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Old 19-02-2010, 05:28 PM   #101
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when are we fitting `em slim?????
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Old 19-02-2010, 10:56 PM   #102
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cheers lads, more to come soon.

stu hows next weekend suit ya? cahs for the blue one clears early next week
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Old 02-12-2016, 03:55 PM   #103
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OK, so, almost 7 years later, maybe i could/should update this.

spoiler alert, lots has happened
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Old 06-12-2016, 02:13 PM   #104
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ok so, after a 4 year absence from 2010 to about 2014 i got the car back on the road looking a little like this.




it was essentially made to run with what i had lying around and as few new bits as possible.

after a while it looked like this and was doing ok except for some rear arch rust that was going to need sorting for the mot.



this was followed by a DanST gsxr 600 throttle body kit



i'd always wanted the car to be wider and i couldnt justify a maxi kit so i got a set of +25mm f2000 style arches from www.maximotorsport.com













with the impending rust requiring treatment i got the car down to my mate paulR's workshop.





i discovered a terrible turbo manifold i'd bought previously and tried it again before binning the idea off





some wheels arrived too



with the impending rust requiring treatment i got the car down to my mate paulR's workshop.





i discovered a terrible turbo manifold i'd bought previously and tried it again before binning the idea off





some wheels arrived too

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Old 06-12-2016, 02:34 PM   #105
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so we started stripping the car down







bay started going down to bare metal







same under the arches



after a couple of good months at work i managed to afford some satchell +25mm lower arms



i tried again to get this turbo manifold to work using a gtiR downpipe



After trying to find a good quality n/a manifold and getting to the point of spending 80 quid on an edwards item a colleague said "surely you could buy a turbo and manifold for that price"!

they were right and a nice compact cast manifold was ordered along with a cheap ebay turbo for mocj up purposes



after an unfortunate incident on the rollers with his saxo turbo my mate had a BE gearbox conversion going spare so along it came.





onto the spit the shell went!



i cant begin to tell you how useful this spit was!



i started to bare metal the underside and treat rust



while i was there we decided that stitching my shell would be a good way to learn to weld





the rear end rust was started



this was a rather rusty panel on the floor that is connected to the chassis leg where it goes to the sill


the back end all welded up and good times starting

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Old 06-12-2016, 03:06 PM   #106
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remember that rusty panel, well this was my first go at making a replacement. it took some fettling but i was pretty impressed with myself





after getting lost by the bratislavian postal service my rear wide track kit turned up from vd motorsports iin ukraine



now, back to that rusty panel under the floor, on further inspection the rust went further up that section a little further, actually a hellof a lot further, it turned out water had go into the chassis legs and rotted them massively on the inside, some endoscope work revealed the extend of the rot, it was all down the chassis legs, the floor rienforcers and out to the sills, after trying to repair the sill section things got too much and it was time to do something drastic!

which is where a top lad sold me his little daily drive

from the littlest acorns and all that!



then work started







engine bay had nothing but a little surface rust



off went the rallye shell to someone with more time, skill and facilities than me to repair it



then this was found



and at this point i felt rather deflated, the only place i hadnt looked, up at the side of the fuel tank, was rotten!

man options were weighed up including a 197, many tu based pugs and my mate essentially slaped me around the face and said he'd fix it



i have no idea if this poor little car had any clue what was about to happen, but it looked something like this!



the old man gave the beam a lick of paint for me



you can see here just how much needed to come out of the quarter



a sign of things to come



wides



into the workshop and we trial fitted the engine





parts galore

i had 28 parcels arive in 3 days at one point



part way through mounting intercooler 1

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Old 06-12-2016, 03:47 PM   #107
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getting there



my bracket wasnt the greatest but sometimes you have to use whats lying around and have a go



due to the turbo sittin flat it pokes forward quite a bit so the decision was made to move the rad 3 inches forward and then fit a fan offset behind the rad



now started the hosing! luckily auto silicone hoses are a few villages away so for a month or so dad was down there every couple of days for more bits



all along i said i did not want any hoses or anything hanging lower than standardand no amount of buggering about could get the boost pipes where they needed to go



everything seemed to be in the way of everything else





so this lead me to a new intercooler from rally design



after more buggering about the hoses finally got where i need them



oil cooler was placed behind the fog blank



with the bumper back on







i also wanted to keep the boost pipes neat and keep as much access to the engine bay as possible so i don't have to take half the car off to get to something else below.





finally onto the other side of the car

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Old 06-12-2016, 03:48 PM   #108
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looking like a car



the arrival of technocrab!



one of many many oil pipes, or maybe its a water pipe, who knows



plumbing into the oil cooler

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Old 06-12-2016, 04:00 PM   #109
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i wont lie, i have no idea how best to fill this lot with oil as the piping to the cooler is thermostatically controlled.

so i'll probably have to messily prefill them





at this point it was time to start painting the paint is i believe 1pack poly in aersol form. i was ver impressed with the results









engine out again



satchell reinforcing gear going in





the engine looking quie tidy



some paint work on the inner wings









beam spacers going on



these are designed to use 406 hubs as they allow for a bigger stub axle




2.5" outward rolled tailpipe arrived too, should look like a pugsport to the untrained eye



beam getting there now



the bay getting less red and more sexy slinky white



tidying up inside

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Old 07-12-2016, 11:05 AM   #110
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satchbrake plumbed in, wilwood mastercylinder



some heat reflective sheeting and another delivery from maxi motorsport, a lovely carbon binnacle



my roof scop arrived, a word of advice, find one that comes apart. making his fit the roof has been a pig and it still doesnt fit right!



at this point there was a brief gap in the cold weather to paint the bay







had another go at the wing that i messed up previously



a quick lick on the servo



the inside got some more white paint



my graphics arrived next



finally some reassembly





bump strip holes hidden the pikey way!






painted the underside of the bonnet



some white on the rear arches too

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Old 07-12-2016, 11:11 AM   #111
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first fit of the satchell arms and standard struts



next thing this little lot was shipped off to someone much better with wires than me







i made some side skirt brackets









more reconstruction of the bay



power steering relocation started





new removable wing brackets



tidied up the BE box a bit



oil return on the sump



block painted



pulleys painted too

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Old 07-12-2016, 04:48 PM   #112
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Nice work going on here and plenty of good quality parts. Keep it up.
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Old 08-12-2016, 08:54 AM   #113
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cheers Dave, i'm not gonna lie, it might get to a point where you think i'm been a bit cheeky

so, at this point we started messing with suspension







some very pretty borrowed satchell struts



full compression



diff dropping in



trying to adjust the angle of the BE gearbox



sort of looking like a car



taking the slack out of the clutch cable with a couple of driveshaft nuts



pretty top mounts



proto adjustable camber strut conversion



maxi/f2000 spoiler from www.maximotorsport.com







adjusting oil pipes for wheel clearance

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Old 08-12-2016, 09:02 AM   #114
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more trying to make boost and filter pipes fit



outside for the first time in about 8 months











a brief view of the amount of oil hose, all desined to not hang any lower than ultimately required. the car is bult around clearance where possible.















and i think thats me until i get some more photos uploaded to the bucket
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Old 08-12-2016, 09:22 AM   #115
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Loving the car dude, looks mega
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Old 08-12-2016, 09:47 AM   #116
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cheers mate, it get better!
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Old 08-12-2016, 10:26 AM   #117
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Looking the part now but you gotta change that front bumper.
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Old 08-12-2016, 12:31 PM   #118
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LOL keep reading the updates dave!

new gpahics, the pts stripes are oviously covering some scratches







some really bad welding on proto strut



how the wheel sat with the wider suspension, this didn't please me as it didnt look right






looking shiny under there though



side graphic





right few words, many pics






















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Old 08-12-2016, 01:53 PM   #119
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Old 08-12-2016, 02:14 PM   #120
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Some VD motorsport strut adapters




vauxhall leads to use the 8v coil pack and locate it on the edge of the battery tray





how i wanted the wheels to sit but this would heve resulted in serious arch damage on compression



think the rear spacers are a bit big



more playing with struts







catch tank in place



a brief play with some old ac sport wings i had. the wheels needed moving out 75mm and forward 30mm



which was done like this to get an idea



in place





the last i saw of the satchell suspension

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Old 08-12-2016, 02:49 PM   #121
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so, this brings us up to date up until around a week ago.

there was much messing around in between these pictures and i expect there is much i have missed.

now, a couple of weeks back i got an email from a man in the south with a tracking number.

What arrived at work a few days later was the realisation of a decade long dream!



















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Old 08-12-2016, 03:20 PM   #122
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like i said, i've wanted a maxi for over a decade, actually seeing a genuine factory one in the pug museum in france parked up with a 405 t16 (the one from the pikes peak vid) and many more group B, wrc and lemans cars, i couldnt keep my eyes off the little maxi!

Now here i am with one in the workshop, i know its not the sympathetic replica that daves might be with the high revving NA engine and man original parts, but its here, its's mine and i'm bloody excited about it.
Power wise (judging by CraigyT's car with the same turbo) i should be looking at around 180bhp at 8 psi and 250bhp at 14psi, although that doesnt sound much by todays standards it seems a bloody good staring point!

I have a couple of suspension bits in the works at the moment but sice i'm not ready to unveil them, you are up to date!

i hope you've all enjoyed reading and if you need any info, just let me know!

big thanks to
PaulR
tony@ www.maximotorsport.com
Shenpar Bitch
Salvesta
Diesel Dave for the inspiration
all the other people who have helped me out, you know who you are!
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Old 08-12-2016, 04:25 PM   #123
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Very nice and wide
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Old 08-12-2016, 05:46 PM   #124
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Thanks mate. She's getting there
Next big piece of the puzzle is on the way
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Old 08-12-2016, 05:55 PM   #125
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Epic journey you have been on, really looks like it is finally coming together!
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Old 08-12-2016, 06:36 PM   #126
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It's starting to look the part now alright, fair play to you.
Your bringing back serious memories here.

PS mine is a recreation not a replica
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Old 08-12-2016, 06:49 PM   #127
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What kind of fucking stupid, octane frazzled dickhead would let YOU... YOU!! borrow their Satchell Struts to twat about with.. ....
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Old 09-12-2016, 07:22 AM   #128
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Quote:
Originally Posted by chatie1975 View Post
Epic journey you have been on, really looks like it is finally coming together!
cheers mate, its looking right on the outside, i dunno if its quite coming together yet!

Quote:
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It's starting to look the part now alright, fair play to you.
Your bringing back serious memories here.

PS mine is a recreation not a replica

ok then, mine is an evolution!

wait til you see the suspension set up


Quote:
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What kind of fucking stupid, octane frazzled dickhead would let YOU... YOU!! borrow their Satchell Struts to twat about with.. ....

well obvs you!
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Old 09-12-2016, 12:48 PM   #129
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Great work Andy, good to see this coming along again.
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Old 12-12-2016, 08:22 AM   #130
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so, this weekend i got a bit of time in down the workshop and i decided to do some more work on getting the kit fitted properly, the quality of the kit is that good, i have managed to fit the factory plastic bumper reinforcers from some spare GTI bumpers that i had lying around. i have however had to modify the bumper and chop a huge chunk out of the plastic bar for the intercooler,











tonights job is to do some more figuring out how to cut the filler neck hole!
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Old 13-12-2016, 07:31 AM   #131
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last night i made a to do list, which was ridiculously log and got longer as the night went on, amongst a bit of a sort and a tidy i finally got around to mounting the bottle for the pas system



we got my dash back in too, i was going to fit a flocked one but now i want the car done so a furry dash can wait.



as well as this we played with fire and air tools to get the ball joints out of my 307 hubs, they have no been replaced with some custom made pins ready for going into the spherical bearings on the lower arms.
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Old 13-12-2016, 07:43 AM   #132
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Fun times, keep up the good work.
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Old 13-12-2016, 08:01 AM   #133
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There is a version of that PAS pump that comes with the bottle grafted on.
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Old 13-12-2016, 01:53 PM   #134
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Fun times, keep up the good work.
cheers mate. will do

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There is a version of that PAS pump that comes with the bottle grafted on.

there is indeed, i thought this way it would be easier to fill or top up once the seat is in place.

i also kind of like the look of it!
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Old 23-12-2016, 08:15 AM   #135
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Ok firstly! ignore the terrible welding tacks! i have no idea how to set up a welder and the welder i normally use was broken so i had to mess with the settings until it managed to tack it on. it will be welded properly.

so, in some blatant copying of diesel Dave i have purchased a Hockly strut body for a nova. i already had some 307 hub converters for std 106 struts from VD motorsport in Ukraine. they were designed to slot on to the standard strut but the Hockly strut body was a mil or so wider so i had to modify the hub converter quite a bit.
The damper is a pug 205 tarmac long spindle unit so that i didnt have any issues with thread length like dave did.

leaving me here





here is a sneaky peak of the fully adjustable jig arm designed to get my wheel exactly where i need it whilst checking there are no issues under compression etc. so far i mayhave got it set up so that i can use a standard picasso shaft on the off side but i need to check there will be no issues with this



as you can see here i have plenty of wheel clearance at the moment so there should be no danger of hiting the strut. this is using standard 206 gti wheels and no spacers



i work for a division of vw and they were having a massive factory clearout and one of the lads found some 2.5 inch diameter back boxes for 2.60
it is from a leon and even came with the joining clamp.
my plan is to remove the gash tail pipes and lift the back box up as high as possible then fit 2 hidden tailpipes.
as the back box is quite sizeable i'm hoping it will leave the car quiet enough to not annoy the neighbours when i move into my new house.





my next problem was how to get the battery wire through to the bay when i had originally planned to keep the batery in the bay and i had no room to get in to the bulkhead with a drill. this lead me to adding a hole to the blank in the oe loom where it goes through the side of the pillar.



the wires will have insulated terminal boots on and split from here to the relevant fuse boxes and starter motor.

now messing with the suspension brought me to the conclusion that i needed some "light relief" of the inner wing section. so out came the air tools.
it will be tided up tomorrow and then any joins will be stitched to make sure there are no strength issues. hopefully as i am only on 16's i wont need to tub the arches. well i really hope not as that would mean relocating my fuse box and header tank

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Old 06-02-2017, 10:59 PM   #136
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Holy shit you're back. I'll be wanting a passenger ride when done matey. Looks awesome
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Old 07-02-2017, 07:39 AM   #137
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not a problem joe! not a problem!

hopefully not be too long before its seeing the light of day!
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Old 31-07-2017, 04:06 PM   #138
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Nice to see you turn it in to something different and also good restoration of all the rust repairs..
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Old 01-08-2017, 06:51 AM   #139
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thanks mate, loads more has happened since then, i just haven't had time to get everything uploaded and on here.
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Old 01-08-2017, 12:53 PM   #140
Steven_c
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Quote:
Originally Posted by infamous aidy View Post
thanks mate, loads more has happened since then, i just haven't had time to get everything uploaded and on here.
This something I will be looking at doing to mine not the maxi kit, but repairs and get it back to a sensible standard, owned 6 rallyes in my early days, but would be looking at fixing up and exporting across to aus.
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Old 01-08-2017, 02:56 PM   #141
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as i've just put on your newbie thread, your car is my old daily lol
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