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Old 25-01-2011, 09:08 PM   #1
Dj_mini
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S1 rallye tb 16v

Hello
My name is dan iv been on the forum a few years as iv always had pugs a few people know me as iv taken my 205 to a few RR events but iv always had a thing for s1 rallyes so when one came up at the right price last year i snapped it up.

So far its sat in storage but this week i brought the car home it was sold as seen as the engine had "stopped" on the previous owner the engine wouldnt turn over upon removing it i found a rod out of the block lol!

My plan is suspentsion overhall and a jp4 lump (unsure of spec yet prob just j4 bits) and colins gsxr set up apart from that std rallye inside and out the last few nights iv got it all stripped down ready for the rebuild there was grease every where as two cv boots had gone so not a nice job.
Hope you like it progress so far:



Scuttle out ready for tbs
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Old 25-01-2011, 09:13 PM   #2
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looking good mate!
that engine bay looks really clean considering these cars are getting old now!
not going to wild like the 205 then
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Old 25-01-2011, 11:03 PM   #3
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awsome, wots happend to your 205? that thing went like fuk and sounded fukin nice wot i can see of the rallye it looks tidy
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Old 25-01-2011, 11:38 PM   #4
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Looks like a great little project dude, is this going to be the weekend toy whilst the beasty stays as the pure track toy/race car?
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Old 04-02-2011, 07:18 PM   #5
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Hello
No not going mad just making a nice drive to use as a weekend blast.
205 is broken at the mo so will be out of action for a wile

Any how iv had two evenings free this week so managed to do a bit more, Iv welded on strut tops as iv had previous cars bend here i bought them but didnt realise they had cut outs for s2 bonnet stays but they met the criteria of being cheap so cracked on! There was a bit of rot around the washer bottle and engine mount so iv cut this out but have yet to weld it up.
I also stripped the rear beam to find its mint bust have been rebuilt recently so just a strip and clean an it will do the job fine
forgot to take many pics will get some more at the weekend.

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Old 04-02-2011, 07:23 PM   #6
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lookin good dude, wots brokrn on your 205? this rallye is guna be awsome wot bhp will it be?
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Old 04-02-2011, 07:23 PM   #7
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Good stuff
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Old 06-02-2011, 07:09 PM   #8
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205 engine is going to be a wile as looks like oil starvation has caused the big ends to fail damaging two rods so not good

Any how iv had a free afternoon so have got on with a bit more the iner wing had gone around the washer bottle and engine mount so i had to cut that out aswell but after a bit of welding it looked much better.
Iv also built up the bottom arms ready to go back on, the rear bushes were a pain but after a bit of messing around i managed to squeaze them in to my press


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Old 06-02-2011, 07:36 PM   #9
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I normally get the old whacking stick out to put those bushes on.
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Old 06-02-2011, 08:28 PM   #10
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i found that a lump hammer with a cloth taped to it is just as good.
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Old 13-02-2011, 08:10 PM   #11
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Some more up dates my custom faulkner 260mm 155lb springs have arrived so i built up the front struts bilstien b8's new wheel bearings and strut tops.

Iv also made up the loom for the dta / tb's after much piss take from my mate james iv also tidyed up the remaining pug loom



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Old 11-03-2011, 09:57 PM   #12
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Small update iv been working away alot so have not had much spare time but have done a bit more on the rallye:

I striped the rear beam and found the tube had very little wear so what iv done is press the arms off the beam tube and rotate it 180 so the the bearings sit on the new face of the tube on the places that hold the load.
Iv built it all back up with new bearings,shoes,cylinders,hoses and fitted the b8's ect



Iv also stripped and rebuilt the gearbox now includes s1 final drive, quaife, new bearings, new syncros, new seals.
I had to get the crown wheel machined to fit the diff but had bit of a job getting it off the std diff in the first place but after a bit of heat i got there in the end

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Old 11-03-2011, 10:10 PM   #13
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looking good Dan
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Old 28-05-2011, 08:10 PM   #14
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Up date time
Alot has happend since the last update iv rebuilt the gearbox and built up the engine its all in and running after a bit of bother i had to take the engine back out as the brand new water pump was leaking! so got that sorted but couldnt get it started this turned out to be the starter using loads of power but not turning fast enough so put a new starter on it been fine ever since.

Spec of the engine is std jp4 bottom end rebuilt jp4 head with j4 internals port matched to the inlet 3 angle valve seats 708's and colins gsxr tb's
After i put a few miles on the car i got it down to sandy to trim the map up all went ok we were seeing about 153bhp @ the wheels so roughly around 175-180bhp at the fly i was happy with this as it was budget build this is the car as it stands iv been using it a fiar bit this has highlighted a few issues ill have have to adress but all going ok.
Dan


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Old 28-05-2011, 08:54 PM   #15
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Looks nice Dan, this a daily run about then?

Decals?
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Old 28-05-2011, 09:46 PM   #16
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looks really nice mate. pretty similar to what im aiming for. you useing jp4 708s?
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Old 28-05-2011, 10:22 PM   #17
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will have to come see this now!
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Old 29-05-2011, 09:21 AM   #18
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Did you have the pistons notched? How much headwork was done?
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Old 29-05-2011, 09:58 AM   #19
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Where you at that petroc motorsports day? I'm sure this was there!
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Old 30-05-2011, 11:55 AM   #20
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Quote:
Looks nice Dan, this a daily run about then?

Decals?
Long time no see.
Yeah run around for the road and going to use it @ gurston untill the 205 is sorted the roof, bonnet and boot need sorting then will get some decals on.

Im using j4 708's and got colin to notch the pistons to give me loads of clearance at tdc.
As for the head work i cleaned it up around the new vlave seats and opened up the inlet side to match the manifold.

Quote:
Where you at that petroc motorsports day? I'm sure this was there!
Yes we were there me and james (corsa s1400) got dragged in to it by our mate what a waste of time and fuel that show is rubbish! But it highlighted a problem with it popping out of gear mid corner that resulted in spinning all the time lol iv fitted some new engine mounts since that seems to sorted it.

Dan
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Old 30-05-2011, 06:02 PM   #21
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Should of popped over. I couldnt work out whos car it was.

I had traction issues there aswell!
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Old 03-08-2011, 06:18 PM   #22
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How's the car going Dan?

Any updates?
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Old 03-08-2011, 07:07 PM   #23
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Nice car this, bet it goes well!
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Old 04-08-2011, 08:37 PM   #24
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No updates to the 106 just been using it as a run around i have a quick rack but have not had time to fit it yet lol!

Been getting on with sorting bits for a new 2L engine ready for the 205 as brown has made a start with it now will add some pics at the weekend.

Dan
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Old 31-08-2011, 07:02 PM   #25
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updates on either dan?
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Old 01-09-2011, 08:23 AM   #26
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I want this car, let me have first refusal on it please!
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Old 29-02-2012, 01:25 PM   #27
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car still running?
any updates on the 205?
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Old 14-06-2012, 03:56 PM   #28
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How's the car Dan? much happened to it?
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Old 13-11-2012, 11:17 AM   #29
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bump!
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