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Old 08-03-2012, 09:00 PM   #101
mattrallye
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Good work Hoyle, looking forward to seeing it soon!
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Old 16-03-2012, 10:51 AM   #102
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Cheers Matt, shouldn't be too long now.

Valves cleaned and ready;





Block ready for gasket and gasket fitting;





I then re-lapped the valves and fitted new stem seals;



I also cleaned the block and painted it up in high temp silver. I then re fitted the water pump housing and fitted a new seal, fitted new crank seals and new washers on all of the sensors.

Once this was done, I fitted up the head and timed and tenioned the belt.



And also painted the inlet manifold after a good clean up;



The engine is ready to go back in but I am awaiting the sump / rocker cover and various other parts from the powdercoaters.

I've also been busy in the engine bay;









I have also built up my quaife quick rack and have fitted it - again, housing painted silver;



And then refitted the struts (new wheel bearings fitted) and fitted the new wishbones;



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Old 16-03-2012, 11:32 AM   #103
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Good work mate. Looks like a top job.
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Old 16-03-2012, 11:45 AM   #104
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Good work mate. Looks like a top job.
Thanks Cris - I tried my hand at POR15 - easy enough to use and follow the instructions. Also, that metal ready solution is great stuff!

Also now awaiting some copper brake line and fittings to remake the front lines.

And after fitting the rack I need to loosen and adjust the track rods to get everyting central and near enough straight, ready for proper alignment. Easier said than done - they're seized solid! May have to buy fresh stuff - makes sense to do so whilst I'm at it.

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Old 16-03-2012, 11:57 AM   #105
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Go for new Hoyle, so much easier for you in the long run! Whats this metal ready solution?
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Old 16-03-2012, 12:05 PM   #106
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Go for new Hoyle, so much easier for you in the long run! Whats this metal ready solution?
http://www.por15.com/Data%20Sheets/metalreadyreg.pdf

It's an etching solution which is ideal for bare metal and surface rusted areas. I applied it before POR 15 and it stuck like sh*t!

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Old 17-03-2012, 12:52 PM   #107
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It's an etching solution which is ideal for bare metal and surface rusted areas. I applied it before POR 15 and it stuck like sh*t!

Hoyle
Yep it's cool stuff on bare metal. Bugger all use over paint though.
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Old 17-03-2012, 03:17 PM   #108
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Steering alignment issue solved! I had the rack end bracket (where the inner ends join) on the wrong way, throwing everything out!!

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Old 17-03-2012, 03:50 PM   #109
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That looks absolutely cracking mate, rack looks great too.
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Old 17-03-2012, 04:56 PM   #110
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Very nice! Glad that paint was still ok for you! Looks amazing.
Jack
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Old 18-03-2012, 12:54 PM   #111
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Good job mate, v impressive!!

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Old 18-03-2012, 07:17 PM   #112
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Top job lad.
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Old 21-03-2012, 10:06 AM   #113
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Thanks for all the comments!

I've been busy but now I'm back in work so the rebuild pace will retire to a stroll again!

Here are the latest pics, work includes;

Uprated wishbone bolts fitted,
New droplinks fitted,
New clutch cable fitted,
New throttle cable fitted,
New bonnet cable fitted,
Car loom refitted,
Alternator scrubbed up,
Tappet clearances adjusted,
Powdercoated parts fitted (sump, rocker cover, gearbox mount bracket, alternator pulley),
New genuine clutch fitted,
New crank seals both ends,
New washers on all engine and box sensors/plugs,
Near new GrpN bushes fitted,
2x copper 3/16 lines made up to replace the front lines (not corroded but the end nuts on the flexi's were seized and I have a goodridge front set to fit.













Next steps are to refit the loom, fit new filters and add oils, bleed brakes, fit shafts, fit exhaust, fit cooling system and fill, fit dash, weld cage plates, fit linkages.

All about a days work so hopefully she'll be runnign and driving this weekend!

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Old 21-03-2012, 10:27 AM   #114
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...if its running and drivable this weekend/next weekend...fancy a drive out?! Get some photos of the pair?! You have a done an epic job on that engine and engine bay! Looks amazing!
Jack
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Old 21-03-2012, 10:40 AM   #115
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...if its running and drivable this weekend/next weekend...fancy a drive out?! Get some photos of the pair?! You have a done an epic job on that engine and engine bay! Looks amazing!
Jack
Keep an eye out in the North West section - Cris B mentioned a North Wales drive too!

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Old 21-03-2012, 10:47 AM   #116
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That looks absolutely cracking Hoyle, it really will be minty once you've finished.

I'd be up for a wee drive out weekend after next, could make the pilgrimage.
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Old 21-03-2012, 10:54 AM   #117
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have we just created a driving meet for the NW section by accident?! haha! I will keep the weekend after this one free for just this occasion.

PS Hoyle, have you got your old wishbones still?! Might be interested in getting my hands on them, giving them a quick refurbishment and getting all my new stuff pressed into those before stripping mine off the car!
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Old 21-03-2012, 10:57 AM   #118
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That looks absolutely cracking Hoyle, it really will be minty once you've finished.

I'd be up for a wee drive out weekend after next, could make the pilgrimage.
Cheers Harv! I appreciate it's a fair hack for you to come down for a drive out, but we'll make a good day of it - great roads, grab some food and get some shots (pictures, not tequila slammers).

Hoyle.

Quote:
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have we just created a driving meet for the NW section by accident?! haha! I will keep the weekend after this one free for just this occasion.

PS Hoyle, have you got your old wishbones still?! Might be interested in getting my hands on them, giving them a quick refurbishment and getting all my new stuff pressed into those before stripping mine off the car!
Jack

It was Cris who first mentioned it last night - I'm up for a nice drive out!

Yeah I've still got my old wishbones here.

Hoyle

Last edited by Hoyle; 21-03-2012 at 10:57 AM. Reason: Automerged Doublepost
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Old 21-03-2012, 11:03 AM   #119
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Name a price Hoyle! I will have them off you and I can drop them in with Dunc then to get my Bushes pressed in! Should make stripping and rebuilding my suspension easier than...if everything isnt seized on and rotten! :/
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Old 21-03-2012, 11:11 AM   #120
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Name a price Hoyle! I will have them off you and I can drop them in with Dunc then to get my Bushes pressed in! Should make stripping and rebuilding my suspension easier than...if everything isnt seized on and rotten! :/
Jack
PM sent.

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Old 21-03-2012, 11:53 AM   #121
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Cheers Harv! I appreciate it's a fair hack for you to come down for a drive out, but we'll make a good day of it - great roads, grab some food and get some shots (pictures, not tequila slammers).
Heh, sounds good to me. Better get the polish out and try making her a bit more photogenic.
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Old 29-03-2012, 11:59 PM   #122
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Top work Chris! I always thought the standard Steering rack was awful and was a real weak point. Good to see you've addressed this. Did you do all this work yourself? You're far more handy with a spanner than I am!
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Old 30-03-2012, 07:39 AM   #123
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Top work Chris! I always thought the standard Steering rack was awful and was a real weak point. Good to see you've addressed this. Did you do all this work yourself? You're far more handy with a spanner than I am!
Well bugger me sideways! You realise this is not FCCUK!

Yeah all done myself apart from the powdercoating and head skim pretty much.

Hit a milestone last night - she runs!! I couldn't drive it however as the seats are still in my living room - but hopefully by tonight I can finish it off and maybe even have a test run!

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Old 30-03-2012, 08:17 AM   #124
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Car looks really well. After the French car show, i'm doing the same with my White S1. So ill be asking for some tips.
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Old 30-03-2012, 09:11 AM   #125
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Car looks really well. After the French car show, i'm doing the same with my White S1. So ill be asking for some tips.
Cheers Gaz. No worries, it's just a case of stripping and rebuilding as you go really.

That'll be even better once finshed!

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Old 30-03-2012, 10:01 AM   #126
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Cheers Gaz. No worries, it's just a case of stripping and rebuilding as you go really.

That'll be even better once finshed!

Hoyle
I've got a slight bubble of rust on one of the rails that's been on my mind for about a year now. So it needs sorting our as it wont go away!!!

But I want to keep it's originality., I dont just want to slap loads of new paint on it...so just in the process of a few quotes from classic restoring places to see which is best option
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Old 30-03-2012, 10:16 AM   #127
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If you need a hand with it I'm not too far away.
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Old 30-03-2012, 02:10 PM   #128
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Well, here she is running - the idle is a little lumpy and low as you can hear, but otherwise all good!



And for fun, here's an old rolling road video!



Hoyle

http://youtu.be/CTV66mw-iM8">http://youtu.be/CTV66mw-iM8" type="application/x-shockwave-flash" width="425" height="350">

Whilst we're posting vids!

Last edited by Hoyle; 30-03-2012 at 02:10 PM. Reason: Automerged Doublepost
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Old 30-03-2012, 03:36 PM   #129
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It doesn't make it go faster, all that cleaning and painting, but it certainly will make it last longer!

Very nice work indeed. Hope it goes as well as it looks!
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Old 03-04-2012, 11:10 PM   #130
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IT LIVES!

Aww little red Rallye, why do I feel like going and buying one again? There's something so cute and cheeky about the lil things.

This isn't Fccuk? Ah yes! wrong forum, sorry! I'm off to talk rust and Aux belt failures!
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Old 19-11-2012, 11:08 AM   #131
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Yet again, I've left my thread for over 6 months! Well, in that time, a few things have changed.

Here's the story in pictures since the front end build!

I finally had my cage footplates welded in, and had the inner boot seams repaired. With this done, I cracked on with prepping and painting the interior;















Then fitted the cage, seats and harnesses;





At this point I went for my 1st full OPL day since the rebuild, and the car performed faultlessly all day!



Then, I hit a turning point... I went and bought and old Audi to restore. I had to find some funding from somewhere to put into the audi project, and I was NOT going let the Rallye be sacrificed! In the end I came to a compromise... I'd keep the 106, but as a standard road car. I knew there was some funds tied up in it from the shiny bits, so I sold them on, and proceeded to return the car to standard spec;

I dug out my old carpet, seats and seatbelts from the loft, removed the bags I'd placed them in, hired a carpet cleaner and got to work!

Before:







After:







The interior was then all fitted up and I've been using the car on weekends when dry.

That's all for now, I'll update with pics when I've got a chance and it's light!

Hoyle.
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Old 19-11-2012, 04:57 PM   #132
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Looks great with new paint and shiny seats, can we have a bit of insight into the Audi as well?

Good to have you back mate.
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Old 23-01-2013, 07:11 PM   #133
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Great blog this. What a lovely Rallye. Like the Audi too.
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Old 26-02-2018, 12:16 PM   #134
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Well well well, over 5 years have passed since I updated this thread, and the main reason being that I sold this car in 2015 after a lack of use and the need to free up cash to move house.

Since selling the car I've moved house twice and many other vehicles have come and gone.

I regretfully sold this car and ever since have kept my eyes peeled for another S1.

It was inevitable then, that when a half decent S1 came up on ebay, I had to get stuck in...

See below....













Within 48 hours, I'd agreed a sale and was using a day off work as an excuse to travel 550miles to bring her home.

Scenes from Gloucester services (you know, the farm shop one):



The car has covered approximately 800miles between the date of sale in Feb '15 and the date of collection almost 3 years later to the day!

I sold the car to Nick locally who had some welding and undersealing carried out to the underside of the car, along with ditching the standard brakes for some 266s. It also had new rear shocks and a quickshift during Nick's 5 month ownership. Nick then sold it on to Davey in Bideford, who bought the car as an investment. Davey refitted the standard exhaust and a new backbox along with some new rear brake cylinders to get it though the MoT.

I took a chance on driving the car back from Bideford to North Wales - the biggest concern being cracked tyre sidewalls, as these were the very same Kumho KU31 tyres I fitted new in 2009!

I'm pleased to say that the car didn't miss a beat and got me home like it was nothing.

During the following days, I gave the car a good clean and started sourcing some replacement parts:













My general plan is to return the specification to standard, restore the bodywork & steel wheels and generally enjoy it.

Watch this space...
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Old 26-02-2018, 03:29 PM   #135
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He’s back

That looks seriously clean. Good find!
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Old 26-02-2018, 06:20 PM   #136
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Welcome back Chris, will follow the new project with interest!
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Old 26-02-2018, 06:45 PM   #137
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Old 27-02-2018, 11:26 AM   #138
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Cheers gents, couldn't help myself!

General plan of action is to return the car to standard spec and throw it down some B roads.

Parts sourced and purchased thus far:

Genuine standard front & rear washer jets - fitted
Valeo wiper blades front & rear - fitted
Bonnet stay rod clip - fitted
Replacement headliner from an S1 (GTI currently fitted)
Original grab handle
Various dash plastics / column surround
Standard gear lever
Bulkhead sound deadening mat
Spare wheel hanger & fixings
2x handbrake cables

I'll go through these parts and try to fit them in a logical order as I also intend to strip the shell and send it in for full paint & have the steels powdercoated.

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Old 27-02-2018, 11:55 AM   #139
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It's been said before, but, they all come back!
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Old 28-02-2018, 01:54 PM   #140
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It's been said before, but, they all come back!
It was like slipping into an old pair of shoes
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Old 12-11-2018, 05:49 PM   #141
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How have you got on with this Chris?
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Old 31-01-2019, 01:35 PM   #142
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How have you got on with this Chris?
Not much since March/April last year as 2 other cars of mine suffered engine failure! Hoping to get a fresh test on it next week though
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Old 01-02-2019, 12:28 PM   #143
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I like the sound of that!
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Old 01-03-2019, 08:30 AM   #144
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Location: North Wales
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Fresh MoT done! Needed new shoes and handbrake cables (adjusters were seized, so for the sake of the cost of new shoes, I replaced the lot).

The car has a small hole in the passenger side outer sill that is outside the prescribed area, so this will get covered when I get it in for bodywork.

I'm also looking to refresh the front struts (wheel bearings, shocks, springs if available, top mounts etc.) and I managed to find a pair of genuine wishbones which are already on.

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Old 02-03-2019, 07:32 PM   #145
Cris B
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Great to see this in the flesh mate
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Last edited by Cris B; 02-03-2019 at 07:34 PM.
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