sill and started getting ready to part it for donor material



The 3d curved section is the prize here and is the best I have to work with. It'll need a little repair. So just to be clear, I'll be repairing the repair section for the repair panel to repair the panel on the car.

#WishTheyStillMadeReplacementPanels



The hallmark of the scrapyard slashers. I don't need these end bits yet but will keep them until all the repairs are complete as they are always useful references for making new parts from scratch.



Box load of new twisted knot and standard wire brush wheels for the angle grinder on the way for next weekend's action...
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Old 25-03-2019, 12:54 PM   #142
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New spot weld cutters now dialled in and working a treat. Managed to get various remnants of floor and bulkhead and reinforcement removed and then opened up the sill.



Pretty pleased with the state of them - much better than the first replacement sill!

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Old 16-04-2019, 10:42 AM   #143
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Bit behind on posts so here is a couple of weekends worth of updates:

Jacking points were rust magnets. Sitting in an acid bath for a week didn't shift it, so had some new ones laser cut and fabbed. Quicker than doing them myself.





Identified the bit needed to repair the repair panel sill. Marked up the repairs it needed:





Welded that up and chopped out the first repair attempt I wasn't happy with. The shape wasn't right and it seemed best to just start again.





New repair section in, just needs the welds dressing and we can crack on (photos to follow).

This is the most important panel in the sill repair as all of the other three layers of sill tie to it and this panel ties into the rest of the car.

Rest of the sill is now in three parts, so just need to drill the spot welds to part the other half and then I can repair that can start cutting into the shell and getting this all fitted.
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Old 16-05-2019, 04:38 PM   #144
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Having been scuppered in my plans for regular progress, I took a day off earlier this month to "finish off" the two parts of the sill that were "done". Ended up spending the entire day getting them finished and prepped. Started at 10am and finally finished painting them with epoxy primer at 11pm!



I have started user Lechler epoxy primer which was highly rated by the great Steve Lang (RIP). It stinks as it goes off however!



So this weekend just gone I parted the other half to give me the final two panels.



I am pretty happy with these as on the whole they are in pretty good shape in comparison!

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