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Old 23-04-2012, 01:00 PM   #1
Neb
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Indigo S2 Rallye & S1 Rallye (Road Rally)

So following on from the still born XSI Enduro rally car build i was going to do last year i had a hankering for another Pug, this time without any grot. We recently did a 16v conversion on another Rallye which i'm really impressed with so this maybe an option for the future.

It popped up last week on here, for a decent price, with only 47k miles on it. It's got literately not rot whatsoever, other than a couple of spots in the boot which i'll sort out. I've got to change the reg plate as it still belongs to the previous owner & the V5 has not come through yet.

The inside is absolutely mint, albeit the cig lighter doesn't work and the drivers seat bolster has collapsed. The suspension is supple with no bangs, creaks etc and the turn in is spot on.

Not sure what I'm going to do with it yet, probably restore it back to a good standard and use it for autotest's & club events over the summer as it's too nice to build a rally car out of.

List of Jobs:
Good service
Good polish
Drivers door lock
Maybe replace both doors, both have a car parking dents
Get some steels - maybe
Bit of lacquer peel under o/s/r quarter-light
Repair drivers seat bolster
Fit my stereo
Repair drivers window
Fit new decals
Sort windscreen washer pumps

The kids & the wife approve thus far, having taken them out in it yesterday, we managed to get some air over the local "yump" which made the kids giggle.

Personally i had forgotten how much fun these are to drive, it pulls really well to all the way to the redline. It's more drivable than the S1 we had with the added torque from the 1600.

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Last edited by Neb; 02-10-2012 at 12:45 PM.
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Old 24-04-2012, 12:42 PM   #2
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Got the window, door lock opening/locking again along with the stereo fitted but an investigation into the washer pumps not working has left me a bit stumped. Fuses look ok, so could be the pump itself....

Ordered the new plates and oils & filters from Opie a bit later in the day hopefully.

Had some fun in the damp conditions last night, these things love to be driven sideways.

Going to do the Maidstone Mid Kent MC Autotest series in it (starting next Wednesday) so will try and get the handbrake adjusted to a couple of clicks an insert a pin in it so it works as a fly off.

Happy Days..... so far......!
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Old 24-04-2012, 01:05 PM   #3
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Looks like a nice one.

Any plans for wheel change and stickers? Looks wrong with silver wheels and no decals.
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Old 24-04-2012, 04:48 PM   #4
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Thanks Harv. Paid enough for it, but the mileage is genuine.

I agree, will order the decals this week and undecided what to do about the wheels. They have a set of A539's on them at the moment in decent nick so will probably stay on it for the time being.
I have some 13" Minilites which are group 4 fitting which i might try.Will probably look a little weird though.
Going to have a scan around the interweb & see what people have put on Indigo S2's to see what I like best.
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Old 24-04-2012, 11:52 PM   #5
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The washer water pumps are not the best, but are cheap enough to replace. I suspect it will be seized. I did manage to get one going again, taking it apart and cleaning it, but it didn't last long, so it was just putting off the inevitable.
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Old 25-04-2012, 08:11 AM   #6
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In this pretty poxy weather darn sarf i could use them at the moment! I'll do a bit more investigation tonight & check it's got a power supply.

Had another good run in it last night, in the rain, had a bit of a moment coming down into a 90 left where the back end had a wiggle but caught it easy enough. Great fun..... Need to adjust the handbrake, it's like a boat tiller currently.
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Old 25-04-2012, 12:12 PM   #7
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Love it!
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Old 26-04-2012, 12:24 PM   #8
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Cheers Gus.

Washer pump has a whacking great split in it so that's solved that one....

Tided up some bits under the bonnet last night, removed about a ton of wiring from inside the car from a previous amp installation, found the aftermarket imobilser ECU and actually attached it to something stable. Not found any cash in the car yet though....

Interestingly it has had twin fans installed at some point with one of them not wired in which is a bonus as i can easily have a switch inside the car for when it's abused. Looks like the rad may need replacing at some point (bit scruffy in places with a bit of green filth), it's not currently leaking so i'll leave it alone for a while. I'll probably replace the thermostat at the same time.

Need to spend a bit of time with the wench tonight but might do a bit more over the weekend....

Oh and my new "Dawson Motorsport" plates turned up..... i must be getting old, i think they are great!!!!

Thanks for your guidance on the other post Harv, dunno what I'm going to do about the 'box oil yet.
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Old 03-05-2012, 12:41 PM   #9
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So..... with all this rain the autotest had been called off. I was hoping to get out play this week too. Poxy British weather.

Still it's given me the opportunity to do quite a bit on the car in the garage.

Full Service inc box oil, thermostat, tappets, Painted the rocker cover while it was off along with the ecu plate (black) & surprisingly the exhaust manifold cover came off without breaking the 3 bolts that hold it on, which has been sprayed with some zinc paint so is now silver and shouldn't rot, I might change it to satin black..... New washer pump installed along with the locks.

Got my "other" fan to wire in, although i have had it working i need to find a suitable grommet in the engine bay for the wiring to pass through into the cabin, which has proved to be a bit of a bitch so far.

On the lookout for some new rims at the moment, i must admit to liking the Speedline Chronos which Scott has offered, so that could be the next thing on the list, and then keep the TSW's & A539's for Gymkhanas, autosolos etc. I've got some 13's with Dunlop Gravel tyres for the winter and a couple of Xsi rims left over too.

Weekend coming, make some arch guards & probably time to wash & polish it. I'll try and get some pictures up too.

I'm going to have a go at making my own decals up, i have some of the technology, and following taking some pictures of the S2 we converted to 16v on Sunday I'm relatively confident I can do a semi decent job of it.....
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Old 25-05-2012, 12:59 PM   #10
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The old man & I went out and had a play the other night at the MMKMC Grass Autotest at Headcorn.
I came 23rd o/a out of 40 (5th in class B) and beat the old boy.
Dropped 20 seconds nicking posts with the front bumper which would have got me a mug and really struggled with front end grip and a shite handbrake. I haddn't dropped the pressures at all and was running the A539's.
Next time I'm going to "cheat" & run some Colway Road Plus's which we have left over on the 13" rims.

Just put my entry in for the Chelmsford MC Gymkahna at Debden which was a good craic last year, bit of gravel mixed with sections of quick tarmac, the Rallye should be in it element.

Decals are on, given the old girl a good polish and just had some steels shot blasted to replace the TSW shite.

The slight miss has gone and following the autotest the other night it feels a lot more lively, now it's had a good clear out.

Fun times.....
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Old 03-07-2012, 01:02 PM   #11
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So.... 2nd time out competitively in the Puglet and the old girl didn't disappoint.
A mate & I (Lee Bez) went up to RAF Woodbridge this weekend and did the CMC JJJ Gymkhana. We finished 5th o/a & 21st (me 21st having got a maximum on a test). Lee set a fastest time & both of us were generally in the top 5 for most tests. Bearing in mind it's a completely standard car (other than a chavvy induction kit) we were really pleased with the result. Even got a trophy!

Just waiting for some photo's to come through and i'll stick them up. Got a bit of air on one of them.

Car was faultless other than the rear being over braked causing a couple of tank slappers here & there, really impressed by how it got the power down though. We reduced the pressures over the day which helped alot. Obviously a diff would have made it even better but on some worn T1-r's it was really hooking up out of corners.

Lots of 2nd gear stuff, only pulling 4th once or twice. Where as previously we'd be using 1st out of the tighter corners 2nd seemed to pull well from low down (2000rpm ish) to the redline.
Handbrake was shite, unless we really gave it some abuse and unstuck the rear end under braking.

Next up - 7oaks MC Autosolo at North Weald with the missus, looking for a top ten at the very least.

Been asking questions about 16v'ing it but not sure now..... Quite like it as it is!
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Old 11-07-2012, 12:48 PM   #12
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Another weekend, another event. This time with a better result. 5th overall & 2nd in class. The missus was 28th overall, and we both had a great day out. Shame the weather was shite. Another trophy too. Beat a Boxster S & a CTR in my class so pretty pleased all round.

Had a couple of issues, one of the ignition leads went down just before lunch causing an intermittent misfire which i managed to sort with my spare leads (after we found the twat in question), and a sudden lack of all power in the middle of one test. I think I knocked the key as it fired back up straight away, but cost me 10 or so seconds, otherwise car was perfect again.
Ran A539's which at lowish (24ish) pressures worked fine so long as the back end was used to help the front turn in and A509's on the back. Still got this issue of it locking up the rear under braking, but starting to get used to it (quite fun), caught the missus out a couple of times but she did well controlling it.

Pictures came through from the JJJ, I'll post a few in a bit.

Still in a quandry as to what to do about the 16v J4 lump..... waiting for some bits to turn up to allow work to start, not sure still. I'm liking the <100bhp 8v and it's revvy "kick my ass you b@stard" nature.






Last edited by Neb; 11-07-2012 at 01:06 PM.
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Old 01-08-2012, 01:03 PM   #13
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Not been a massive amount to update recently, but a few bits and bobs done.

New skinny mirrors - to stop the twats in thier Q8's through the lanes knocking the originals off.
Arch guards fitted

16v J4 has gone off to my buddy Ian to be built, we have come up with a hopeful figure of 150bhp, with a nice usable torque curve for everyday use.
I got the Cup Car cams, and bought a ported & polished throttle body (not sure if it'll make a difference - i'm not convinced) along with the Raceland Induction set-up for decent money so the top end parts are complete. We are going to run standard sized valves but he's going to skim the head & open up the ports a bit.

Still looking for a few bits (see wanted section) including a Pugsport, Manifold & sump.

Still not sure what i'm going to do about management yet.... a Dastek piggy back came up for decent money last week but struggling to find someone local to map it.
I think i'm going to go with the standard ECU for running in and then have a look at after market later on. I'll probably have a chat with chip wizards to see if the have a map they can install on it for Cup Cars with the upper rev limit and go from there.

Was out again last weekend with the Missus on the Maidstone Mid Kent MC Summer slalom, i won't go into results, suffice to say it wasn't a very good one (for either of us), but set a few fastest times on the tarmac tests and got close to the top boys on the grass. Was a good craic and the sun shone all day so what more can you ask for - a decent result maybe....

I get alot of our fellow competitors remarking how quick this little blue pug is off the line, dunno if it's me or the car, but I know 60 comes up quick, it goes round corners sideways pretty well too. I've got used to just slipping the clutch a tad to quell the tyres spinning up, launching at about 2500rpm and it just pulls to the redline. Little bugger.
Handbrake is still shite though unless i pull it hard enough which means it's basically in-line with the seat back. Disc rear ends are crap. Going to take a look before i do my next event to see if a couple of spacers between caliper & cable might sort it.

Old girl is up to 48k miles now, still going nicely, but a session with the dentmaster is due soon, fricking car parks and autotest poles.
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Old 01-08-2012, 05:34 PM   #14
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What pads are you running in the rear calipers?
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Old 01-08-2012, 06:01 PM   #15
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nice blog mate, be good to see it in the flesh in the coming weeks!
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Old 02-08-2012, 08:24 AM   #16
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Cris - Just standard pads, probably due to be replaced, which is probably half the issue, the amount I've been yanking on the tiller hasn't helped either.

Cheers Big J, will be good to meet up soon. The old girl gets used like the French intended.
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Old 03-08-2012, 03:06 PM   #17
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Just come across this now, what a fun and sorted standard car it is too! Had a great time as always with Ben on that Gymkhana. Also a huge thanks to Ben, alround nice guy, for helping me with my Rally preparations next weekend.
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Old 22-08-2012, 01:07 PM   #18
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Been a quiet few weeks on my Blue Pug, with all the other works going on and getting the Escort ready for Brands. The old girl has just ticked over 49k.

Regarding the puglet it has had a pugsport fitted now, following buying Ian E's (his is a nice little motor - we met in a Mcdonalds in Uxbridge very pikey...!), it's a 3" one although i was after a 2" but beggers can't be choosers.

It sounds ok, quite a low bass'y sound until it gets to 4.5k then all hell breaks loose. It's not to over the top (got an additional silencer in roughly the position of the CAT) so perfect for the family.

I also replaced the tired rear shocks for a pair of B4's at the same time. I had noticed the brake compensator bolt was a bit loose on the beam - not sure if this has been my issue with the rears locking up....
The front shockers, ARB drop links, upper strut bearings & probably bottom arms will be replaced soon too, probably when the new 16v lump goes in.

16v build is all coming together, Spoke to Ian Mep (who's building the engine) the other week and 2 of the rods in the freeby J4 block were bent, probably from being hydraulic'ed at some point but my bud in Canterbury WallE helped me out with another set of rods and pistons so back on course again.

Bought the Dastek, it was so cheap i couldn't turn it down and found a mapper round the corner from the Meppster who will do the job on it.

Still aiming for 145 to 150bhp, we'll see....

Lee Bez's Red S1 Rally car - Was brought to Dawson Motorsport to have some well needed TLC before the Bullnose, and now sports a pair of DM strengthened top mount plates, and all new front suspension. He has used the B4's that i had bought for the front of my car for the Bullnose to see how he gets on with them. They have to be better than what came of it, one was a GAZ (with the leg used for the damper oil) and the other one was a standard Peugeot shock - in any case both were, to put it bluntly, pretty fucked. New bottom arms - with a strengthener in the cabin, new drop mounts, group n top mounts (trophy 380's) and a various splattering of Nylocs dotted around to keep everything in place.

The Escort - Well, Friday night it was a bare shell. Sunday at 2pm we took it up the road for a spank. She feels good, i forget how much i love this car. RWD with a "proper diff" it's like the best night of your life (with a woman) without the bullshit you have to spout afterwards to her for it happen again! I luuurrrrvvveee going sideways (on private roads - obviously).
We have a had a couple of teething issues, it was never going to be perfect, the brakes need bedding in, the tracking & camber are that of a three wheeler (turns out one of the steering arms is bent after the LtoCT) plus a few other things.
I bought a job lot from Mankee of 13" trackday tyres which we are going to use for Brands which is this coming Bank Holiday Monday, i suppose i should stop typing this bollocks and get on with getting it ready....

New S1 Rallye - hopefully going to be picking up another Rallye this week from 7oaks and am looking to building it into a Endurance rally car to go out and play next season. Miss the gravel. More news on this when i have actually bought it!

Most stick some pictures up of the S2 it in it's current state as soon as i get the chance.
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Old 29-08-2012, 11:03 PM   #19
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Another rallye graces chez Dawson tonight. She's slightly smaller, lighter and red. Looking forward to getting under the skin of her tomorrow to see what she needs.

Really fancy some gravel but it's a pretty nice shell (from what I have seen so far). I may just restore it with rallye prices being what they are. Paints a bit flat, engine is wrong, box is crunchy, knocks and bangs left right and centre. We'll see.

Brands hatch stages in the escort went well. 45th o/a 6th in class (out of 85 starters). Not bad for a 100 bhp, tonne+, well travelled gravel car. Couldn't keep up with most, but made up for it in the corners. Mankees tyres did well too! Got a couple of videos and loads of photos. Great day out with friends and family.

Will try and get photo's up tomorrow and a bit more about the new rallye.
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Old 30-08-2012, 10:27 AM   #20
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From Brands - on the Rally School section of Stage 7.

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Old 30-08-2012, 10:32 AM   #21
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Great photo! Can't beat a bit of arse out. Glad that the tyres did you proud. I may have some more A048s in the near future if you have managed to muller all the ones you picked up from me a few months back.
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Old 31-08-2012, 08:19 AM   #22
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You know I'll take those 48's Mr C. Surprisingly the 205 profile ones lasted well, they were the best of the 32r softs. Are the Avons even better? I haven't tried them yet.
Need more power now...... So the 40's are going to go on it, currently it has a single downdraft.
Andy the tog was standing on that corner too so we should get an even better photo in the next few days.

We are looking at doing the tempest next in November. Gravel, love it.

106 related - started looking at the new S1 yesterday. It'll be an enduro road rally car. Watch this space.....
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Old 02-10-2012, 12:44 PM   #23
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Indigo S2 & S1 Rallye (Road Rally)

So, as some of you may of seen in another topic I have bought another 106 Rallye to go and play on enduro's and i'd like to do a few "proper" road rallies and thought I might document the build.

The plan is to get out and do next season, starting with the Xpart in Jan/Feb.

Also part of the plan is to complete the build for less than 1000 using whatever kit we have left over from various builds, and 2nd hand parts from eBay, lax bowels style forums and here. I'm not going to include in the build pricing any fuel used to collect parts.

I'm hoping the car will be competitive and at the same time showing it doesn't have to break the bank.

The car - a N reg Peugeot 106 in a shade of cherry red. I found the car on the here, for 250 which had been stripped to be used as a track day car. The shell is clean and straight in the right places, but has been resprayed by a blind man at some point in the past. I haven't factored in another respray so it will be built as it is and I'll get the kids out with the T-cut.....

It currently has a 1600 xsi/S2 Rallye engine in it but does have the correct gear box which is a bonus as these are like rocking horse droppings. It has the S1 Rallye ecu, inlet manifold, exhaust manifold & wiring loom so it should be a case of just swapping the lumps over to the correct CC..... Best laid plans and all that....

On the shopping list:
Cage
Fire extinguisher
Trip
Engine (will probably require a cursory check over)
A cheap interior & carpet.
Various consumables
Gearbox rebuild by the Mepster, currently crunchy!
Sump & tank guards - will fabricate my own.
Suspension
Driveshafts

I already have some seats & harnesses so I have saved a fair amount there.

I have spent a few days/nights on the car, got the first few bits sorted, indicators now work, cleaned up inside, replaced the ignition barrel, got the doors built up including a new drivers check strap and re-fitted the battery & terminals as they were hanging off, nice. The sun roof has been plated, done a few bits of welding, striped all the unneeded wiring, removed the sound deadning, but work has been a bit busy so not had much time on it in the last week or so.

Next on the list to spend a bit of time underneath to cover the brake lines, and generally sort out any dodgy bits, then it'll have to be the cage.

I have got a few ideas with the build, of which i'll take a load of photos etc for.

I'm excited, I'm not sure Mrs. Neb is yet!

If anyone here can help out with parts it would be appreciated.

Couple of photos when i bought it, will put some more up as i go along.





The S2 is going well, just replaced the Rear Shocks which felt a little tired, the fronts will be done soon and she's just ticked over 50K. The 16v lump is taking time, but i'm not to worried, got plenty to get on with with the S1. I must give the S2 a clean and get some photo's up. I seem to type alot, but don't add pictures..... I have slapped my own wrist......

Next event is the Maidstone Mid Kent MC Autosolo.

I've just become a Instructor at Brands Hatch Rally School, it's good fun and interesting to see the different levels of ability from people. One bloke on Sunday was really quick and i had to show off a little to put him right. The cars are 206 Cup Cars, and are quite quick, cheap tyres though!

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Old 02-10-2012, 01:10 PM   #24
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Hi Ben, I promised you some photos of the suspension I'll try and sort them out this week!
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Old 02-10-2012, 02:15 PM   #25
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Cheers Matt, it'd be great if i could have some measurements too!!!!!
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Old 02-10-2012, 04:12 PM   #26
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lol I'll see what I can do!
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Old 15-10-2012, 12:45 PM   #27
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From yesterdays Autosolo at Sittingbourne FC.

Good fun but balls'ed the 2nd test up and got a maximum. Got the fastest time O/A on the last test though.

Looks slow on video now! I preferred it when it was wet, to much grip on the back in the dry.

Car sounds ok with 3" PS on it & filter, other than that it's standard. FD a bit short for these things so hit the limiter in first quite a bit.

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Old 04-01-2013, 03:58 PM   #28
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The S2 just about to tick over onto 51k, hasn't seen much action over the last few months as it's older sister has taken pride of place - see here.... http://www.106rallyeforum.com/forum2...ad.php?t=81935

The 3" pugsport is gone, back to the original and i haven't noticed a difference in performance. Currently she is sitting on some winter tyres on some cheap 206 rims.

Everything running well, touch wood, few bits i need to sort but will happen in the next few months along with a service.

Who said French motoring had to cost shit loads of money & time!

Considering selling it soon, depending on the Rally Wallye, but no idea what it's worth and I'm still enjoying roundabouts.....
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Old 31-03-2013, 11:52 AM   #29
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Been a while since the S2 got any love so i finished work early on Thursday and treated the old girl to a wash then went up the road to rekindle our love. She has now just passed 52k.

As always she performs faultlessly, with smooth power delivery from 2k all the way to the redline with a wonderful mechanical shift to pull the next cog which always seems to drop back in the sweet spot on the torque band and pulls again.

Turn in is epic, with lift off over steer on tap when I feel like cracking the whip.
Brakes never seem to fade with a semi long pedal now but there is plenty of feel to them, although the rears need replacing along with the handbrake cables which caught me out on a long way round triangle.

The roads run here are tight and twisty, pot holed everywhere at the moment but the standard suspension just laps it up, no banging, no tram lining, just arrow sharp.

A bit of "The Pretender" (Foo's) playing in the back ground at just masking the engine until the bark at full tilt just finished the drive off. We even stopped to get a few photos in some of the hop fields.
Heaven..... maybe.

I had missed her, i had considered selling the old bitch but when she treats me so well all of those thoughts of a Scooby fall by the wayside.

So that was part of the good bit. The other good bit is the 16v engine is almost finished and the plan is to get her in in April. I'm hoping for 150bhp following a remap but i'm really after a nice smooth torque curve rather than "big" numbers. As it is going to remain a road car with standard brakes (albeit decent pads) and standard dampers (B4's) i didn't want to go to nuts on chortle bodies or carbs, so most of the work is internal.
The cup car cams are relativity mild, but i've got a ported head, the compression has been up'ed a bit, and it's all about as light as it can get. I've got a couple of add on's like a polished and ported TB (yet to be convinced it will make any difference) cup car induction set up and i'm thinking about a manifold and 2" PS but they will be added later once it has all been run in.
Same with the ECU, i have bought a Unichip, but might see if i can have the ECU remapped for the cup car map, i'm led to believe it was a generic map used on all the cars, so someone should have a copy of it somewhere.
I'm also considering a diff, but we'll see how she copes with the engine first. I have been impressed by the ATB's in the Rally school 206's so i might plump for one of them if i feel the need.

With pricing of these remaining a bit stagnant at the moment i thought F*ck it. I'm keeping the 8v to go with the car when she does eventually get sold for the next owner to decide what they want to do with her.

The bad bits.... well looks like a bit of tin worm has started to set in in the boot, which i'll catch now rather than waiting for her to fall apart, they are really only spots where the previous owner had installed a load of kit in the boot and the screws had penetrated the shell. Nothing an evening of wire brushing won't sort out, it's only surface at the moment.

Some of the paintwork externally looks a bit scabby in places too, the laquer peel under the rear O/S window has got a little worse, the passenger door needs replacing or a bit of filler (dent) and the bumpers could do with the inserts being painted to, i've been quoted for the lot to be done along with some other small dents which will happen during the summer.
The Steels have started to corrode again around the edges so they will be blasted and powder coated this time. I'm going to run some 15's soon though as i'm doing a few motorway miles to Brands Hatch & back and also the choice of tires is far greater (and cheaper).

A couple of photos (taken on the iphone so not great):




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Old 19-05-2013, 03:16 PM   #30
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So.... After finally getting my finger out this weekend the S2 has received it's new heart.

A pretty intensive few weeks of preperation for the conversion, had a shite week at work and thought that I would try and get the job done this weekend.

Tuesday, picked up the engine.
Spec:
J4 rebuilt with new rings, lightened and balanced.
Worked head, cup car cams, built by my bud Ian
4-2-1 stainless manifold & 2" pug sport, ported throttle body, K&N, 8v alternator set-up.
Re-mapped & raised rev limit 7800k ecu.
82 deg stat, new Nissens rad, twin fans.

Friday night, out with old. She was being a bitch, started at about 6pm and was out by 11. She wasn't going to give up her old ticker without a fight. Lost my middle finger knuckle early on. Pain, insulation tape 1 to the S2.

Saturday, 8am start, quick steam clean and knowing I had all day took my time checked and checked again all the fittings before the 16v lump was inserted. 10.30am on the block and tackle ready to go in.

By 12, lump was in, s2 Rallye box on.

An afternoon of fettling saw all components on by 7ish, including new track rod ends and bilstein B4's.

8pm oils, water in car, dropped to the ground and spun over to get the pressure up. 8.15pm coil plug on, fired straight up. I was a bit shocked!
Run for 15mins on idle to pump up the followers, no leaks slightly tappy. 1 all.

Shut down and allowed to cool a bit, re- check levels, no leaks. Fired up again given a little rev. Sweet as a bag on testicles. No tappy, me happy. 2-1. Clean up, home for 11.30pm. Job jobbed.

This morning bonnet back on, slight drip from sump plug seal but levels fine, quick run up the road, no more than 3k revs for 100miles.... Dunno how I'm going to cope!

Really pleased that it went so well, and couldn't of done it without Alex & Alex who came over and gave me a hand for a few hours in separate shifts. Thanks chaps.

Dunno how you do them but dirty, smiley face.
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Old 26-05-2013, 11:46 AM   #31
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Hopefully some pic's from last weeks engine swap!

Friday night... About 5ish.



Friday night 12ish...



Sunday morning.... Sun was out!



I've managed to get about 120 miles on it this week, and although a slight issue with idle when cold seems to be running well. I took the inlet apart again in the week to make sure it was sealed but other than that has been ok.

Wierdly it quite different animal from the 8v, quite linear delivery of power where the 8v needed some aggression to make progress. Not sure if I miss it yet, it's just different.

More work yesterday.... Will upload some pictures.

Right.... Got to hold my hands up here..... I copied another RR members idea. My apologies but it is great one!

Combined bias valve and hydraulic handbrake.



A quick trip to rally design on Friday got me all the line & fittings I needed for about the price it would have cost me for a new compensator from pug.

Of course nothing is ever straight forward and upon removing the glove box and opening the sound deadening around the bulkhead hole with a Stanley knife I nicked the supply fuel line. TWAT. I'm blaming the ball and chain for it as she rang just as i did it.
2 hours later repair effected but felt like a prize prick. At some point I'll replace the line from the tank but its holding pressure with a section of steel pipe jubilee clipped into the plastic line.

Must of the fabrication for the mount was done on Friday night, as was the handbrake bracket so it was a case of plumbing the lot in. In hienz sight, I would have used copper line instead of aero quip but it does look neater with the braided line.

From the front I just popped out the plastic dowel that holds the bulkhead grommet in and replaced it with the connection from the MC and capped the other.

Into the car the line runs under the carpet, out of a small hole and into the bias valve then handbrake and to a 3port tee under the rear seats. It's then run out to either side. N/S goes to the connection which used to come from the compensator (male) and o/s goes directly to the flexy (female).

Started bleeding the system and of course there was a leak from the o/s so replaced the olive and hand another go. All good this time.

Fitted.


Note there is a bolt missing from the bottom of the cylinder, as I had to space the cylinder as it was so effective (much more than I imagined) and wouldn't give me a click on the handbrake. A bit of fettling still required....

Test drive... Much better, no rear end lock ups and subsequent brown trousers, bit of adjustment required to get it spot on but at least I have some control over the rear brakes now.
Handbrake is pucker.



Hole in the handbrake is for a split pin for events. The wife uses the car too and would struggle to work out a proper fly off.

So all good... No leaks yet... Will check through the week though just to make sure.

Hopefully next week some new wheels. I'm doing cartwheels about these. Can't wait to get them. SL434's!

Last edited by Neb; 26-05-2013 at 11:46 AM. Reason: Automerged Doublepost
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Old 26-05-2013, 10:16 PM   #32
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That setup looks familiar
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Old 28-05-2013, 08:33 AM   #33
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It does Cris, and my apologies for pinching your idea, i hope you don't mind.

It works but a bit of fettling required with the handbrake clevis as at the moment I'm only on one click of the mechanism before it locks up the rear wheels as the cylinder is a bit "too" effective!
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Old 10-06-2013, 01:17 PM   #34
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300 miles on from the 16v conversion and touch wood, all seems swell so far. The engine seems to be opening up a bit and although i haven't ventured any further than 4.5k and half throttle yet she pulls well. Couple of bits needed to be looked at are the timing belts is a bit tight and whines a little, and i think there is a very small air leak from the inlet (where it bolts in it's 2 parts). This week it'll come off to be checked out.

I'm starting to wonder if re-mapped ECU's are the way to go, with the distance to go to actually get it mapped properly plus the cost to actually get it mapped it seems like a bit of a false economy. So i've been looking into MEF's DTA S40's in standard ECU cases. Looks like this is the way to do it, whilst keeping it standard looking and future proofing. I'm not sure TB's are on the list of things to do yet, but would be nice to be able to have that option if i feel like it. We'll see.

The bias and HH have been working well, at least now i'm not locking the rears every time I look at the middle pedal, but i do have a slight weep from the connection from the bias valve to the banjo on the handbrake, again to be looked at this week, i'm pretty sure it's just where the olive has not seated 100%. I need to have another go at the clevis and bracket on the handbrake to get a few more clicks but works fine as it is.

Went for it's MOT on Friday and passed first time with no advisory's. I was worried that it would fail on the emissions and cause me a load of ball ache to try and sort it but it was fine once she got really hot.

Put a deposit down on the SL434's but just waiting for some more cash to come through to pay them off, the tyres on the steels were not great for the MOT (some minor cracking) so will get some new T1-R's for them. Can't wait to get them on the car.

But that brings me on to the next issue of the body work.... mufafunkers in various car parks around the county have taken there toll on the tin. I'm considering getting the summer club man events out of the way before getting it smart repaired. I'm going to attack the boot this week to clean up the surface grot that has appeared, shouldn't take to long to sort out, better to catch it now than let it kill the shell.

So 200 miles to go.... then i can give it some beans! Speedo just ticked over 53100k.
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Old 13-07-2013, 01:12 PM   #35
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So speedo now sitting at 53604 and just done my first oil change on the 16v lump.
Mileage on the engine was about 750 miles and i have been slowly bringing the revs up since 500. It was a little dirty, as to be expected but no signs of anything metallic in it.

I haven't been at the redline yet (7800) but in honesty i haven't needed to. The torque is superb above about 3.5krpm and it just pulls i can feel it drop away at about 6800 so can't see the point of going too nuts.
I have put one of the enclosed Peugeot Sport style induction kits on it now which seems to be doing it's job, but not noticed any difference in power. Maybe slightly quieter. Not sure what i'm going to do about the ECU yet, will probably see what she's making on the rollers first.

Got the boot done, wasn't to bad a job, it was only surface grot so didn't take to long (evening). I'm going to give it a coat of underseal i think just to stop anything else appearing over the next couple of years.

The hydraulic handbrake still needs a bit of fettling, with the pivot point i think, i'm struggling to get her to lock up on hot tarmac so might invest in some uprated pads at the back. I can adjust out the rear now and the brakes overall are fantastic, loads of feel and not many brown trouser moments from the back. The 1144's will get a proper roasting tomorrow though.

First event tomorrow at RAF Wethersfield in Essex, one of the CMC Targas, and looking for decent result with my buddy Bez. I think she's got it in her.
Going to run some 15" medium A048's, and maybe the soft R888's but if it is going to steaming hot then the tarmac will eat them.

My SL434's arrived. I'll let them speak for themselves but this being the first set of new wheels i have ever bought i'm very happy. In fact i think i'm in love.....



It sits a bit high now, but i like the way she handles on the standard suspension so may leave as is.
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Old 13-07-2013, 03:45 PM   #36
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Phwoar. Very jealous!
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Old 15-07-2013, 12:39 PM   #37
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Love the wheels Ben and some great progress since I last checked out the blog

I much prefer the 16v lump you dont seem to have to work so hard to get the performance
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Old 15-07-2013, 12:58 PM   #38
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Cheers Rob/Harv.

The 16v was enough this weekend to take a string of fastest times and 3rd overall on the Targa, will do a bit more of a report on it later. We almost beat a S2000, but unfortunately he reeled us in as the tyres started to fall away.

I think i have done a shaft though - i ran R888's and it was F***ing hot so i think the grip levels have overcome the standard O/S one. Not sure yet though, haven't had chance to look yet.
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Old 19-07-2013, 01:30 PM   #39
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Bit of a write up following the Targa Rally At RAF Wethersfield (from another forum - bit more of an explanation under):

Enjoyed that. Felt the heat toward the end though admittedly.

I have to be little disappointed with my result personally, but really buoyed having looked at the test times this morning (Monday).

Lee set 3 fastest and 7 2nd fastest times.
Generally one of us was in the top 5 for each test.
Tomasz (in a Honda S2000) reeled us in toward the end which we thought he would, we had a little buffer over 4th so elected to take the last 3 tests smoothly rather than flat out and loose the result.

Me not so quick! Picked up a couple of maximums, cone faults and a spin as well. Once my first max on test 3 occurred we turned our attention to getting Lee the result.

I loved the middle test of the 3 (per loop). It just flowed and our times showed it. Lots of grip and the "Mepsport" lump just pulled all day long. Thanks Ian - great engine.
The 2nd hand soft R888's helped alot too, once we had got the pressures right the grip was superb on the tarmac/concrete sections.

Drive of the day has to go to Lee. Almost.... faultless. Even he would admit he made a couple of mistakes through the day, and i didn't help either with my navigational skills or lack of....
He's bloody quick ladies and gentlemen and also a great bloke.... if a little mental.

The Pug is in ill health this morning.... on the way home i started getting a knocking noise from the O/S/F which got worse as i got closer to home, i haven't inspected it yet. I hoping it's just a ARB drop link but i fear it's a shaft that has shit itself....


So what is a Targa Rally:
Basically a road rally held held at a single venue, with just special tests.
Some tests range for .5mile to (at RAF Woodbridge) up to 5 or 6miles.
Driver and Navigator.
We are given a A4 road book which gives us a route round a series of cones, all timed and 30mph average speed (bogey time). For those that have done a road rally they will know how difficult it is to actually hold 30mph whilst trying to negotiate all the cones and get the route right!
It is tight and twisty, on tarmac, concrete, broken concrete, gravel and some grassy bits.
It is a cheapish form of clubman motorsport (50 entry) and we got between us about 30miles of tests. You can double drive to.
Usually 50 to 70 entries, some basic cars (us) and some proper rally/road rally cars which meet the regs.

Our weekend went well, few beers and a Chinese on Saturday night and early start on Sunday morning from a local hotel.

Arrived at the venue at 7.30am ish got scrutineered, signed on, checked the pressures & levels and following a drivers briefing first car away at 9.30ish.

First test didn't go well (me driving), tight venue all on mostly tarmac but not used for a while so alot of duct/grit had laid on top of the tarmac which we as first cars (seeded 6th & 106 - Lee) scrubbed for the later runners. Tyres were a little high on pressures (32ish hot) at the end of the test explained a bit of understeer and lack of traction coming out of K's & hairpins. Still set 9th quickest time including a 10sec pen for clouting the cone at the finish (would have been 3rd fastest).

Next test went better, bit more open, pressures down a bit, loads of grip on mostly concrete (some gravel). 4th fastest. I liked this particular test of the loop, suited the car, suited my driving style etc.

Test 3 - start on tarmac but toward the end of the test ended up on broken concrete & gravel - with a bit of grass at the end. I got a wrong route, just couldn't find the cone which was hiding behind a pile of gravel. Bastard. Got a maximum time.

Back to the paddock, handed my time card in then back out for Lee to do his runs. Startlingly quick from the off as he always is. 2nd quickest. The route was known now from doing my runs and he made it work. Bit slower on 2, but 2nd quickest again on test 3.

Again back to paddock and bonnet up to let her cool down. About 20mins restbite, then back out for 4, 5 & 6.

Me not so good but Lee Fastest on 4 & 5 and 2nd fastest on 6. Really starting to kick on now. We were 2nd overall with about 10 seconds to 1st place and about the same behind. We would still have to push, but the car leading was a Spaxo with a diff & a bit more power also on semi slicks driven by a mental Polish chap. We would have taken the result there and then TBH, but long way to go yet!

3rd loop - I started to pull my finger out, a couple of 2nd fastests, but another max on test 9 just about buggered my day. We decided to crack on with Lee and get him the 2nd place. He was going well but the S2000 was pulling us in, only a couple of seconds behind at the end of the loop.

4th loop - We were still pushing, but knew the S2000 (and another crazy Polish chap (nice bloke though) would reel us in so cut our losses and concentrated on using my runs as recce's (but still going well) for it to count on getting Lee's tests spot on. At the end of the loop the S2000 had had us by a second but we wouldn't catch him. We were 3rd overall.

5th and final loop - we checked the tyres in the paddock, and the fronts were basically bald. About .1mm of tread left and in some parts nothing at all (but no de-lamination or cords showing so elected to finish the day on them. We had about 20 seconds on 4th place so could afford to take it easy.
Still managed a 3rd, 2nd & 5th fastest time between us though. We took 3rd by about 10 seconds in the end.

Pretty happy with the result for a basically standard road car - Standard suspension, standard brakes but Mintex 1144's, 16v lump & CC cams - see spec above). The R888's made a difference and was very pleased with them seeing as they were only just legal to start with.

We picked up first in class (experts) and 3rd overall.

Couple of photos (more to come):

Lee hailing a cab! (me driving)


Lee sideways on the last test (check out the lack of rubber!)

On the way back got a terrible knocking from the O/S/F corner.
Where i had thought it was a shaft it turned out to be the collar on the suspension leg that holds the shocker in place had come undone by about 10 turns. Not good.... but better than a shaft. Other than that car is fine and ready for the next event next weekend which is the Maidstone Mid Kent MC Summer Slalom (mixed surface) which i'm doing with the ball and chain (wife). Should be fun!

Might try and get the car on the rollers next week to see what the engine is doing, it felt quick enough but i think a proper ECU is on the cards now, to try and dial out a flat spot before the cams come in.
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Old 19-07-2013, 04:30 PM   #40
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Car looks great in the pictures Ben and a nice write up....Top work
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Old 19-07-2013, 04:44 PM   #41
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Cheer Rob, She's getting abused like Pug intended. Body work looks better from a distance, the car parks have taken their toll over the last year or so thanks to all the other fu(kers that don't know how big their wanky 4x4's are.

Hopefully will get some more photo's over the weekend from the rally tog. Got a good one sideways on the gravel with the new rimage.

Must catch up soon mate.
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Old 19-07-2013, 06:53 PM   #42
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Haha certainly looks like she's getting some abuse.

Definitely mate will have to look in some track day dates/availability at Brands
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Old 21-07-2013, 11:36 AM   #43
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Will do Rob, i have had a chat with the powers that be at Brands and hoping we may get a bit of discount from me working at the rally school. Maybe mid to late August?

A few more pictures from last weekend.


On the Handbrake.


Just liked this shot, cocking a rear.


Love a bit of gravel.


South African.... sideways


2 very knackered R888's and a couple that will go again.
I might see if i can cut them to get a little longer out of them. We did a set of A048's the other week which held up ok, but wouldn't use them on the road.

Last edited by Neb; 21-07-2013 at 11:41 AM.
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Old 21-07-2013, 01:39 PM   #44
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SL434's looking awesome. Brave stuff to use them on a rally car though!
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Old 21-07-2013, 02:10 PM   #45
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Pictures are great...... very sideways!!

Later in August or early september would be better for mate as work is pretty full on at the moment but let me know
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Old 22-07-2013, 12:09 PM   #46
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I was a little worried about them TBH Harv but wanted to get some proper pictures of them on the car. I have not seen any damage on them from the Targa, besides they are proper motorsport rims so are reasonably strong.

"Rally drivers do it sideways"?

Sounds good to me Rob, I'm not working over August but have a few dates in September so will try and arrange something for around then. Hopefully get a few of us along.
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Old 15-10-2013, 12:33 PM   #47
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Been a quiet few months with the Blue one (almost at 55k now) but was getting bored so competed on the MMKMC autosolo at Sittingbourne on Sunday.

The morning went ok but was freezing and tipped down with torrential rain which almost stopped the event. Set a couple of decent times and whilst changing the tests around at lunch the sun came out for a few hours.

The afternoon was better, setting a fastest time on the last test. In all finished 1st in class and 2nd overall, which i'm pleased with.

Couple of small modifications to her over the last few months:
New Atspeed coil kit
New T1-R's (but looking a bit more 2nd hand after the Solo
Replaced the injectors
Service

I had been having issues with an intermittent misfire that seems to have been solved by replacing the injectors and the fuel filter.
The coil kit was cheapish on here and was something i had been meaning to do with an 8v coil but it came as a kit so replaced the lot. Is it any better with the coil kit? Dunno really, it feels quicker again in the midrange to top end but could just be that the injectors are flowing better than the previous set.

Got a few plans for the future, probably involving bodywork. Need to replace the bottom arms too which are starting to knock.

In other news:
Out in the Escort on the Woodbridge stages a few weeks ago and came home 24th overall & 4th in >1600cc class. Not bad for a tank with 118bhp. We couldn't catch the vtec Civics and MR2 on throttle bodies. Great day out, sideways everywhere. Not fastest but fun.
Thanks to Mankee for helping me out with some tyres.



If i get any pictures of the solo i'll stick them up.
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Old 05-12-2013, 02:28 PM   #48
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A busy couple of months with various events meant that the Pug has just been bumming around as my road car (and course car on the Targa).

My intermittent misfire has come back, still reckon it's fuel. So I took it up to BD Engineering this morning and got him to check her out and he hasn't found it. So back to the drawing board on that one.

Good news! He ran it up on the rollers. 163bhp..... 190bhp per ton.
On standard injection.... well pleased with that.

Anyone do RWD conversions on Pug engines?
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Old 05-12-2013, 08:51 PM   #49
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Nice figures, what was the engine spec in the end?
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Old 05-12-2013, 09:54 PM   #50
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I'd done a JP4 engine conversion on a local mates Rallye and he had a box full of old shit left over , a head and a bottom end with a bunch of bent rods. Crank was good though and the head was also in good condition. Looked like it had been hydralic'ed.
So, took it down to my bud in Hastings with a set of cup car cams and we set about building a cheap lump for the Puglet.
I had to find a set of standard rods and pistons, but they weren't silly money.
Ian lightened and balanced everything and worked the head, put it all back together with the cam data (thanks Sandy) and basically here we are. About 2000 miles later. The standard cam covers have a little oil misting around them, but I'm not running a breather bottle.

It has a aftermarket exhaust manifold, 2" pug sport, polished and ported throttle body, orange banded injectors and a K&N and a remapped ecu from ED Ecu, the map is not specific for the engine. I have also recently put a Zetec coil conversion on it. It probably returns 30 to 35 mpg, more on a long run.

It's lumpy on idle, but I like that, feels a bit special... Also turns a few heads which brings out the Nova boyo in me.
It relatively docile in traffic, but once above 3k the cams start to chime in a with my toe to the floor, I do suffer a bit of torque steer, or wheel spin.

I won't go into pricing of the lot, some deals were done here and there with me doing work on people's cars in exchange for cups of coffee and pug bits, but for the kind of events I do its perfect, enough power in a nimble car.

Currently, I'm happy with it, needs a pair of bottom arms, arb bushes & drop links, and some new rear beam bushes, but I'm not going to mess to much with the brakes (247mm & 1144's are fine now I have done the bias valve) so I'm going to bite the bullet and get the bodywork done, which I'm not so happy with. It looks 15 years old and needs the little dents and paint imperfections sorted. Oh and the fuel issue. It's currently on nearly 56k.

New project on the horizon. Kit car. Shame pug didn't produce RWD bell housings....
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