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Old 10-05-2010, 10:16 PM   #1
Tom J
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Katie Jones' Black S1

...it's not mine, you see. I'm just looking after it for someone!

Nevertheless, I will do the thread for now.

L838 BBB is the new project, bought with a knocking bottom (ooh, er!) which let go (even worse) after about 25 miles of only having third gear down the M6. Thank goodness for the RAC.



There she is as pictured in the advert, and I will follow up with some more soon. YOU could even appear in them!

Tatty, knocking old engine and box need to come out to be replaced with a nicer bottom, rather like how I got rid of my ex-wife

If anyone is able to make it over of an evening to lend a hand, I'd be very pleased to see you! I'd like to get it done asap before the tax and MoT runs out as it will need a weld for the MoT and I'd like to take it to Pugfest with a fair wind.

Made a start yesterday but the two year old who was looking after the tools got easily distracted and I only got the manifold off. You pay peanuts...
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[CENTER]
[B]Harrow Rallye Sanctuarye (Formerly also the XND Centre of Excellence)
[COLOR="White"]JDU[/COLOR][/B] - Progressing slowly in the secret restoration lair
[B]BBB[/B] - Head Gasket kit purchased; to fit (hopefully curing the misfire) before MoT
[B][COLOR="Red"]YKP[/COLOR][/B] - Taxed, Tested and Burning Oil
[B][COLOR="Blue"]MYM[/COLOR][/B] - Rallye Bus: In traffic
[B][COLOR="Red"]DFR[/COLOR][/B] - RIP, Rallye Bobsled, whose body was stolen... [B][COLOR="White"]XTL[/COLOR][/B] - [URL="http://www.106rallyeforum.com/forum2008/showthread.php?t=57523"]Please Pray for the Dervinator's Soul.[/URL]
[URL="http://www.106rallyeforum.com/forum2008/showthread.php?t=61502"][IMG]http://www.motorphoto.co.uk/rallye/sigs/nexttripsig.jpg[/IMG][/URL]
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Old 11-05-2010, 06:59 AM   #2
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Cool number plate I still think you should put a 16v in though

I'll be able to get to my engine crane this week if you want to borrow it to get the job done, I've got a few days off next week as well.
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Old 11-05-2010, 07:17 AM   #3
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Funny how when buying a Rallye, the state of the bodywork is usually more important than if it has a working engine or gearbox or anything minor like that
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Old 11-05-2010, 11:52 AM   #4
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You're right Matt - this one has some nasty rot where (as so often is the case) some numpty has jacked it under the bulge in the floor behind the front wheels. Both sides. Not had chance to get in there with the wire brush yet but it should be plateable. Likewise the boot floor has the usual problems, but nothing scary. James Sutlow's White S2 changed my perception of rot!

Otherwise it's not the best example of a Black S1, certainly not the kind of minter that my red one was, but it will do the job as an introduction to Rallye ownership for my young lady! She has bought herself a Haynes and was apparently reading it on the tube last night!
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[CENTER]
[B]Harrow Rallye Sanctuarye (Formerly also the XND Centre of Excellence)
[COLOR="White"]JDU[/COLOR][/B] - Progressing slowly in the secret restoration lair
[B]BBB[/B] - Head Gasket kit purchased; to fit (hopefully curing the misfire) before MoT
[B][COLOR="Red"]YKP[/COLOR][/B] - Taxed, Tested and Burning Oil
[B][COLOR="Blue"]MYM[/COLOR][/B] - Rallye Bus: In traffic
[B][COLOR="Red"]DFR[/COLOR][/B] - RIP, Rallye Bobsled, whose body was stolen... [B][COLOR="White"]XTL[/COLOR][/B] - [URL="http://www.106rallyeforum.com/forum2008/showthread.php?t=57523"]Please Pray for the Dervinator's Soul.[/URL]
[URL="http://www.106rallyeforum.com/forum2008/showthread.php?t=61502"][IMG]http://www.motorphoto.co.uk/rallye/sigs/nexttripsig.jpg[/IMG][/URL]
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Old 11-05-2010, 11:58 AM   #5
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Doesn't look too shabby there Tom, hopefully get to see it at Pugfest and have a long overdue catch up

Black ones in my experience seem to fair better with the rot than the white ones
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[URL="http://farm3.static.flickr.com/2761/4531940528_98a56bc409_o.jpg"][U]Onyx Black S2 Rallye :s2:[/U][/URL] [COLOR="DarkGray"]|[/COLOR] [URL="http://i151.photobucket.com/albums/s144/james106rallye/306%20Rallye/xlow2.jpg"][U]Bianca White 306 Rallye :s2:[/U][/URL] [COLOR="DarkGray"]|[/COLOR] [URL="http://i151.photobucket.com/albums/s144/james106rallye/x1-1.jpg"][U]Onyx Black S1 Rallye :s1:[/U][/URL] [COLOR="DarkGray"]|[/COLOR] [URL="http://i151.photobucket.com/albums/s144/james106rallye/app11.jpg"][U]Bianca White S2 Rallye :s2:[/U][/URL][/B]

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Old 11-05-2010, 12:03 PM   #6
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Quote:
Originally Posted by Gregg View Post
Cool number plate I still think you should put a 16v in though

I'll be able to get to my engine crane this week if you want to borrow it to get the job done, I've got a few days off next week as well.
How are you fixed next Monday, Gregg? Katie and I are both off work that day. I reckon I'll have the engine ready for lifting by then.

Yes, I like the plate, too. Shame it's not 888 BBB!

16v?! Wash your mouth out. For as long as I've got as many 8v engines as I own, I can't really defend doing it anyway! I'm back to the plan of having a standard one and a track one in my care...
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[CENTER]
[B]Harrow Rallye Sanctuarye (Formerly also the XND Centre of Excellence)
[COLOR="White"]JDU[/COLOR][/B] - Progressing slowly in the secret restoration lair
[B]BBB[/B] - Head Gasket kit purchased; to fit (hopefully curing the misfire) before MoT
[B][COLOR="Red"]YKP[/COLOR][/B] - Taxed, Tested and Burning Oil
[B][COLOR="Blue"]MYM[/COLOR][/B] - Rallye Bus: In traffic
[B][COLOR="Red"]DFR[/COLOR][/B] - RIP, Rallye Bobsled, whose body was stolen... [B][COLOR="White"]XTL[/COLOR][/B] - [URL="http://www.106rallyeforum.com/forum2008/showthread.php?t=57523"]Please Pray for the Dervinator's Soul.[/URL]
[URL="http://www.106rallyeforum.com/forum2008/showthread.php?t=61502"][IMG]http://www.motorphoto.co.uk/rallye/sigs/nexttripsig.jpg[/IMG][/URL]
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Old 11-05-2010, 09:53 PM   #7
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Update:

After much head scratching caused by a bolt with a 12mm head holding the o/s end of the front bumper on, the bumper, slam panel, exhaust manifold, radiator and a few other bits have come off tonight. I also took off the offending gear linkage, which has completely disintegrated at the 'big' end (the rod that goes onto the selector arm). I wouldn't mind betting it was caused by the quickshift being set to a very, very short throw - the one on JDU did a similar job and I never had the shift that short even.

Anyway, it now looks like a Rallye, since it is up on stands, with half the front end missing. Katie wields a mean 13mm spanner, I have to admit, and I am losing far fewer tools now that I am being made to be tidy!

Pictures tomorrow in daylight.
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[CENTER]
[B]Harrow Rallye Sanctuarye (Formerly also the XND Centre of Excellence)
[COLOR="White"]JDU[/COLOR][/B] - Progressing slowly in the secret restoration lair
[B]BBB[/B] - Head Gasket kit purchased; to fit (hopefully curing the misfire) before MoT
[B][COLOR="Red"]YKP[/COLOR][/B] - Taxed, Tested and Burning Oil
[B][COLOR="Blue"]MYM[/COLOR][/B] - Rallye Bus: In traffic
[B][COLOR="Red"]DFR[/COLOR][/B] - RIP, Rallye Bobsled, whose body was stolen... [B][COLOR="White"]XTL[/COLOR][/B] - [URL="http://www.106rallyeforum.com/forum2008/showthread.php?t=57523"]Please Pray for the Dervinator's Soul.[/URL]
[URL="http://www.106rallyeforum.com/forum2008/showthread.php?t=61502"][IMG]http://www.motorphoto.co.uk/rallye/sigs/nexttripsig.jpg[/IMG][/URL]
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Old 12-05-2010, 07:48 AM   #8
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That looks like a nice black s1 and as Dyno said the bodywork means more especially with a black s1, they are hard to find in that condition
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Old 12-05-2010, 08:50 AM   #9
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It's not the most pristine, it's had a lot of repainting (everything bar the hatch and the roof skin I reckon) but there is no lacquer peel and the interiour paintwork is good.

I still can't work out which colour I prefer, now I've had all three(!). JDU was my first Rallye and like a second child to me, I loved the red one (a smart little bright red sports car was what I wanted when I was a little boy!) but I suspect that the black one is growing on me; it's got rarity on its' side too.

Clear to me already though is that you have to keep a black car cleaner!
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[CENTER]
[B]Harrow Rallye Sanctuarye (Formerly also the XND Centre of Excellence)
[COLOR="White"]JDU[/COLOR][/B] - Progressing slowly in the secret restoration lair
[B]BBB[/B] - Head Gasket kit purchased; to fit (hopefully curing the misfire) before MoT
[B][COLOR="Red"]YKP[/COLOR][/B] - Taxed, Tested and Burning Oil
[B][COLOR="Blue"]MYM[/COLOR][/B] - Rallye Bus: In traffic
[B][COLOR="Red"]DFR[/COLOR][/B] - RIP, Rallye Bobsled, whose body was stolen... [B][COLOR="White"]XTL[/COLOR][/B] - [URL="http://www.106rallyeforum.com/forum2008/showthread.php?t=57523"]Please Pray for the Dervinator's Soul.[/URL]
[URL="http://www.106rallyeforum.com/forum2008/showthread.php?t=61502"][IMG]http://www.motorphoto.co.uk/rallye/sigs/nexttripsig.jpg[/IMG][/URL]
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Old 12-05-2010, 09:32 AM   #10
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White is the best colour overall IMO but out of your collection the red was my favourite just because it felt so good to drive

Last edited by Bonnie; 13-05-2010 at 08:25 AM.
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Old 12-05-2010, 09:59 AM   #11
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Not sure if you need one but there is an S1 engine in the for sale section.
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Old 12-05-2010, 10:49 AM   #12
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Quote:
Originally Posted by Tom J View Post
How are you fixed next Monday, Gregg? Katie and I are both off work that day. I reckon I'll have the engine ready for lifting by then.

Yes, I like the plate, too. Shame it's not 888 BBB!

16v?! Wash your mouth out. For as long as I've got as many 8v engines as I own, I can't really defend doing it anyway! I'm back to the plan of having a standard one and a track one in my care...

I'm working Monday until about 2pm unfortunatly, you're welcome to come and collect the engine crane in the afternoon though. I've not really got a suitable vehicle for transporting it either. I'm off the rest of the week.

Just noticed in your trailer thread you'll be in Rugby on Friday evening, did you want to collect the crane then?
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Old 12-05-2010, 12:47 PM   #13
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ive got my 1.3 re conditioned bottom end up for grabs if you need it PM me
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Old 12-05-2010, 01:56 PM   #14
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Looks a nice example

I recognise the registration from somewhere, was it for sale on the site recently? then on ebay?

Whats the list of jobs to be done? Where are you based?
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Old 12-05-2010, 02:34 PM   #15
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Between my two servicable shells, I now have (demics included) 5 or 6 S1 engines, and four gearboxes!
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[CENTER]
[B]Harrow Rallye Sanctuarye (Formerly also the XND Centre of Excellence)
[COLOR="White"]JDU[/COLOR][/B] - Progressing slowly in the secret restoration lair
[B]BBB[/B] - Head Gasket kit purchased; to fit (hopefully curing the misfire) before MoT
[B][COLOR="Red"]YKP[/COLOR][/B] - Taxed, Tested and Burning Oil
[B][COLOR="Blue"]MYM[/COLOR][/B] - Rallye Bus: In traffic
[B][COLOR="Red"]DFR[/COLOR][/B] - RIP, Rallye Bobsled, whose body was stolen... [B][COLOR="White"]XTL[/COLOR][/B] - [URL="http://www.106rallyeforum.com/forum2008/showthread.php?t=57523"]Please Pray for the Dervinator's Soul.[/URL]
[URL="http://www.106rallyeforum.com/forum2008/showthread.php?t=61502"][IMG]http://www.motorphoto.co.uk/rallye/sigs/nexttripsig.jpg[/IMG][/URL]
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Old 15-05-2010, 09:37 PM   #16
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Got back from the epic session delivering JDU for cage fitting and did a couple of hours on BBB.

Corrosion is the name of the game! There's a bit to deal with in the engine bay, but nothing too scary.

Short of a couple of odds and ends, the engine is ready for lifting.
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[CENTER]
[B]Harrow Rallye Sanctuarye (Formerly also the XND Centre of Excellence)
[COLOR="White"]JDU[/COLOR][/B] - Progressing slowly in the secret restoration lair
[B]BBB[/B] - Head Gasket kit purchased; to fit (hopefully curing the misfire) before MoT
[B][COLOR="Red"]YKP[/COLOR][/B] - Taxed, Tested and Burning Oil
[B][COLOR="Blue"]MYM[/COLOR][/B] - Rallye Bus: In traffic
[B][COLOR="Red"]DFR[/COLOR][/B] - RIP, Rallye Bobsled, whose body was stolen... [B][COLOR="White"]XTL[/COLOR][/B] - [URL="http://www.106rallyeforum.com/forum2008/showthread.php?t=57523"]Please Pray for the Dervinator's Soul.[/URL]
[URL="http://www.106rallyeforum.com/forum2008/showthread.php?t=61502"][IMG]http://www.motorphoto.co.uk/rallye/sigs/nexttripsig.jpg[/IMG][/URL]
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Old 25-05-2010, 07:43 PM   #17
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Thanks to Tom for getting the thread started! However, since it's my car (bought with my money, registered in my name, kept in my garage, for the nosey parkers out there - you know who you are) I suppose it should be my thread!

The old grotty engine is now out. Thanks to Gregg for his engine crane and labour over the weekend. It's fair to say that I had absolutely no hand at all in the engine lift, which probably explains why it went smoothly.

Found out why there is no oil in the engine - it's all smeared around the engine bay. This week's task: clean off grot and rust. I'm sure I will come into my own here. Cleaning is much more up my street. The car already has an extra hole in the inner wing, courtesy of my wire brush wielding antics, so the car and I are making friends, and it's learning who's boss. Rust at your peril, BBB!

The bonnet has moved into the living room (pride of place, in front of the TV) and the old engine has moved into the garden (who wants gnomes when you can have 106 rallye parts for decoration?)

Future in-laws are storing (and very kindly servicing) the 'new' engine, so once we've collected it from their garden, it's all stations go to get it in before the MOT runs out. Please, no more offers of 1.3 engines, we have more than our fair share already!

Sad news to report: between us, we have lost all four (yes, four) 10/13mm spanners. Three of them lost without ever having seen a Rallye. It seems that the Rallye gods are as hungry for rigger jiggers as the river gods. That brings my rigger jigger total loss to 7. 5 in the Thames and 2 somewhere between the house and the garage. I blame our apprentice. Perhaps they are with the TV remote and the lost "Percy"toy. On a happier note, the Fat Controller has this evening turned up under the settee. All's well that ends well, eh?

Picture is from before the engine lift (rather obviously!). Just like a nature film. "the Rallye in its' natural habitat":


Last edited by Katie J; 25-05-2010 at 08:10 PM.
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Old 15-06-2010, 10:04 PM   #18
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Progress report: the "new" engine and the old engine are now installed side by side in the front garden for the transfer of ancillaries, before the "new" engine is lifted in. We (and by that, I mean mainly Tom) made a start this evening.

Successes: Fuel rail and injectors are now attached to new engine (overcoming a reluctant bolt and some dodgy thread on the head); oil cooler attached (just waiting for a new filter); upper engine mount moved to new engine; inlet manifold removed from old engine.

Hiccups: (Well, it wouldn't be one of Tom's jobs without a couple, would it?) the cam belt needs tensioning, so we haven't moved the alternator yet; we need a new gasket before the inlet manifold can be attached to the "new engine", and it got dark. Which made the idea of tackling the engine loom impossible.

So more to do for another day.

Here's a before shot of the "new" engine.


And here's one of me putting the engines to bed, and tucking them in with a couple of nice tarpaulins:


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Old 21-06-2010, 09:25 PM   #19
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New PTFE inlet gasket arrived on Saturday morning, so Thomas Ivor helped us fit it. Alternator is also on now, so just the cambelt to check and we can think about clutch, gearbox and, to quote Thomas Ivor, "Engine....IN!"

Pugfest tickets are purchased and we both have a run up the hill booked. Don't get scared now.
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[CENTER]
[B]Harrow Rallye Sanctuarye (Formerly also the XND Centre of Excellence)
[COLOR="White"]JDU[/COLOR][/B] - Progressing slowly in the secret restoration lair
[B]BBB[/B] - Head Gasket kit purchased; to fit (hopefully curing the misfire) before MoT
[B][COLOR="Red"]YKP[/COLOR][/B] - Taxed, Tested and Burning Oil
[B][COLOR="Blue"]MYM[/COLOR][/B] - Rallye Bus: In traffic
[B][COLOR="Red"]DFR[/COLOR][/B] - RIP, Rallye Bobsled, whose body was stolen... [B][COLOR="White"]XTL[/COLOR][/B] - [URL="http://www.106rallyeforum.com/forum2008/showthread.php?t=57523"]Please Pray for the Dervinator's Soul.[/URL]
[URL="http://www.106rallyeforum.com/forum2008/showthread.php?t=61502"][IMG]http://www.motorphoto.co.uk/rallye/sigs/nexttripsig.jpg[/IMG][/URL]
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Old 21-06-2010, 09:49 PM   #20
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thats alright tom, i'll run up behind you so you got my monster growling to push you along
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Old 24-06-2010, 09:32 PM   #21
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BakerBM hoses arrived today, thanks to Stewart for a very quick tunround. Have also got some gear linkages for whichever car is ready first!!
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[CENTER]
[B]Harrow Rallye Sanctuarye (Formerly also the XND Centre of Excellence)
[COLOR="White"]JDU[/COLOR][/B] - Progressing slowly in the secret restoration lair
[B]BBB[/B] - Head Gasket kit purchased; to fit (hopefully curing the misfire) before MoT
[B][COLOR="Red"]YKP[/COLOR][/B] - Taxed, Tested and Burning Oil
[B][COLOR="Blue"]MYM[/COLOR][/B] - Rallye Bus: In traffic
[B][COLOR="Red"]DFR[/COLOR][/B] - RIP, Rallye Bobsled, whose body was stolen... [B][COLOR="White"]XTL[/COLOR][/B] - [URL="http://www.106rallyeforum.com/forum2008/showthread.php?t=57523"]Please Pray for the Dervinator's Soul.[/URL]
[URL="http://www.106rallyeforum.com/forum2008/showthread.php?t=61502"][IMG]http://www.motorphoto.co.uk/rallye/sigs/nexttripsig.jpg[/IMG][/URL]
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Old 04-07-2010, 07:56 PM   #22
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Time for an update. As you may have seen from threads elsewhere, when Tom J was discharged from hospital on Tuesday, I embarked on Project Pugfest: get BBB roadworthy and up the hill on Sunday. The starting point was a shell with no engine, out of MoT, SORNed and with no insurance, with an engine in the garden of the house.

Tuesday evening: read the Haynes, and wonder whether I am in fact mad.

Wednesday: check the engine timing and cambelt tension. I had never done this before, so it took me a LONG time to be confident that I had got it right. Fitted the clutch.
Aleksander came round after work and lent a hand. We lugged the engine and all its ancillaries round to the garage where the car and engine crane were waiting. We went to fit the gearbox to the engine.
DISASTER 1: locating peg in the gearbox is in the same hole as locating peg in the engine. Both are stuck solid. After a heroic attempt (whilst Tom J was passed out in the back of the people carrier), we abandoned at about 11pm.

Thursday: Tom J and I tackled the gearbox peg. With a drill. And a hammer. And a screwdriver. And a file. And we broke the drill bit. And two and a half hours later, the peg fell out.
We fitted the gearbox. The clutch arm jammed solid. The good folk on the forum said that there should be play in it. We took it apart again. We scratched our heads. There was no reason for it to be jammed. We put it back together again. It still stuck. We gave up for the night.

Friday: We decide to risk it, and lifted the engine and box into the shell with clutch arm stuck. In our excitement, we forgot to connect the heater matrix hoses and the starter motor wiring before lowering the engine, leaving ourselves having to do some unnecessary contortionist poses to sort them out. We got everything connected up and were starting to think about trying to start it. Tom J fitted the battery.

DISASTER 2: the fuel pump primed. And kept running. There was no key in the ignition. The pressure built up in the system. White smoke started to emerge from the engine bay. Panic to disconnect the battery. Scratch heads again and abandon (again after 11pm), disappointed, to ask RR members for help.

Saturday: disheartened, we went back to the garage. After several phonecalls to Gregg, we identified that the two black "live" wires we had connected to the terminal near the battery positive, were in fact earths that should have been on the gearbox. Problem solved, we rang Richhimself to guide us on the sequence for the plug leads. Tom J climbed into the car. We said an emotional farewell in case he was about to disappear in a fireball. He turned the key....

IT STARTED FIRST TIME! We nearly cried. Then we realised that it was only 1pm, and there was still a shot at getting it to MoT. We refitted the cooling system, lights, slam panel, bumper. Lights and wipers worked first time, apart from the nearside indicator repeater. It hit 5.30pm.

New plan for a Sunday MoT.

Sunday: early start. Exhaust to fit. We crawled under the car and decided to brush off some rust under where the backbox would hang. Tom J had forgotten to eat with his medication and rushed home feeling nauseous. I set to with the wire brush. Suddenly I could see daylight in the boot floor. A lot of daylight. I dragged Tom J back to the garage. We had to admit defeat. The floor needs a weld, and we think the MoT man would be interested in the hole, due to its proximity to the rear suspension mounting points.

The Skoda went to Pugfest. BBB drove back into the garage for another day.

Current snag list:
Clean off rust and sort out welding of boot floor, and the floor under the front footwells where some numpty has clearly jacked it in the wrong place.
New battery cleat.
New hose from washer bottle.
New rear wiper blade.
New gearstick.
Tighten handbrake.
Check torque on intermediate driveshaft bearing nuts.
New clips for radiator to slam panel.
Fix nearside indicator repeater.
Fix oil temperature sensor lead.
New plug to cooling fan.
New bolt for exhaust manifold heat shield.
Hang exhaust.

Tomorrow is another day....
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Old 05-07-2010, 04:51 PM   #23
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I will post some pictures when I get time, but I need to get some lunch and take some antibiotics.

BBB has major 106 boot cancer. It's going to need plating both sides and I don't see the point in cutting corners to get through the MoT now, when it will only rot again later. The front left 'don't put your jack here - oh, you have already' spot needs a plate as well, although the right and side might pass muster.

I've removed the back bumper (outer bolts wouldn't come off and will need to repair the bumper!) and tacked it back on with just two bolts, having wire brushed everything from the rear seatbelt nuts backwards, and knocked out all the rust I can reach with the hammer or screwdriver. Need to get it to someone who can do the work now. I'm interested in how other people have had it plated...

Standard exhaust is on, although the fire ring is blowing a little. I've pasted the cat to mid pipe joint but left the back box so it can be removed by whoever does the welding.

Sparco steering wheel is also fitted and the engine has been run and taken up to the limiter - all sounds fine.

Only snag now is that I have to go to work tomorrow!
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[B]Harrow Rallye Sanctuarye (Formerly also the XND Centre of Excellence)
[COLOR="White"]JDU[/COLOR][/B] - Progressing slowly in the secret restoration lair
[B]BBB[/B] - Head Gasket kit purchased; to fit (hopefully curing the misfire) before MoT
[B][COLOR="Red"]YKP[/COLOR][/B] - Taxed, Tested and Burning Oil
[B][COLOR="Blue"]MYM[/COLOR][/B] - Rallye Bus: In traffic
[B][COLOR="Red"]DFR[/COLOR][/B] - RIP, Rallye Bobsled, whose body was stolen... [B][COLOR="White"]XTL[/COLOR][/B] - [URL="http://www.106rallyeforum.com/forum2008/showthread.php?t=57523"]Please Pray for the Dervinator's Soul.[/URL]
[URL="http://www.106rallyeforum.com/forum2008/showthread.php?t=61502"][IMG]http://www.motorphoto.co.uk/rallye/sigs/nexttripsig.jpg[/IMG][/URL]
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Old 05-07-2010, 06:41 PM   #24
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cut it all out and plate in from in the wheel arch, then filler and fibreglass the inner and your'll never see it
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Old 16-07-2010, 09:37 AM   #25
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Picked BBB up from the back street garage that agreed to do some welding to the boot and the "usual" spot under the drivers' footwell this morning.

Had fun and games driving it home - the idling problem (described elsewhere) saw me stall at least 3 times on a journey that takes about 2 minutes to walk, and the misfire started up again as the car got warm. Trying to manoeuvre it into the garage in a pretty tight space when it can't idle is torture (add on another 12 stalls, and treble the time it should take to park it!), so I was late for work.

Since I was in a suit, I'm now sat at my desk itching to get home and have a proper look at what he's done with it. I'm a bit worried, because (despite having agreed to chop back any remaining rust before welding) he kept telling me how hard it is to weld to rust.....
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Old 16-07-2010, 05:16 PM   #26
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It's not looking like a good day - the engine's been nicked from outside the house, too! Mind you, I've got my son back after 4 weeks so I am not as interested in other things today. Welcome home, Thomas Ivor!
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[B]Harrow Rallye Sanctuarye (Formerly also the XND Centre of Excellence)
[COLOR="White"]JDU[/COLOR][/B] - Progressing slowly in the secret restoration lair
[B]BBB[/B] - Head Gasket kit purchased; to fit (hopefully curing the misfire) before MoT
[B][COLOR="Red"]YKP[/COLOR][/B] - Taxed, Tested and Burning Oil
[B][COLOR="Blue"]MYM[/COLOR][/B] - Rallye Bus: In traffic
[B][COLOR="Red"]DFR[/COLOR][/B] - RIP, Rallye Bobsled, whose body was stolen... [B][COLOR="White"]XTL[/COLOR][/B] - [URL="http://www.106rallyeforum.com/forum2008/showthread.php?t=57523"]Please Pray for the Dervinator's Soul.[/URL]
[URL="http://www.106rallyeforum.com/forum2008/showthread.php?t=61502"][IMG]http://www.motorphoto.co.uk/rallye/sigs/nexttripsig.jpg[/IMG][/URL]
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Old 19-07-2010, 09:01 AM   #27
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Thomas Ivor enjoyed sitting in the Rallye with his Daddy and beeping the horn, so even though it misfires and looks like some of the welding was done by a two year old, BBB made a little boy happy this weekend :-)
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Old 26-03-2012, 11:32 AM   #28
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We've not done a very good job on this blog, have we?

Well, BBB is going for MoT very soon, with thanks to Gregg for changing the head, which seems to have solved the 'missing' under load.
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[B]Harrow Rallye Sanctuarye (Formerly also the XND Centre of Excellence)
[COLOR="White"]JDU[/COLOR][/B] - Progressing slowly in the secret restoration lair
[B]BBB[/B] - Head Gasket kit purchased; to fit (hopefully curing the misfire) before MoT
[B][COLOR="Red"]YKP[/COLOR][/B] - Taxed, Tested and Burning Oil
[B][COLOR="Blue"]MYM[/COLOR][/B] - Rallye Bus: In traffic
[B][COLOR="Red"]DFR[/COLOR][/B] - RIP, Rallye Bobsled, whose body was stolen... [B][COLOR="White"]XTL[/COLOR][/B] - [URL="http://www.106rallyeforum.com/forum2008/showthread.php?t=57523"]Please Pray for the Dervinator's Soul.[/URL]
[URL="http://www.106rallyeforum.com/forum2008/showthread.php?t=61502"][IMG]http://www.motorphoto.co.uk/rallye/sigs/nexttripsig.jpg[/IMG][/URL]
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Old 26-03-2012, 11:29 PM   #29
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Nice one Tom, or should I say Gregg
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Old 27-03-2012, 11:03 AM   #30
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I did replace the Driver's seat runners and fit the rear seat squab. I did quite a lot to it during the initial rebuild, until my medical incident.

But yeah, mainly Gregg.

We are all due another Rallye adventure, when they are fixed and we have some money for fuel!
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[B]Harrow Rallye Sanctuarye (Formerly also the XND Centre of Excellence)
[COLOR="White"]JDU[/COLOR][/B] - Progressing slowly in the secret restoration lair
[B]BBB[/B] - Head Gasket kit purchased; to fit (hopefully curing the misfire) before MoT
[B][COLOR="Red"]YKP[/COLOR][/B] - Taxed, Tested and Burning Oil
[B][COLOR="Blue"]MYM[/COLOR][/B] - Rallye Bus: In traffic
[B][COLOR="Red"]DFR[/COLOR][/B] - RIP, Rallye Bobsled, whose body was stolen... [B][COLOR="White"]XTL[/COLOR][/B] - [URL="http://www.106rallyeforum.com/forum2008/showthread.php?t=57523"]Please Pray for the Dervinator's Soul.[/URL]
[URL="http://www.106rallyeforum.com/forum2008/showthread.php?t=61502"][IMG]http://www.motorphoto.co.uk/rallye/sigs/nexttripsig.jpg[/IMG][/URL]
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Old 27-03-2012, 11:06 AM   #31
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Quote:
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We are all due another Rallye adventure, when they are fixed and we have some money for fuel!
I fully agree, I've hardly used mine for anything fun at all in the past year
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Old 27-03-2012, 11:11 AM   #32
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I think if I organise anything this year it will be Scottish or Welsh based...

Trouble is having now got back into cycling, I'd want to take the bike, but I'm not sure it will fit in the Rallye! Scotland is too far for Katie and I to take a car each with fuel prices as they are.

Speaking of cheaper fuel, maybe BBB could be the car to do the trip across America I've always fancied? Maybe do that on the way home from Paris - Peking?
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[B]Harrow Rallye Sanctuarye (Formerly also the XND Centre of Excellence)
[COLOR="White"]JDU[/COLOR][/B] - Progressing slowly in the secret restoration lair
[B]BBB[/B] - Head Gasket kit purchased; to fit (hopefully curing the misfire) before MoT
[B][COLOR="Red"]YKP[/COLOR][/B] - Taxed, Tested and Burning Oil
[B][COLOR="Blue"]MYM[/COLOR][/B] - Rallye Bus: In traffic
[B][COLOR="Red"]DFR[/COLOR][/B] - RIP, Rallye Bobsled, whose body was stolen... [B][COLOR="White"]XTL[/COLOR][/B] - [URL="http://www.106rallyeforum.com/forum2008/showthread.php?t=57523"]Please Pray for the Dervinator's Soul.[/URL]
[URL="http://www.106rallyeforum.com/forum2008/showthread.php?t=61502"][IMG]http://www.motorphoto.co.uk/rallye/sigs/nexttripsig.jpg[/IMG][/URL]
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Old 27-03-2012, 11:13 AM   #33
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Would be keen for either. I'm planning on doing the west coast (inc Applecross pass) this year.
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Old 27-03-2012, 05:50 PM   #34
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OK, so in news about the actual car, we almost got an MoT for it today. Well, Gregg did.

.003 of lambda to find, and a couple of small welds to attend to. Close but no cigar - and the deadline looms! We can do this, though...
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[B]Harrow Rallye Sanctuarye (Formerly also the XND Centre of Excellence)
[COLOR="White"]JDU[/COLOR][/B] - Progressing slowly in the secret restoration lair
[B]BBB[/B] - Head Gasket kit purchased; to fit (hopefully curing the misfire) before MoT
[B][COLOR="Red"]YKP[/COLOR][/B] - Taxed, Tested and Burning Oil
[B][COLOR="Blue"]MYM[/COLOR][/B] - Rallye Bus: In traffic
[B][COLOR="Red"]DFR[/COLOR][/B] - RIP, Rallye Bobsled, whose body was stolen... [B][COLOR="White"]XTL[/COLOR][/B] - [URL="http://www.106rallyeforum.com/forum2008/showthread.php?t=57523"]Please Pray for the Dervinator's Soul.[/URL]
[URL="http://www.106rallyeforum.com/forum2008/showthread.php?t=61502"][IMG]http://www.motorphoto.co.uk/rallye/sigs/nexttripsig.jpg[/IMG][/URL]
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Old 31-03-2012, 05:50 PM   #35
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1.033. That's the closest the lambda got to passing, and believe me we tried, revving it over 3.5k for quite a while CO and HC were spot on so the general consensus is an airleak in the exhaust, characterised by a regular popping from the exhaust.

With this in mind I spent a plesant couple of hours swearing at the Raceland manifold (and exhaust in general) today trying to seal it up. There was signs of a leak between gasket and manifold on one cylinder so all this was stuck together with high temp sealant. Already had a new fire ring fitted so that left the other two joints to fill with exhuast paste and tighten up the clamps.

It's going in on Monday to have the welding done, unfortunatly they're quite busy so it'll be squeezed in around other work. With Easter getting in the way next weekend we're looking at a retest on Tuesday 10th. With the wedding on the 13th that leaves plenty of time, what could possibly go wrong?
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Old 31-03-2012, 07:03 PM   #36
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I'd try a lambda, I had similar hunting on idle and slightly rich running that was solved but a replacement.
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Old 31-03-2012, 08:15 PM   #37
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Not keen on chucking 50+ of lambda sensor at it in the hope it fixes it just yet. It needs running for a while so I can check the plugs and see if it is running rich (or even lean on one cylinder). In an ideal world I'd plug it in and see what the senors are doing but I may just have to attack it with a multimeter and Autodata instead.

Just for a laugh I checked Service Box for a lambda sensor, they only want 198
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Old 31-03-2012, 10:29 PM   #38
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I had an issue with my raceland leaking. The problem turned out to be an oversize flange where it mates to the block. The bottom edge was too long and fouled on the block leaving a gap. Oddly though the sealant I was using before I realised the problem, would only leak in a few odd places, not along the bottom edge as you might think! Ive drawn a pic to show you, maybe its the same thing? A quick blast with a grinder soon fixed it. The slightly odd angle that the problem caused also gave me issues with the fire ring seal, which again were resolved once I had ground the bottom edge of the manifold flange back.

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Old 02-04-2012, 10:15 AM   #39
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This Raceland was second hand and had already been modified in the way you describe Dyno, so it pulls up flush to the head. The leak was only very slight and not audible anyway.

Drove it to the garage this morining and took a (slightly) scenic route and despite a lost foreign lorry drive getting in the way I managed to stretch it legs a bit, it certainly goes well and sounds good
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Old 02-04-2012, 05:00 PM   #40
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My recollection from the test drive, two years ago, is that the chassis is is quite tight - arguably more so than the red one! That's the last time I drove it any distance with more than one gear

You reckon the popping has gone now?

Have been exhausted this afternoon following an unexpected meeting this morning and a solid weekend in Romford (I am now 'first aided' for another three years, which was also unexpected!) but am intent on sorting out presentational issues for both cars tomorrow...
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[B]Harrow Rallye Sanctuarye (Formerly also the XND Centre of Excellence)
[COLOR="White"]JDU[/COLOR][/B] - Progressing slowly in the secret restoration lair
[B]BBB[/B] - Head Gasket kit purchased; to fit (hopefully curing the misfire) before MoT
[B][COLOR="Red"]YKP[/COLOR][/B] - Taxed, Tested and Burning Oil
[B][COLOR="Blue"]MYM[/COLOR][/B] - Rallye Bus: In traffic
[B][COLOR="Red"]DFR[/COLOR][/B] - RIP, Rallye Bobsled, whose body was stolen... [B][COLOR="White"]XTL[/COLOR][/B] - [URL="http://www.106rallyeforum.com/forum2008/showthread.php?t=57523"]Please Pray for the Dervinator's Soul.[/URL]
[URL="http://www.106rallyeforum.com/forum2008/showthread.php?t=61502"][IMG]http://www.motorphoto.co.uk/rallye/sigs/nexttripsig.jpg[/IMG][/URL]
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Old 10-04-2012, 08:49 AM   #41
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That was a bit stressfull! MOT retest this morning didn't quite go to plan but it passed eventually

Car threw a proper French hissy fit and refused to even attempt to pass the emissions, CO over 4% and lambda below 0.9 at 2.5-3k, 0.04% CO and lambda over 1.1 at idle After bit of swearing, head scratching and checking to see if the lambda sensor was actually plugged in the MOT tester got distracted and I took control of the emission tester Pulled up the live gas readings on screen and went looking for the sweet spot. About 4k was the answer (with no popping like before) and it then sailed through the test, with the welding passing inspection as well
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Old 10-04-2012, 09:39 AM   #42
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[CENTER]
[B]Harrow Rallye Sanctuarye (Formerly also the XND Centre of Excellence)
[COLOR="White"]JDU[/COLOR][/B] - Progressing slowly in the secret restoration lair
[B]BBB[/B] - Head Gasket kit purchased; to fit (hopefully curing the misfire) before MoT
[B][COLOR="Red"]YKP[/COLOR][/B] - Taxed, Tested and Burning Oil
[B][COLOR="Blue"]MYM[/COLOR][/B] - Rallye Bus: In traffic
[B][COLOR="Red"]DFR[/COLOR][/B] - RIP, Rallye Bobsled, whose body was stolen... [B][COLOR="White"]XTL[/COLOR][/B] - [URL="http://www.106rallyeforum.com/forum2008/showthread.php?t=57523"]Please Pray for the Dervinator's Soul.[/URL]
[URL="http://www.106rallyeforum.com/forum2008/showthread.php?t=61502"][IMG]http://www.motorphoto.co.uk/rallye/sigs/nexttripsig.jpg[/IMG][/URL]
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Old 12-04-2012, 07:16 AM   #43
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Bugger. Was running well until the clutch failed I thought the MOT restest was cutting it fine...
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Old 15-04-2012, 09:51 PM   #44
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Well, what a week for the car! 0715 on Thursday morning and the release bearing came adrift from the fork, leaving the clutch jammed in the outside lane of the dual carriageway approaching Luton Airport.

12 hours later, I was back at the same lights, the gearbox having been off and the clutch replaced.

Friday morning it had Gregg's sister in it on the way to the church for his wedding.

Gregg, you thoroughly deserved all three cars on Friday - the one and only time BBB and YKP will be seen driving together for a long time to come, in all likelihood. Well done and thank you!
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[B]Harrow Rallye Sanctuarye (Formerly also the XND Centre of Excellence)
[COLOR="White"]JDU[/COLOR][/B] - Progressing slowly in the secret restoration lair
[B]BBB[/B] - Head Gasket kit purchased; to fit (hopefully curing the misfire) before MoT
[B][COLOR="Red"]YKP[/COLOR][/B] - Taxed, Tested and Burning Oil
[B][COLOR="Blue"]MYM[/COLOR][/B] - Rallye Bus: In traffic
[B][COLOR="Red"]DFR[/COLOR][/B] - RIP, Rallye Bobsled, whose body was stolen... [B][COLOR="White"]XTL[/COLOR][/B] - [URL="http://www.106rallyeforum.com/forum2008/showthread.php?t=57523"]Please Pray for the Dervinator's Soul.[/URL]
[URL="http://www.106rallyeforum.com/forum2008/showthread.php?t=61502"][IMG]http://www.motorphoto.co.uk/rallye/sigs/nexttripsig.jpg[/IMG][/URL]
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Old 23-04-2012, 11:25 AM   #45
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I think all the hassle & work was worth it in the end, there's been plenty of favourable comments about the Rallye's at the wedding

Presuming it's now in regular use, how's it been running since last week?
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Old 23-04-2012, 12:27 PM   #46
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It goes like stink, not a trace of smoke, pulls hard but missing at circa 2k and 3.5k, and sporadically failing to idle reliably. New VSS arrived this morning

Thank you, Gregg, for all your hard work. I'm delighted that just for those few hours, we got them all working at the same time!
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[B]Harrow Rallye Sanctuarye (Formerly also the XND Centre of Excellence)
[COLOR="White"]JDU[/COLOR][/B] - Progressing slowly in the secret restoration lair
[B]BBB[/B] - Head Gasket kit purchased; to fit (hopefully curing the misfire) before MoT
[B][COLOR="Red"]YKP[/COLOR][/B] - Taxed, Tested and Burning Oil
[B][COLOR="Blue"]MYM[/COLOR][/B] - Rallye Bus: In traffic
[B][COLOR="Red"]DFR[/COLOR][/B] - RIP, Rallye Bobsled, whose body was stolen... [B][COLOR="White"]XTL[/COLOR][/B] - [URL="http://www.106rallyeforum.com/forum2008/showthread.php?t=57523"]Please Pray for the Dervinator's Soul.[/URL]
[URL="http://www.106rallyeforum.com/forum2008/showthread.php?t=61502"][IMG]http://www.motorphoto.co.uk/rallye/sigs/nexttripsig.jpg[/IMG][/URL]
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