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Old 22-10-2018, 12:01 PM   #1
Stis
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S2 Rallye Resto

I thought it was about time I started a thread for my S2 Rallye.

I found the car while picking up parts for a previous Saxo project, I went to see an old friend who had a Bianca white S2 Rallye stored in the corner of his lockup. The car had been stood since 2009 and needed a lot of work to get it road worthy again. I offered to buy it a few times and eventually the owner needed the space so agreed to sell it. I never properly looked around the car, the current owner sent me a list of modifications, a few pictures and confirmed heíd had it running at some point, we agreed a price and I had the car delivered to my house. I had no idea what was going to turn up. The car has changed hands a few times and I believe all the owners have been enthusiasts. Iíve found a few posts on different forums, including this one, but if anyone knows the history of this car please let me know. The plate is R40LYE, which I think was transferred on to the car in 2003, but intend on putting the original plate back on.

From what Iíve found on forums and in the paperwork that came with the car, as far as Iím aware the spec is:

Original S2 1.6 8v Rallye engine on 91k
S1 Rallye inlet and TB, all sensors and longer throttle cable
Norris Motorsport ported and polished head
Piper 284 deg. fast road cam
Piper Vernier Pulley advanced 10 deg.
Raceland 8v 4 Branch Manifold
Ecosse Sports Cat.
Ecosse Devil Catback exhaust with no tip (previous owner said it had been cut off)
Ecosse loom and mapped, dyno'd in 2005 at 138bhp
Spoox (?) quickshift
Lowered about 60-70mm, no idea on the make of the springs
Polybushed rear beam
Bilstein shocks
OMP lower strut brace
Unknown brace across the rear bench floor panel, I think some harnesses were attached here
Welded subframe rails
15Ē Speedline Comp2 Wheels in White
Goodridge stainless braided brake hoses
266mm brake conversion with Wilwood 4 piston calipers
Clear side repeater - passenger side missing
White Mirror Caps
White Door Handles
Aero quick release bonnet catches
Tornado Motorsport full roll cage
OMP Corsica steering wheel and lifeline wheel boss Ė not sure whether this is fake
Stripped interior, no seats, no carpet etc., dash and been chopped and heater matrix removed. But it does have the original S2 Rallye door cars.
Fuel lines and fuel filter have been relocated in to the cabin

The car comes with loads of paperwork, including a few £1k invoices. It has some minor cosmetic damage, thereís the odd scratch here and there, the bonnet has taken a beating and needs replacing. The aerial has been crudely removed and the roof has rusted. Rear beam looks fine. I got in running a few weekends ago, it started straight away but idled a little high and the revs fluctuated about a bit.

I started working on the car this summer. The engine has since been removed and welding has started in the engine bay and across the sub frame.

The plans are to get the car back on the road, then maybe do a few track days next year. Iíll post some pictures up this evening.
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Old 22-10-2018, 02:09 PM   #2
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Another active midlands member. Where are you from? Look forward to seeing some pics.
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Old 22-10-2018, 04:38 PM   #3
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Welcome along, sounds like another epic S2 restoration!
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Old 22-10-2018, 04:47 PM   #4
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High lift cam is probably responsible for the idle issues. Get some pictures up when you get chance. ��
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Old 22-10-2018, 08:37 PM   #5
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Another active midlands member. Where are you from? Look forward to seeing some pics.
I'm from Derby. There are a couple of us with Rallyes here.

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Welcome along, sounds like another epic S2 restoration!
Thanks mate.

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High lift cam is probably responsible for the idle issues. Get some pictures up when you get chance. ��
Possibly - I found a few forum posts about the car from the previous owner who had a similar issue. I'll keep this thread updated as I go.

The Rallye when it was first delivered:




Last edited by Stis; 22-10-2018 at 08:37 PM. Reason: Automerged Doublepost
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Old 24-10-2018, 07:22 PM   #6
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Ah that’s cool. You’re not far from me then. Nice looking motor very similar to my previous build (build thread on the same page)
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Old 24-10-2018, 08:42 PM   #7
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Looks awsome with the speedlines !

I’m from near derby to, we should have a meet in a few months when the weathers good again !
I’d be the odd ball unfortunately as I’ve a indigo gti not a rally :-(
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Old 25-10-2018, 02:41 PM   #8
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Ah that’s cool. You’re not far from me then. Nice looking motor very similar to my previous build (build thread on the same page)
Loughborough is only 40 minutes away from me. Cheers mate, I’ll have a read of your thread on evening – always nice to read a good build, especially if it’s local.

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Looks awsome with the speedlines !

I’m from near derby to, we should have a meet in a few months when the weathers good again !
I’d be the odd ball unfortunately as I’ve a indigo gti not a rally :-(
Where is it you’re from? I doubt the Rallye will be on the road any time soon but I also have a Saxo VTS which I could bring out, and a friend of mine has an Indigo S2 Rallye. I’m sure we could get a few people together for a coffee or a pint somewhere.
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Old 26-10-2018, 08:13 PM   #9
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im From near Ripley/ Alfreton

I’ve had a few saxos myself, currently seeking a set of vts wheels to put on the pug !
My 106 is off the road for winter, I really hate driving it in the rain as I can litrially feel the hard work I’ve put into it just rotting away !

How do I post pictures like the ones above ?
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Old 27-10-2018, 06:19 AM   #10
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Yeah if you’re building a track car may be a good build for you to have a read through. I saved loads of weight and by the end it was a rather quick little car. Just a shame I only did Oulton in its final spec.

Mou1t I use flikr to upload and link to.
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Old 29-10-2018, 12:08 PM   #11
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im From near Ripley/ Alfreton

I’ve had a few saxos myself, currently seeking a set of vts wheels to put on the pug !
My 106 is off the road for winter, I really hate driving it in the rain as I can litrially feel the hard work I’ve put into it just rotting away !

How do I post pictures like the ones above ?
I know what you mean haha. I put the Rallye back in the garage yesterday for storage. As for the images, I host them from my own website but like Bendee suggested, flikr, or any other image hosting website will work.


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Yeah if you’re building a track car may be a good build for you to have a read through. I saved loads of weight and by the end it was a rather quick little car. Just a shame I only did Oulton in its final spec.

Mou1t I use flikr to upload and link to.
I’m going for a fast road car really. I don’t want to get seriously in to racing at this point, I just want something I can take out on a Sunday afternoon and enjoy, and maybe do a few track days for the experience. I’ll give your thread a good read though and might possibly call on you for advice in the future haha.
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Old 29-10-2018, 07:31 PM   #12
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yeah no worries ive built a few now so should be able to help with a few things. and theres plenty threads on here to read through for inspiration
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Old 06-11-2018, 08:14 PM   #13
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Engine out. Pictures courtesy of f/stops & Stares;


















And a quick picture of Neil's VTS.

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Old 06-11-2018, 09:01 PM   #14
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Good pictures there! That RH chassis leg looks nasty!
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Old 06-11-2018, 09:14 PM   #15
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Youl need a few more bottles of bud while your tackling that !
I’ve an awfull feeling mine may look the same once engine is out....

Always liked the mk1 vts better than the mk2, had a green one years ago.

https://flic.kr/p/2bjwycP

Quick pic from summer, still can’t get them to appear as a post tho ?
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Old 07-11-2018, 11:02 AM   #16
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Good pictures there! That RH chassis leg looks nasty!
Haha. I know. That’s probably the worst area on the car.


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Youl need a few more bottles of bud while your tackling that !
I’ve an awfull feeling mine may look the same once engine is out....

Always liked the mk1 vts better than the mk2, had a green one years ago.

https://flic.kr/p/2bjwycP

Quick pic from summer, still can’t get them to appear as a post tho ?
Nah the Mk2 is much better. The Mk2 is the car I grew up with on my bedroom wall. I like the Mk1 but it looks very dated compared to the Mk2 – not that the Mk2 looks in any way modern.

You need the image URL of the image, which should end .jpg or similar. Then use the ‘insert image’ button, or stick the image function, [ I M G] and [ / I M G ], without spaces, either side.

It should look something like this, again without the spaces: [ I M G] http://picture.jpg [ / I M G ].
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Old 07-11-2018, 01:57 PM   #17
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Wow some work going to be involved in that. Good luck with it. More than what mine had and it’s been a drag lol.
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Old 07-11-2018, 04:39 PM   #18
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Wow some work going to be involved in that. Good luck with it. More than what mine had and it’s been a drag lol.
Haha. Thanks mate. The fun is in the doing, not the getting it done.
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Old 07-11-2018, 07:22 PM   #19
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Definitel, maximum respect if you stick it out and get that done. I’ve seen a few people trying to flog the inner arches etc I’d be stumping up the cash and making life easy and replacing as much as you can with new bits.
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Old 27-11-2018, 07:40 PM   #20
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A few images of the rust up close...





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Old 28-11-2018, 04:45 PM   #21
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In a hell of a state, good luck, huge respect if you stick it out and repair it!
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Old 28-11-2018, 05:15 PM   #22
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Oh my!! That chassis leg and wishbone mount is in a proper state, look forward to your updates when you get cracking!!
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Old 28-11-2018, 09:09 PM   #23
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Did you pull that out the North Sea?
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Old 29-11-2018, 08:55 AM   #24
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At least your restoring it and not just going to send it to scrap yard heaven! Good luck!
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Old 29-11-2018, 11:13 AM   #25
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In a hell of a state, good luck, huge respect if you stick it out and repair it!
Cheers mate.

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Oh my!! That chassis leg and wishbone mount is in a proper state, look forward to your updates when you get cracking!!
We’ve already started the welding. I’ll update when I’ve got some pictures.

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Did you pull that out the North Sea?
Almost – I think, from what I’ve found on other forums, the car has spent most of its life in Scotland.

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At least your restoring it and not just going to send it to scrap yard heaven! Good luck!
Thanks mate.
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Old 29-11-2018, 12:20 PM   #26
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Brave!!!! That's gonna need some tin!!
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Old 06-12-2018, 04:04 PM   #27
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I see the light! Not in a good way.

Good luck with that. Proper rust.

How are the chassis rail gussets behind the wheel arches and rear wheel arch/boot seams?

If it is bad I would seriously recommend you consider a reshell into a poverty spec model.

Assess the whole thing because if it is really bad you may regret too much time on repairing it...

If you have a good quality weld in cage and a lot of other prep work done a Dave Hunt style front end swap might be a better fix particularly if the chassis rails are shot as the dip under the bulkhead which is a natural water trap.

See this post: http://www.106rallyeforum.com/forum2...0&postcount=21
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Old 06-12-2018, 08:11 PM   #28
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First couple of days of welding.





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Old 07-12-2018, 05:18 PM   #29
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Brave!!!! That's gonna need some tin!!
Yeah haha, I reckon it’ll take us a good few days of solid work to repair it all.

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I see the light! Not in a good way.

Good luck with that. Proper rust.

How are the chassis rail gussets behind the wheel arches and rear wheel arch/boot seams?

If it is bad I would seriously recommend you consider a reshell into a poverty spec model.

Assess the whole thing because if it is really bad you may regret too much time on repairing it...

If you have a good quality weld in cage and a lot of other prep work done a Dave Hunt style front end swap might be a better fix particularly if the chassis rails are shot as the dip under the bulkhead which is a natural water trap.

See this post: http://www.106rallyeforum.com/forum2...0&postcount=21
Rear aches, boot, and sills have all been welded in the past, although the boot was pretty terrible, so we’ve re-done some of it. The car as a whole is salvageable, at least I believe it is. I want to keep the original shell if possible, but I’ll definitely take a look at that front end swap. Cheers for the advice.
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Old 08-12-2018, 05:43 AM   #30
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Wow, that's by far the worst I've seen.
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My resolution for 2011 is to sort my fucking car
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Old 08-12-2018, 03:38 PM   #31
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oh my dayz. Fair play to you!
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Old 10-12-2018, 01:47 PM   #32
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oh my dayz. Fair play to you!
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Wow, that's by far the worst I've seen.
Cheers for the confidence lads.
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Old 10-12-2018, 08:01 PM   #33
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Wow that’s pretty bad. Can’t help but think you’re patching holes to metal that’s too far gone. That whole front end needs coming off and replacing. Wouldn’t like to think how much strength has been lost to rust. I’ve seen panels on fb for sale that would make a lot of sense for you to buy.
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Old 11-12-2018, 03:54 PM   #34
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Wow thatís pretty bad. Canít help but think youíre patching holes to metal thatís too far gone. That whole front end needs coming off and replacing. Wouldnít like to think how much strength has been lost to rust. Iíve seen panels on fb for sale that would make a lot of sense for you to buy.
Does seem to be some welding to rusty bits... not a good idea, it all needs cutting out

I am looking for some panels, what have you found?
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Old 11-12-2018, 09:27 PM   #35
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fair play for having a go but i would cut my losses right there. That front end is too far gone.
When you finish it will be like a patch work quilt and still rusty.
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Old 12-12-2018, 07:44 PM   #36
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Does seem to be some welding to rusty bits... not a good idea, it all needs cutting out

I am looking for some panels, what have you found?
Iíve seen one or two full front end chassis rail/strut top/inner wing on one of the Facebook groups. Canít seem to find it atm but Iím sure a wanted post will bring them to light.
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Old 15-12-2018, 06:57 AM   #37
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Cheers mate
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Old 19-12-2018, 03:20 PM   #38
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Wow that’s pretty bad. Can’t help but think you’re patching holes to metal that’s too far gone. That whole front end needs coming off and replacing. Wouldn’t like to think how much strength has been lost to rust. I’ve seen panels on fb for sale that would make a lot of sense for you to buy.
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Does seem to be some welding to rusty bits... not a good idea, it all needs cutting out
Well we’re having a good go at cutting out the rust and repanelling it. Most of the welding work has now been done, and a few of the panels have been completely reconstructed. We're still cracking on. Worst case I will either buy new panels if I can find them, or cut out the front end and replace it, potentially with a donor 1.1.
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Old 22-12-2018, 03:31 PM   #39
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100% go for a new front end the metal you’re welding too is too far gone. You’ll be patching it up in no time. You’ll see the welds being poor because of how bad the existing metal is. Keep cutting it out till the metal you’re welding to looks the same as the stuff you’re putting in.
Really not trying to put a downer on it for you more save you a lot of time and effort.
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Old 24-12-2018, 03:49 PM   #40
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^^^^This
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Old 04-01-2019, 11:54 AM   #41
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100% go for a new front end the metal youíre welding too is too far gone. Youíll be patching it up in no time. Youíll see the welds being poor because of how bad the existing metal is. Keep cutting it out till the metal youíre welding to looks the same as the stuff youíre putting in.
Really not trying to put a downer on it for you more save you a lot of time and effort.
Haha. Thanks for the concern mate. All the welding has now been completed and we've undercoated and sealed the rest of the engine bay. We're going to start spraying hopefully this weekend, and get the engine back in next weekend.

The car is locked away in the garage surrounded by Christmas stuff at the moment, but I'll get some pictures of the welded engine bay when I next can.
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Old 08-07-2019, 11:49 AM   #42
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A few updates.

The engine bay and strut welding has finished, the engine bay has been painted in an anticorrosive undercoat and sprayed matte white. The engine was refitted on Saturday. There were a few issues along the way; the alternator was seized, so a new one was ordered and fitted. Initially the engine wouldnít turn over, but we traced this to a poor earth where the engine bay had been repainted, once the paint had been ground off the car started without any problem. The fuel line connections on top of the pump and around the filter, which was fitted at the pump, leaked, these were removed and replaced with braided hose Ė eventually the whole line will be braided. The throttle cable is really long, Iím not entirely sure why but on a thread started by one of the previous owners they stated a longer throttle cable was fitted for the S1 inlet, but the long cable caused issues with the idle speed. Depending on where the cable ran and sat in the engine bay, the carís idle differed. This needed adjusting and securing which has solved the issue for now, but eventually I will look to fit a shorter cable. Lastly, when refitting the brakes, the connection from the brake line to the caliper on the driverís side front broke, which needs replacing.

Along with the brake caliper, there are a few other outstanding issues. There are a few minor bits of welding still to complete on the cars floorpan. When refitting the passenger driveshaft we noticed the gaiter was leaking. I will probably end up changing both sides, as theyíre looking a bit tired. It needs an aux belt Ė the one supplied with the alternator was the wrong shape. The ECU, fuse box and washer bottle donít have threads to bolt to, the original metalwork containing the holes were cut out and replaced when the engine bay was welded, I need to drill a few holes and bolt these in. The car needs a fuel filter as it was removed when the lines leaked. I bought a new battery prior to refitting the engine, but the car has screw down terminals. I bought one adaptor for the negative side, but the car is still missing a positive side adaptor. A few wheels bolts are missing, a few bulbs are out/missing. The side indicator cover on the driverís side is missing. Wipers are missing. The car has nothing on the open side of the S1 inlet, so it needs an air filter and oil breather. Finally, the interior, seats and belts etc. still need fitting. Otherwise, itís looking pretty good. Big thanks to the lads at Wheatley Motorsport and Chad Cars for helping Ė and by helping I mean doing the work while I wandered about, trying to be helpful.

The car is still in the garage to sort the brakes and refill the gearbox oil. After which Iíll bring it home and fix the rest.

Pictures to follow.
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Old 15-07-2019, 11:22 AM   #43
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Progressed a bit more on the Rallye this weekend. All the welding needed for the MOT, and to ensure the car is structurally sound, has been finished, but we’re still planning on welding the holes in the floor, usually covered with rubber bungs, just so there are no holes or areas for new rust to form. We removed the rear wiper motor. We removed the front and rear bumpers, ground back the towing eyes, and painted them matte black. We fitted some 2800k Lunex Plasma Gold headlight bulbs, the yellowest road legal bulbs available, for a proper 90s look. We ground out the rough patches where the previous seat frame bars had been cut out, finally we painted any area of exposed metal or weld.

Since the last update, the brake caliper has been repaired. But still to sort are the passenger side driveshafts gaiter, the missing aux belt, the loose ECU and fuse box, the car needs a washer bottle, fuel filter, battery terminals, wheel bolts, side indicator covers, front wipers, an air filter and oil breather, and an interior. In moving the car, we also noticed that there’s no reverse gear. The gear linkages under the car are knackered, and need replacing. But up to now they got us by. Long term I’d like to get a Satchshift system, which will replace the linkages anyway. Now however, reverse has gone completely so I will need some new linkages in the meantime.

Apologies I’ve not got round to uploading any pictures yet. I’ve been too busy fixing the Rallye…
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Old 15-07-2019, 06:48 PM   #44
Stis
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Few pictures as promised.

New alternator;



Engine going back in;





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Old 16-07-2019, 11:11 AM   #45
Mou1t
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Looks well mate !

Hope she’s on the road soon !
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Old 17-07-2019, 08:24 AM   #46
Stis
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Quote:
Originally Posted by Mou1t View Post
Looks well mate !

Hope she’s on the road soon !
Thanks mate. Hopefully I’ll get these last few issues resolved over the next couple of weeks or so. Fit an interior and anything else it needs, and stick an MOT on it. I’m looking forward to getting the car on the road.
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