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Old 25-07-2017, 01:42 PM   #301
Dieseldave
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The stupid bastard was older than me.
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Old 26-07-2017, 08:45 AM   #302
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interesting how the header tank fits with the tubbed arches. can't beat a bit of extra bay space thanks to parts that fit well!
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Old 26-07-2017, 04:32 PM   #303
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Loving the updates as ever - this thread being featured on Build Threads was inevitable
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Old 27-07-2017, 08:20 AM   #304
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Thumbs up

Quote:
Originally Posted by infamous aidy View Post
interesting how the header tank fits with the tubbed arches. can't beat a bit of extra bay space thanks to parts that fit well!
Its a lot more forward that it would be in a standard diesel etc.
Its pretty obvious they went through the parts bin and the 605 part was
"good enough"

Quote:
Originally Posted by Cris B View Post
Loving the updates as ever - this thread being featured on Build Threads was inevitable
Cheers Cris.
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Old 08-08-2017, 09:21 PM   #305
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So after all that, I made up some battery cables and stuck the booster pack on it to see if
it would turn over, and it did.

I then stood back for a second and asked myself "Is there any reason this thing wont start"
The answer was no. I plugged in the injectors, fitted a standard coil pack and did that adrenaline
filled drive to the filling station for a can of fuel.

I checked everything over again, switched on the fuel pumps and cranked it over but no joy.
I plugged in the laptop and tried again, Bingo, no RPM reading. I closed in the gap on the crank
sensor, nailed the start button for only the 3rd time and Boom, we had noise and lots of it

https://www.youtube.com/watch?v=AL3wRICAA9w




Chapter 33, Keep Yer Cool

The roof vents turned into a project of their own.



Old mesh

[url=https://flic.kr/p/XjS1NM]

New mesh



[url=https://flic.kr/p/XsWB8N]

Mesh held to the vent with sticky foam

[url=https://flic.kr/p/Wgbp6b]

[url=https://flic.kr/p/XjS18i]

5mm nutsert fitted to make a tidy hole in the mesh

[url=https://flic.kr/p/XwYELR]

[url=https://flic.kr/p/WVU6d1]

[url=https://flic.kr/p/XwYErn]





Some shoe laces.



[url=https://flic.kr/p/WiASdg]

[url=https://flic.kr/p/WVUiYm]

[url=https://flic.kr/p/WiAQgk]

[url=https://flic.kr/p/XwYNnn]

[url=https://flic.kr/p/WVUjJu]


Last edited by Dieseldave; 08-08-2017 at 09:36 PM. Reason: Automerged Doublepost
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Old 09-08-2017, 08:08 AM   #306
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I'd often wondered how those vents were designed. Mystery solved!
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Old 09-08-2017, 08:53 AM   #307
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its good to hear that the car has finally fired up! its been a rollercoaster ride just reading the log never mind building the car.

building mine is getting ridiculous now so cheers for the inspiration.
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Old 09-08-2017, 02:27 PM   #308
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Dave could you make a set of the complete vents ? Any moulds made ?
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Old 09-08-2017, 10:10 PM   #309
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The vents are pressed aluminium and the hinges are all pressed in 1 piece too.

I would be very difficult to make in carbon.
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Old 12-08-2017, 10:29 PM   #310
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Chapter 34, Spoiled For Choice

OK, the roof spoiler, just bolt it on right? Fuck no, nothing is that easy on 514.

For some strange reason the 2 stand off's for the spoiler were at totally different angles and
one side had a 20mm spacer between the boot and spoiler.





Here is a pic of the 2 fitted, you can see they are not a mirror image of each other.







So I took the tailgate off the car in order to line up the spoiler to the correct angle.





Aluminium part made up.





[/url]

[/url]



Made in carbon



[/url]



The difference between new and old


Everything Sanded and re lacquered

[/url]



Last edited by Dieseldave; 12-08-2017 at 10:35 PM.
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Old 12-08-2017, 10:30 PM   #311
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And all fitted including a new part number label.

[url=https://flic.kr/p/Xp1Sch]





[url=https://flic.kr/p/Xp1Tif]
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Old 13-08-2017, 05:43 PM   #312
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Thanks Dave
Any idea if there is a company offering roof vents actually ?
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Old 15-08-2017, 01:25 PM   #313
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Love the detail and effort you have gone into for every single part of this build. I'd be afraid to take it out of the garage at this stage.
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Old 15-08-2017, 01:45 PM   #314
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Ooohhh, She will be out
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Old 16-08-2017, 07:42 AM   #315
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Excellent work as always! Not sure if it's been mentioned but have you thought about liveries for when it's done?
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Old 16-08-2017, 09:40 PM   #316
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It's something that's been in the back of my mind from day one but I have yet to settle on
A design. I need to get it down out its wheels and outside for a look before I commit to a style.
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Old 17-08-2017, 02:06 AM   #317
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Given it's a resto and you've had a set of it's original Belgian plates made up, would it not go together having it done up in the livery it ran at the time on those plates?
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Old 17-08-2017, 11:07 PM   #318
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If it were a more famous or recognisable livery then yes but all the graphics this car wore from new were
Pretty shit. I could go with the more famous loeb graphics but then it will look like I'm doing a replica so
I think I will just go my own way.

As they say, it's only original once.
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Old 18-08-2017, 11:20 AM   #319
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That's fair enough,

at least it's not going to be the millionth and first 555 scoob to be done.
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Old 22-08-2017, 09:44 PM   #320
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Chapter 35, Interior Design

Lets start at the rear and work forward.

Spare wheel holder made in carbon













The Jack that started it all (chapter 1) was refurbished.





And fitted



Rear door cards







Front door cards had a bit of loose cloth so this was stretched and re glued.







Electric motors fitted and tested before fitting the cards.



And fitted, check out those factory carbon door bar trims.






Last edited by Dieseldave; 22-08-2017 at 10:15 PM. Reason: more pics for the peeps
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Old 22-08-2017, 09:58 PM   #321
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A french Gentleman called Ludo who is following the build contacted me one day and
advised he had a very rare part for my car in the shape of a carbon washer bottle from
a S1600 evo. He had bought it for his own project but wanted to see it fitted to a genuine
S1600 so a deal was done. Thank you Ludo.









Its designed to fit under the navi seat.





Standard pump fits in too.



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Old 22-08-2017, 10:40 PM   #322
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Thumbs up

Loving the carbon door bar trims and the washer bottle
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Old 23-08-2017, 01:47 PM   #323
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now that washer bottle is a thing of pure overthought beauty! i love it!
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Last edited by infamous aidy; 23-08-2017 at 01:50 PM.
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Old 23-08-2017, 10:42 PM   #324
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Seats direct from Citroen sport, last pair available with logo I was told.









And red Sabelt belts as originally fitted





All the alloy mounting brackets were powder coated gloss black





And temp fitted, positions yet to be set up



This piece of fine engineering was made when the car was converted to RHD







I was blessed that the original shifter top was in a big box of spares that came with
the car. If I'm honest, I looked at it 100 times and asked "what the fuck is that for"
until I spotted a similar one in a picture one night


Last edited by Dieseldave; 23-08-2017 at 10:42 PM. Reason: Automerged Doublepost
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Old 23-08-2017, 11:01 PM   #325
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Another French gentleman and follower of this build thread I would like to thank is a guy called
Mike Shun. I have been helping Mike a little with the restoration of his own S1600 and he kindly
sent me a LHD glove box as a thank you

My original glovebox on the right in this pic had the hinge part broke off.



The perfect part sent by Mike.





Flocked & fitted



I chose not to fit the actual glove box itself for ease of access and better view of
the wiring and pipes etc behind the dash. The ECU is also fitted to the dash just
below the glove box so its a case of open the lid and plug into ECU.



Carbon inserts made for the vents at each end of the dash

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Old 24-08-2017, 08:40 AM   #326
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More great work keeping it original mate.

i'm currently debating if i should have my cage fitted in the same shape as the original maxis as it is all to be cut and profiled it could be the perfect time to make the car a little bit more like the original.

Also do these other people doing restorations have build threads too? it would be good to have more stuff to read.
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Old 24-08-2017, 03:56 PM   #327
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It has hidden cup holders! I reckon the nav is going to end up wearing coffee however
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Old 05-09-2017, 09:04 AM   #328
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Navi foot rest was shop bought This was for no other reason only to buy
me some time.



Fitted with the original reset buttons for the trip meter.





Tight squeeze





Drivers floor try was made to my own design. I fabbed it from a sheet of aluminium first
and used that as a mould.



















BOOM



Now OMP steering wheel was stolen from my Clio V6 as it was too deep for the car anyway.
Luckily it was the same as the weathered original.



Coming together nicely


Last edited by Dieseldave; 05-09-2017 at 09:06 AM. Reason: Automerged Doublepost
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Old 05-09-2017, 11:05 AM   #329
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Chapter 36, Trim Will Fix It

Next in line is to fit all the trim and finish off the outside.

Side mouldings fresh from paint.





New clips from Ebay



Some holes to be drilled after a repair to the panel.





One of the hardest parts to find for this car were VTS badges, I fail to find a new set
and these are from a Xsara.



All fitted.





Grill was split for painting.



And I used a solder iron to plastic weld back together.




Last edited by Dieseldave; 05-09-2017 at 11:05 AM. Reason: Automerged Doublepost
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Old 05-09-2017, 11:27 AM   #330
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Boot catch



Some clear vinyl before fitting





Bonnet pins fitted.



Socket for original lamp pod





LHD wiper motor and linkage got cleaned & powder coated before fitting

[/url]



Scuttle cover before



After



This is the motor cover as fitted to a LHD car













Rubber strip with built in washer hose

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Old 05-09-2017, 11:29 AM   #331
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Another impossible part to find were these new genuine badges.










Last edited by Dieseldave; 05-09-2017 at 12:15 PM.
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Old 05-09-2017, 02:27 PM   #332
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Amazing work
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Old 05-09-2017, 07:55 PM   #333
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Quote:
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Amazing work
Thank you.
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Old 07-09-2017, 07:36 AM   #334
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Nice one Dave. Any chance you have photos of the LHD wiper mounting points in the scuttle?
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Old 07-09-2017, 08:02 AM   #335
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This is all I have Cris but I can get some more & measurements if you need them





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Old 07-09-2017, 03:49 PM   #336
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Spot on mate, just what I needed for reference.
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Old 15-09-2017, 03:22 AM   #337
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Wheel arch liners in the making, I used Carbon Kevlar cloth and a flexible epoxy resin.



I rolled a sheet of 1.5mm alloy and waxed it as a mould









Removed and trimmed to size/shape



Rubber flap fitted to the scuttle drain to stop crap getting thrown up.



Arch liners fitted



Chapter 37, Your Fired

Plumbed in Extinguisher fitted behind navi seat



A few different brackets made for the nozzles, 1 in each footwell, 1 for intake manifold
and 1 for exhaust manifold.










Last edited by Dieseldave; 15-09-2017 at 03:22 AM. Reason: Automerged Doublepost
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Old 20-09-2017, 02:06 AM   #338
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Chapter 38, A Box Of Air

For the airbox I wanted to fit an original Kit Car style setup, however there is no off the
shelf box that will work with the Jenvey's as the Kit Car ran a DTH throttle body.

I bought a fiberglass copy of the original.





I then cut and reshaped this to work with the angle of the Jenvey's





I then made a 2 piece mould from that











Made in 100% carbon







From what I can find out through my research, the early Kit car had a finished airbox
like above but the only problem with this is there is no way to fit the air horn
bolts unless the engine is out of the car.

On the later Evo version of the Kit car there was an inspection cover fitted so I had to
make one.

I searched through my local "Home Store & More" shop and found a baking tray in the
dimensions I needed.



I cut the bottom off it and moulded it to a sheet of glass.



I then pulled a mould off that and made the cover in 100% carbon







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Old 20-09-2017, 02:07 AM   #339
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Fitted to the car with original part numbers and labels





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Old 20-09-2017, 08:22 AM   #340
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I most definitely think that the inspection hatch is a suitable solution/evolution.

i'm currently on with tubbing my front arches so i'm really looking forwards to been at the sort of stages you are covering now!
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Old 20-09-2017, 04:05 PM   #341
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Just had a good read of this, amazing work as always Dave! Do you do this sort of work/fabrication work for work? All your car's look pristine! You've got quite a collection compared to most!

What will this be used for? Local rally's?

Chris.
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Old 21-09-2017, 02:41 AM   #342
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I served my time as a stainless fabricator/pipe fitter but for the last 10 years I'm working
as a service engineer for an automation company.

I also did a 6 month evening course years ago for vehicle body repair and on top of that I'm
just ballsy enough to try anything

Chapter 39, The Final Push

Its getting close now, I order everything I need to finish the car, take my 2 weeks holidays
from work & spend 14-16 hour days to get this girl outside the door.

Carbon Lorraine front and rear pads.





New bleed screws all round





Hand brake also has a bleed screw



New Gel battery



Anderson connector





This is 1 of the original ARB drop links, I only had 1 and it was in bad shape so I
needed to make up a new set.



I had 2 new hex nuts turned up with RH/LH thread



Very difficult to source M10x8 Rose joints. M10 thread but with an 8mm eye








Last edited by Dieseldave; 21-09-2017 at 02:52 AM. Reason: Automerged Doublepost
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Old 21-09-2017, 03:07 AM   #343
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Some money shots for you guys































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Old 21-09-2017, 10:50 AM   #344
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i'm genuinely gutted to be getting to the end of this project. The next one had better be a corker Dave!
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Old 04-10-2017, 04:19 PM   #345
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So whats the chances that I would come across 5 brand new Citroen Sport wheels for this early on
in my build. Story goes that Andrew Bush bought them from Citroen Sport back in the day to fit to
his car for a photo shoot and they sat gathering dust ever since.





(Not the new) Wheels fitted.





And then this happened after 27 months

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Old 04-10-2017, 07:26 PM   #346
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Quote:
Originally Posted by Dieseldave View Post
Very difficult to source M10x8 Rose joints. M10 thread but with an 8mm eye
Dave, I get my rose joints from Autosport Bearings & Components
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Old 04-10-2017, 08:25 PM   #347
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I sourced here in the end. A lot cheaper than your link & Dunlop should be somewhat decent

https://simplybearings.co.uk/shop/Be...205/index.html
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Old 04-10-2017, 09:13 PM   #348
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I hope so.
I've used cheaper ones before and they have not lasted at all.
I'm using them on the rear toe links and camber arms so don't want to risk it.

Car progress is fantastic, and look forward to the next project
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Old 05-10-2017, 12:38 PM   #349
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Old 05-10-2017, 11:08 PM   #350
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