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Old 04-03-2017, 01:19 AM   #251
Dieseldave
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I have a lot of stolen cars.
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Old 04-03-2017, 05:15 AM   #252
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Quote:
Originally Posted by dieseldave View Post
i have a lot of stolen cars.


😂😂😂😂😂😂😂😂😂
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Old 13-03-2017, 09:53 PM   #253
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The back of the Citroen Sport switch panel





Everything removed



RHD holes marked out on a piece of plastic and transferred to the LHD panel.





Drilled out





All fitted



Dash prepped for focking







Resin applied



And Flocked in house.














Last edited by Dieseldave; 13-03-2017 at 09:53 PM. Reason: Automerged Doublepost
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Old 13-03-2017, 09:59 PM   #254
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Selector switch for the dash display was hardwired into the loom so I put a plug on it
for easy removal of the display.





And the dash finally fitted





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Old 13-03-2017, 10:26 PM   #255
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Chapter 27, Glass House

No plastic windows here, it was fully loaded with glass from Citroen Sport
so its going back that way.

Protective film fitted to everything bar the windscreen.























Rear glass fitted with the help of my Go Pro sucky thing.



The bug shield was removed from a Saxo Ive been growing in the field for 2 years, I think
its coming along well.





New seal from Ebay



Plastered on the Tiger seal and I threw it at the car. Unlike Stu, I'm talented enough to fit my own screen


Last edited by Dieseldave; 08-05-2017 at 09:51 PM.
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Old 13-03-2017, 11:11 PM   #256
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Quote:
Originally Posted by dieseldave View Post
unlike stu, i'm talented enough to fit my own screen :d
ooff!!!!

Very true though ;p

Its all coming along nicely. Any idea why they ran galss rather than plastic? Seems a bit odd that they wouldn't try to save the weight if nothing else.
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Old 13-03-2017, 11:40 PM   #257
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Quote:
Originally Posted by Alanapone View Post
ooff!!!!

Any idea why they ran galss rather than plastic? Seems a bit odd that they wouldn't try to save the weight if nothing else.
All Super 1600 cars had to be a minimum of 950kg's. In some cases the Saxo had
lead weights under the seats to meet the requirements. My car actually had the
holes where it was bolted in.
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Old 14-03-2017, 08:58 AM   #258
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Makes sense, I suppose they can use el cheapo production glass then as well.

Looking rather good - I know I'd make an arse of putting a rear window/front screen in and get tiger seal everywhere!
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Old 14-03-2017, 12:28 PM   #259
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Ouch, David.....

If you saw the sealant around my bath you'd understand why i got a fitter in ��������
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Old 15-03-2017, 08:12 PM   #260
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I see. Similar to the JSCC car that I'm helping run. Minimum weights etc so all cars are the same and it's down to driver skill. I'm surprised teams didn't run stock interiors and cassette decks hahaha.
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Old 16-03-2017, 09:15 PM   #261
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Still on the windscreen theme, lets keep it clear.

Heater from Citroen sport. these were fitted to the C2 R2.





I made the alloy bracket to mount it to the dash.








Screwed up to the dash, it uses the original built in ducting and I blanked the 2 ends of the duct where it
would have mated to the outer dash vents.




Speed switch and carbon mounting plate



Speed switch was mounted down here, the breaker in the console will be used to turn on/off the heater
and I can pre-select the speed before strapping in. Saying that, this car will never be out in the rain, wind,
sun or strong daylight.



And these bulkhead's were fitted during the dry build.


Last edited by Dieseldave; 30-07-2017 at 08:55 AM.
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Old 17-03-2017, 05:26 PM   #262
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As Guy Martin would say, he's not a messer this fella.

Always great to see an update on this.
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Old 18-03-2017, 08:53 PM   #263
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Cheers Cris, good to see an update on your build too.
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Old 29-03-2017, 08:15 AM   #264
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Chapter 28, Light At The End Of The Tunnel

When I bought the shell it came with 2 new genuine head lights still
in the box so they were fitted.



I sourced 2 new repo rear lamps







Original number plate lights



50/50 of one cleaned up



Fitted



The original loom for the No plate lights, this can be plugged out here for removal of tailgate.
The dust was cleaned off after the pic.



Blanking the button in the plinth





An Irish company called Eireplates.ie hooked me up with some copies of the original Belgian plates



Fat ass all fitted up. (new badges yet to be sourced)



And some power run through to test everything, a happy day.








Last edited by Dieseldave; 29-03-2017 at 07:17 PM.
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Old 29-03-2017, 12:34 PM   #265
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Lovely, great progress lately
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Old 29-03-2017, 10:27 PM   #266
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Looks fantastic, complete credit to your skills there.
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Old 30-03-2017, 07:20 AM   #267
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serious attention to detail dave. looking good as always!
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Old 31-03-2017, 08:47 PM   #268
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Thank you gentlemen.
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Old 05-05-2017, 09:29 PM   #269
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Chapter 29, Anchor Man

Fitted to the front of the car is a 355x28mm disc mounted with alloy bells.

The bell's were worn way beyond use and should have been changed a long
time ago. They were showing 2mm of backlash.

https://youtu.be/ZMjTfAcwf7U







I sent a bell to BG Developments (and I must thank Mike Nash here for the contact details) and the
guys reversed engineered a pair of new bells for me in only 2 weeks.
They also supplied the set of new mounting bobbins.







The discs were in good shape with no lips or anything so were cleaned up and reused.



Alcon/Citroen 4 pot calipers cleaned up and fitted.



280mm solid rear discs got the same treatment.







Alcon 2 pot calipers cleaned up.









Pad retaining pins were blasted





All fitted including the 20mm tarmac wheel spacer.


Last edited by Dieseldave; 05-05-2017 at 09:53 PM.
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Old 06-05-2017, 07:54 AM   #270
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looking good mate! my maxi must be double tarmac as it is currently on 40mm spacers out back.

looking seriously good though. i feel a little immasculated though now with my piddly little 300mm stoppers.
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Old 06-05-2017, 08:38 AM   #271
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Quote:
I sent a bell to BG Developments (and I must thank Mike Nash here for the contact details) and the
guys reversed engineered a pair of new bells for me in only 2 weeks.
They also supplied the set of new mounting bobbins.
No problem. Good to see a UK manufacturer producing quality goods with a quick turnaround too.

(Only just picked up on the You Tube link too!! Ace )
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Old 14-06-2017, 09:03 PM   #272
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Making up some of the braided hoses





Wrapped in spiral wrap



All 4 corners are fitted with dry break connectors so converting from Tarmac to Gravel spec takes
minimal work and bleeding.







Brackets to mount dry breaks to the uprights, they were blasted before fitting









The route the line takes back to the pedal box

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Old 14-06-2017, 09:45 PM   #273
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Chapter 30, She's A Screamer

The engine is the original Citroen Sport unit but had been worked on by Jondel
in or around 2009.
The car had been converted from its single throttle body setup to ITB's and the cams were
re-profiled to suit.

I was advised by the previous owner that the engine had a revision not many stage miles ago
so I made the decision not to open it up with the exception of pulling off the sump and cam
covers.











Block & head painted





Lots of yellow zinc












Last edited by Dieseldave; 14-06-2017 at 09:50 PM.
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Old 14-06-2017, 09:47 PM   #274
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Double Post
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Old 15-06-2017, 01:44 PM   #275
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Looking as good and as detailed as ever Dave, Can't be that many more major jobs now before she's ready to hit the tar in anger.
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Old 20-06-2017, 06:57 AM   #276
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New belt kit and water pump



42mm Jenveys had been sitting for a while so were cleaned with some scotch brite and carb cleaner











Inlet manifold had been vapour blasted





The alternator cable and catch can return pipe were covered in reflective wrap that had seen better days



Some new wrap was ordered in



Before & after, I used white cable ties this time



And all fitted with a fresh pair of cam covers and yes, that is how Citroen Sport originally
Routed the alternator cable.




Last edited by Dieseldave; 22-06-2017 at 11:02 PM.
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Old 20-06-2017, 07:25 AM   #277
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This car originally had an odd looking pair of coils fitted and were thrown in a box of old parts
I got with the car and a standard GTI coil pack was fitted to the head.



Turns out they are from a Renault Laguna



As the plugs on the original set had been epoxy'd in I got a new set of plugs





Mounting bracket should look something like this













After powder coating









And finally mounted to the head




Last edited by Dieseldave; 20-06-2017 at 07:27 AM.
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Old 20-06-2017, 07:43 AM   #278
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A few pics of the crank position sensor







Manifold (Yet to be unwrapped) is the same as 106 Maxi.





Very light weight flywheel fitted.





New clutch as per original was difficult to source, I was told AP only do this in 4 paddle anymore?



Pressure plate was in good condition so reused



I made up some fuel lines and mounted the pressure sensor





Oil Pressure sensor is remote mounted with a braided line coming from the front of block



And ready to drop in.

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Old 20-06-2017, 09:49 PM   #279
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Looks great Dave
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Old 21-06-2017, 07:37 AM   #280
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Quote:
Originally Posted by LeeThr View Post
Looking as good and as detailed as ever Dave, Can't be that many more major jobs now before she's ready to hit the tar in anger.
Cheers Lee, I think I may be over the hump at last. My parts list is getting smaller
and more normal by the week.

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Looks great Dave
Thank you sir
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Old 21-06-2017, 08:55 AM   #281
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I doth my cap once again to the Irish fella
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Old 21-06-2017, 03:40 PM   #282
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That is most kind of you sir.
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Old 22-06-2017, 01:57 AM   #283
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Originally Posted by Dieseldave View Post
Cheers Lee, I think I may be over the hump at last. My parts list is getting smaller
and more normal by the week.
Always a good feeling. I wish I could say the same, mines at the point of the dry build so I can work out everything that's being added or changed around the existing items. But it means it's all got to come back off before it's painted

Also am I going mad or is the crank sensor reading off the crank pulley rather than the flywheel?
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Old 22-06-2017, 11:06 PM   #284
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Yes, reading from the pulley (like a lot of production cars) to allow flywheel to be lightened.
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Old 29-06-2017, 10:09 AM   #285
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Chapter 31, Life Is Like a Box of Chocolates

The S1600 came with a Sadev St-75 16 6 speed sequential gearbox. Unlike the more "Common"
ST-75 14 which has a removable bell housing the '16's casing was cast with a TU bell housing.

Only 2 ST-75 16's were made, 1 for Citroen and 1 for Renault's Clio of the same era, none of which shared the same ratios.

This is how the 'box came to me.





The main reason this car was parked up and finally sold is because the previous owner noted
some damage/pitting on the pinion shaft and was unable to source a good replacement.
It does however look a lot worse in the pics, there is plenty of meat there yet.



If anyone out there has one, please get in touch.



After I myself failed to source either a new or second hand item I spoke to a local engineering company
about making one, I was advised it was a tricky job but can be done.

I had a second spare damaged/chipped pinion I supplied so he could copy and I continued the build
with the usable pinion. The reason for this is the machine shop advised there was 6 "set-ups" in the
shaft and every set-up was going to cost in the region of €250-€300.

If I was willing to wait as long as it took he could do a bit on my job every time the machine was
set-up for a larger run of gears etc and he could send for hardening when he had a full load and
this would bring the cost of my part down considerably..

So on with the assembly,

First up was to rip the diff apart for inspection, I pulled the 2 diff bearings to source a new set and
sent the diff to Adrien @ MCD Rally Services in Donegal for a check over.



After it was stripped it showed some wear to the diff plates and the bevel plates were broken and
welded at some stage.









So after 6 months of waiting for Citroen Sport to supply these parts, most of which were NLA I
did some research myself, I cross referenced the part numbers with and ST-75 14 'box and they
were all the same, a mail to SWR, a €1000 off my card and a week later I had everything in my
hand including a new clutch fork.



I got the larger bearing from SWR and sourced the small one through work



Diff back and bearings fitted





Everything was washed and laid out ready for assembly.











Selector shaft fitted


Last edited by Dieseldave; 29-06-2017 at 04:16 PM. Reason: Automerged Doublepost
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Old 29-06-2017, 11:01 AM   #286
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Secondary shaft with selector forks.



Primary shaft in.



Diff in



Diff housing and end plates fitted



fitted up with mount, gear selector, gear indicator etc









The Nylon bush at the top of the clutch fork was worn badly causing slop so I had a new 1 spun up







When the black car was built in RHD it was converted to a hydraulic clutch, that is why I needed the
clutch fork mentioned earlier but I also needed this piece (#2) to mount the end of the clutch cable.













And fitted to the side of the mount


Last edited by Dieseldave; 29-06-2017 at 11:01 AM. Reason: Automerged Doublepost
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Old 30-06-2017, 01:27 PM   #287
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Proper job!

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Old 30-06-2017, 02:40 PM   #288
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top notch as always dave.

any news on yours cris B?
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Old 03-07-2017, 10:07 PM   #289
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Phwoar, that's a proper bit of box.
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Old 04-07-2017, 06:53 AM   #290
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I like to have my box clean and well maintained so its always ready for action.

Last edited by Dieseldave; 19-07-2017 at 05:01 PM.
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Old 19-07-2017, 05:14 PM   #291
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I would like to take this opportunity to welcome all the readers from Build-Threads.Com
That's right bitches, I made the cut


Chapter 32, Get Yer Motor Running

So the time has come to once again make 514 a matching numbers car.
Its been 9 years since its engine was donated to another shell but they are
soon to be reunited.

One key part I was missing was the engine mount, No.2 in the pic.



So I had these parts laser cut



Tacked together



Welded up and powder coated



Original Gearbox mount



And the Engine/box is finally hanging






Last edited by Dieseldave; 19-07-2017 at 05:18 PM.
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Old 19-07-2017, 05:43 PM   #292
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Fuel lines fitted

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

Oil lines piped up

[url=https://flic.kr/p/VB2K8w]

Oil cooler yet to be cleaned up

[url=https://flic.kr/p/VB2K4J]

Original alloy rad was in very good shape



[url=https://flic.kr/p/WE4kU4]

Fitted with rad & 2 fresher looking oil coolers, 1 for engine & 1 for the 'box

[url=https://flic.kr/p/WE4kFi]

I then bought a fiberglass rad cowling from AC Sport

[url=https://flic.kr/p/Vzo7E1]

Took a mould from that

[url=https://flic.kr/p/Wgrac5]



[url=https://flic.kr/p/VzBdJ9]

And got this



Some release agent

[url=https://flic.kr/p/WE4cj8]

Carbon Kevlar

[url=https://flic.kr/p/Vzo6Tm]

And out of the mould & 200g lighter than the fiber glass part

[url=https://flic.kr/p/Wg999s]

[url=https://flic.kr/p/WE4eU8]

Trimmed and fitted






And front panel installed

[url=https://flic.kr/p/WE4kye]

Last edited by Dieseldave; 19-07-2017 at 05:49 PM. Reason: Automerged Doublepost
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Old 19-07-2017, 08:22 PM   #293
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Congrats on the Build Threads feature!! You earned the place with all the graft you put in to all these cars.

Great to see this one starting to really look like a full car again. Cant wait to hear it fire up and belt down a private test track
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Old 20-07-2017, 02:01 AM   #294
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Quote:
Originally Posted by Dieseldave View Post

So the time has come to once again make 514 a matching numbers car.
Its been 9 years since its engine was donated to another shell but they are
soon to be reunited.

When's the rear beam being re-donated from the Maxi?
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Old 20-07-2017, 10:00 AM   #295
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Congrats on the Build Threads feature!! You earned the place with all the graft you put in to all these cars.
Cheers buddy, its been some graft alright

Quote:
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When's the rear beam being re-donated from the Maxi?
Yeaaa, that's not gonna happen
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Old 20-07-2017, 01:49 PM   #296
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Exhaust manifold is original Citroen Sport part

[url=https://flic.kr/p/WBSQK5]

Collector before unwrapping and cleaning



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

After

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

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

2-1 section had a ugly lambda blank

[url=https://flic.kr/p/WT214n]

Tidied up a bit better

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

Exhaust system originally had a CAT fitted due to regulations in different countries the car
would have competed in. This CAT was long removed and some rockstar fitted a botched section
of mild steel pipe instead.

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

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

Rear section of pipe, no backbox

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

[url=https://flic.kr/p/WhAj2q]

Some road rash where it passed under the rear beam



So I made up this plate and welded it on

[url=https://flic.kr/p/WTuZ4v]

The rear section of the system had a lot of gravel rash so I polished it up as best as possible
with a straight grinder.

50/50 shot

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

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

All fixed and polished



[url=https://flic.kr/p/Wi5Ho9]

And finally fitted to a nice underside

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

[url=https://flic.kr/p/WTvbdz]
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Old 20-07-2017, 02:17 PM   #297
welshpug
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proper Belgian spec exhaust that! no chance of an MSA logbook
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Old 25-07-2017, 08:18 AM   #298
Dieseldave
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It actually has an MSA logbook believe it or not

Few pics from my other camera

[url=https://flic.kr/p/WPy3RA]

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

[url=https://flic.kr/p/VR8kjc]

[url=https://flic.kr/p/VR8kzn]

[url=https://flic.kr/p/WPy3Zb]

[url=https://flic.kr/p/WSEQH4]

Radiator top mounting brackets were made from alloy

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

[url=https://flic.kr/p/VDnBC8]

Powder coated and fitted with original Citroen Sport part numbers. Also pictured are the 2 remaining
front bumper outer brackets.

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

Lower rad hose bracket

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

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

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

[url=https://flic.kr/p/VRetc4]

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

These PTFE J4 cam cover gaskets work very well on my Maxi with high oil pressure so I got a set for
the Saxo too.

[url=https://flic.kr/p/X24GVb]

Last edited by Dieseldave; 25-07-2017 at 12:37 PM. Reason: Automerged Doublepost
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Old 25-07-2017, 12:25 PM   #299
Dieseldave
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The black car had been fitted with an aluminium expansion tank but I was lucky enough
to find the original in with all the spare parts, although damaged there was a part number
I could work with.

[url=https://flic.kr/p/WSKMq2]

[url=https://flic.kr/p/Wu1tM3]

After some digging it turns out its from a 605 so I called a main Peugeot dealer in Dublin our capital
city, gave the parts guy a part number and explained its a header tank for a 605 only to be told to my amazement "there is no Peugeot 605"
I said, "yes there is, its like a big 405"
Parts guy "Ohh, you mean 406"
Me "No, I mean 605"
Parts guy "There is no such thing as a Peugeot 605"
Me getting a bit pissed at this stage I told him to google it and
I would call back in 10 minutes

The next call went like this,

Hi, I was talking to you earlier about tank for 605.
Parts guy " Yea, we can have that in 3 days"

And here it is.





Starting to come together at last

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

[url=https://flic.kr/p/X5PKUR]

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

Last edited by Dieseldave; 25-07-2017 at 12:30 PM. Reason: Automerged Doublepost
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Old 25-07-2017, 12:31 PM   #300
Wayne D
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Quote:
Originally Posted by Dieseldave View Post


Hi, I was talking to you earlier about tank for 605.
Parts guy " Yea, we can have that in 3 days"
That is the trouble nowadays, these young ones!! lol
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