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Old 30-08-2007, 02:34 PM   #1
J Butler
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J Butler - My track Rallye project

I bought my Rallye complete with 10 point OMP roll cage, 15" Team Dynamic Monza alloys including a spare. It has a 1.6 8v S2 Rallye engine fitted, along with a dodgy powerflow exhaust system. I also got some Cobra bucket seats included in the deal. Unfortunately, the gearbox had a crunch which was increasingly bad.







When I got the car home a coolant hose decided to split which left it stranded for a few days as I had problems sourcing a new hose. I managed to get it sorted in time for French Car Show where I displayed the car on the Rallye Register stand, I sold my track time I had lined up though as I didnt want to risk the car with the gearbox.



On the way home the car began to bog down and eventually stopped idling and cut out on me, I limped home where it has been stranded since. I believe the problem is sensor related.

I intended on changing the gearbox where at the same time I planned on giving it a diagnostics check in hope of solving the problem.

New gearbox with Quaife ATB LSD, thanks to David B...



Lightened and balanced flywheel...



I also ordered Helix Group N ceremetallic clutch plate, and a 1.4 release bearing.

I bought a sunstrip which I recieved from Peugeot Sport france, it couldnt have been much further away from what they described to me via email but I can't be bothered with the hassle of communicating with French people for a refund so I can fit it or sell it on, either way I am undecided currently.

The clutch then arrived and I picked up the release bearing, I was then ready to crack on with changing the box...



We towed the Rallye to a local Nissan garage today where my friend works conviniently and borrowed their ramps for the day. It weirdly fired up first time on and idled fine. With that we cracked on with fitting my new 1.3 gearbox with LSD, aswell as my lightened + balanced fly and paddle clutch.



New flywheel in place



Old and new gearboxes



Old...



and new...



Action shot!



Clutch plate and cover fitted



Finally, the workshop.



Well after all that the car decided not to start! So it was back on with the tow rope, I tried bump starting it and what do you know it started, unfortunately though it cut out in neutral and wasnt idling. The throttle pedal also wasnt doing anything!? It was nice to be able to select 2nd without an almighty crunch though

I have now ordered a new crank position sensor from Peugeot in hope it will solve my problems, I shall be collecting this tomorrow.

Meanwhile over the past two days I have receieved these in the post...

6 point harnesses courtesy of Ben Godney.



Brembo 4 pots



I will need to buy 283mm discs for these. I shall retain the standard master cylinder for the time being, but possibly opt for a larger one in the future depending on how it feels.

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Old 30-08-2007, 04:31 PM   #2
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Anybody who modifies cars is an idiot.



Thought I'd be the first to post!
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Old 30-08-2007, 04:47 PM   #3
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Well youre not wrong!
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Old 06-09-2007, 08:56 PM   #4
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Not much progress really. Ordered the wrong CPS from Peugeot about 3 times now Bought some parts tonigh though, which are just adding to the pile in my room! All thanks to Graham (Stinaris).

Gasflowed S1 inlet







PTFE gasket



K&N



30mm Eibachs



Still waiting on my B8 dampers.
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Old 04-10-2007, 05:47 PM   #5
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Woo!

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Old 04-10-2007, 06:42 PM   #6
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how does the gearbox go now with the quaife diff as i was thinking of doing the same
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Old 04-10-2007, 07:27 PM   #7
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I got my B8 Dampers through yesterday from Kam Racing

You gone for the Eibach Pros then? I had them but sold them for the sportlines. The Pros were way to soft, I like them on the road but personaly prefered the sportlines.
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Old 05-10-2007, 01:10 PM   #8
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Kenich I have the pro kit 30mm springs which are not yet fitted, im considering buying GMC ones though for the same reason.
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Old 05-10-2007, 04:53 PM   #9
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Oh yeah the S1 Eibach springs. What springs do GMC use them?
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Old 05-10-2007, 07:34 PM   #10
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Errrr, I forget now. Doh!

Just been for the drive for the first time in aaaages, wow the LSD is good. It makes a thud when the power goes into the other wheel which is kind of scary.
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Old 13-10-2007, 10:40 PM   #11
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More crap to throw onto the pile of 'stuff to be fitted' lol. My group A engine mounts, solid as you like.

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Old 21-10-2007, 12:51 AM   #12
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Been to the scrapyard today, forgot what I even went for but left with a few bits including a standard gearknob. Unfortunately though it seems some tit has sheered the top half off the stick so il be back again for one of those!



Fitting new door cards the other week aswell but never got a pic, only standard ones but safer and better looking that nothing.



And just for good measure...

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Old 04-02-2008, 07:15 PM   #13
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How's the track weapon going?

Hopefully going to get myself something soon. Probably going the K-Series route in a Metro with VVC. Funnily enough the Metro uses the same gearbox as the Peugeot.

Budget is slightly smaller this time, about 10x smaller. :-(
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Old 26-02-2008, 04:03 PM   #14
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Hey Graham, long time no speak. I havent updated the blog in ages since I got so bored in recording everytime something went wrong lol. Since I last updated the box broke again, a selector snapped and it had to be rebuilt, a week later the clutch cable went but thats since been done and its due to go to Tweeqd automotive soonish to get various bits fitted and generally prepare it for the track. Proposed maiden outing is at combe on April 19th at the performance action day. Took some new pics last night il get them up soonish. Metro sounds like a great idea, ive heard good things about them as track cars Look forward to seeing you soon.
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Old 02-03-2008, 12:18 PM   #15
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Not sure i've made the right decision, but hey.

The engines are absolutely brilliant, 16v 1397cc with 103 bhp as standard with really shitty breathing is very impressive. The best bit is the weight, 68 kg all in.

Just got myself a Rover 25 BRM gearbox with LSD. Gareth and Matt should be pleased. They hate Peugeot gearboxes.

Might be worth considering for yourself, as it's an improved design from the MA. Basically 2nd gear doesn't give up between 70,000-80,000 miles like the MA's do.

Car itself is a peice of crap, rust has already started. But I'll be trading up to a ZR next season so I can put the VVC head on the 1.4 block. Will probably need to machine the liners a bit and possibly upgrade the pistons to make up for the slight loss in compression ratio from the liners.
Should give me an easy 140 bhp, although they are a lot harder to tune.

Should be at Lydden on 29th March assuming I can get some insurance.
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Old 02-03-2008, 01:15 PM   #16
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I was never under the impression the gearboxes fit! I did consider a 200 BRM for a very long time before I bought a Rallye. They are great track cars in themselves. I don't know what t he difference between a Rover standard issue LSD and a Quaife item is, as I love my atb, and wouldnt like to degrade! The ratios of the S1 are what make it aswell in my opinion. I too hate the gearboxes and im not even the one that works on them, just keep on breaking! My gears are getting increasing stiff and im worried it might have to come out again.
Track cars arent meant to be mint, as long as its not structural hey! One thing I will be jealous of is the roar of the VVC! I might pop along on the 29th. I bought a digital SLR with a massive lens not long ago and need to make the most of it.
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Old 08-03-2008, 04:24 PM   #17
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this car is in safe hands
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Old 25-03-2008, 03:20 PM   #18
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283mm brake disks and new pads bought.

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Old 25-03-2008, 04:46 PM   #19
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lookin good... i think it needs stripes tho
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Old 31-03-2008, 12:52 PM   #20
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Quote:
Originally Posted by J Butler View Post
I was never under the impression the gearboxes fit! I did consider a 200 BRM for a very long time before I bought a Rallye. They are great track cars in themselves. I don't know what t he difference between a Rover standard issue LSD and a Quaife item is, as I love my atb, and wouldnt like to degrade! The ratios of the S1 are what make it aswell in my opinion. I too hate the gearboxes and im not even the one that works on them, just keep on breaking! My gears are getting increasing stiff and im worried it might have to come out again.
Track cars arent meant to be mint, as long as its not structural hey! One thing I will be jealous of is the roar of the VVC! I might pop along on the 29th. I bought a digital SLR with a massive lens not long ago and need to make the most of it.
The bellhousing to connect to the engine is likely to be different but the rest looks identical.
Even the lash on 5th gear at the end.

Got an MA with Quaife LSD as someone pointed out I can't fit the PG1 as I must retain the same gearbox housing ....... and it's different.
Rover stuff is sooooo cheap. £110 for the diff and gearbox.

When are you coming out to play.
No point putting all this track specific stuff on your car if it's not going on track.

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Old 31-03-2008, 02:10 PM   #21
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April 19th! Castle combe, got two track sessions booked.
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Old 31-03-2008, 03:13 PM   #22
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Car is looking good. Very nice spec indeed Keep up the good work
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Old 01-04-2008, 07:39 PM   #23
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Quote:
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April 19th! Castle combe, got two track sessions booked.
better pull my finger out
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Old 02-04-2008, 09:11 PM   #24
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Lol! - Nervous laughter of course. I admit I probably could have got the brakes to you sooner but fingers crossed you recieved them today and can get finished with it.
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Old 05-04-2008, 06:10 PM   #25
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it will be fine mate lol

but these bloody S1's seem to be muliplying
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Old 12-04-2008, 08:07 PM   #26
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Car is now ready to collect. Cant wait. Towing hook from an S2 didnt fit so I need to sort that ASAP. Also got Supersprint exhaust system in the post I need to fit. fingers crossed it will arrive on time. Piiiiics...









Cheers Martin for the pics.
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Old 15-04-2008, 08:16 PM   #27
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Picked her up yesterday, big thanks to Martin at Tweeqd for all the work and even picking me up from the station when I couldnt get a lift down! Few pics from today, engine mounts all fitted now - what a mission! Got a quick snap of the brakes. No pics on all fours but it looks so much better now its 30mm down, alot more aggressive. Ive yet to put it through its paces though. Also fitted a new gearknob. The exhaust is on its last legs though and is next on the list, just waiting on kam racing to deliver my new supersprint





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Old 19-04-2008, 03:37 PM   #28
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seen this car at combe earlier, fair doos she looks a bute! i missed it going round the track tho
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Old 19-04-2008, 06:18 PM   #29
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Had two sessions today. Hopefully there will be lots of pics online soon. Cheers mate.
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Old 19-04-2008, 06:25 PM   #30
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How did it go mate?
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Old 19-04-2008, 09:36 PM   #31
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It must be a miracle, I made both sessions without problems and made it home. All my levels are fine and no weird noises on the car so I can only assume its been a problem free trip. The weather wasnt all that great and the back end was very happy. I had two spins, one in each session lol. The proffesional photographer got two great pics of me sliding my way round the final corner that I would love to get my hands on. Im hoping now to get track time at lydden at the BHP performance show on May 5th, assuming nothing goes wrong before then.

I should also mentioned that prior to combe I bought a subframe and got the drivers bucket seat fitted and got a supersprint exhaust system on the car. It was all very last minute, the car sounds great now though, really like the exhaust overall.
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Old 19-04-2008, 11:07 PM   #32
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glad it went well james, i recon the back coming out will be to do with the front brakes a too good compared to the rears and the fact there is no weight in the back
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Old 20-04-2008, 12:19 AM   #33
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Yeah definately, kept locking up in the wet aswell. Martin I text you after my first session, did you get it? Brake bias might have to be next.
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Old 20-04-2008, 08:22 AM   #34
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I got a pic of that wheel barrow handle popping out the back of your bumper lol





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Old 20-04-2008, 12:18 PM   #35
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lol, looks the nuts, if a little long...
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Old 20-04-2008, 02:45 PM   #36
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Nothing an angle grinder wont fix! Car look's great! Good work getting it sorted for Combe, I saw all your frantic posts trying to get bits lol.
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Old 20-04-2008, 03:23 PM   #37
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Lol! Cheers mate. Yeah I was flat out last week trying to get it sorted. The subframe and exhaust only arrived on friday, I fitted them in the rain before driving to combe the night before. Had problems getting them on but got round them and made it in time which was very rewarding! Can't wait to get back on the track in it now.
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Old 20-04-2008, 06:58 PM   #38
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bigger master cyl will help give a better feel to the pedal and prob stop it locking up so much
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Old 22-04-2008, 09:03 PM   #39
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Just a few of my favourite pics from Saturday...















Booked track time at the BHP Performance show at Lydden on May 5th, just got to sort a few niggles on the car. Thinking about getting the rear lowered some more. As it stands its approx 30-40mm higher than the front which proved costly on the track. Was great fun though
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Old 22-04-2008, 10:13 PM   #40
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that one is awesome fair doos
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Old 07-05-2008, 05:37 PM   #41
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Pics from Lydden on Monday. I had so much fun, its a great little circuit. The car handled so much better in dry than at combe. Ive had alot of positive feedback about the car and my driving which has given me a great confidence boost and given me the encouragement to get on more track days in the future

































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Old 07-05-2008, 06:12 PM   #42
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that landrover looks a handful.. not very oftern u get to see them along with a rallye and what looks to be a drift car! haha legend!
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Old 11-05-2008, 08:38 AM   #43
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Quote:
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glad it went well james, i recon the back coming out will be to do with the front brakes a too good compared to the rears and the fact there is no weight in the back
Do what!?!?!
Do what!?!?!

Please don't bias the brakes any more to the rear that will only exacerbate it.

Just don't brake while turning and don't lift off.

BTW you should be taking Paddock Hill Bend at 80mph at Lydden.

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Old 11-05-2008, 05:38 PM   #44
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I was probably in that region Graham, wasnt checking the speedo though if im honest. Im seriously contemplating sprinting in the car now.
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Old 12-05-2008, 09:51 AM   #45
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The only problem you will have is with the engine.

You just need to find an S1 106 that has a cast iron engine that is basically the same as the 1.6 with just different internals. That way you could get into the Mod Prod class, otherwise it's the Sports Libre class.

BTW what's the pea shooter exhaust you've got?
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Old 12-05-2008, 09:55 AM   #46
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Whats the difference between the classes? Im considering buying an original 1.3 and rebuilding it with 1.4 internals, with a higher cam, tbs and standalone. What would you suggest mate? I could do with chatting to you properly really.

Its a supersprint exhaust, do you like it? I love it personally.
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Old 12-05-2008, 10:17 AM   #47
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I'll be in the Scottish road classes with a 16v S1. Regs change next year so will be in mod prod A2! Best thing to do is go to a sprint and talk to the existing competitors, you'll get a lot more helpful advise as oppsed to trying to decypher the MSA blue book!
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Old 13-05-2008, 01:50 PM   #48
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Quote:
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Whats the difference between the classes? Im considering buying an original 1.3 and rebuilding it with 1.4 internals, with a higher cam, tbs and standalone. What would you suggest mate? I could do with chatting to you properly really.

Its a supersprint exhaust, do you like it? I love it personally.
I like it too, simple design which I good.

Are you to run 2 cars.

Personally after some experience doing this, I would buy a 106 XSi and modify that.
Don't bother wasting your money on the rallye, I don't believe it gives you any advantage over a XSi.

Changing the internals - Well you could go the same route as me and do all the same stuff as on the www.ppp-106.co.uk site. But only if you've got about 12K to spare.

All depends how far you want to go and how much you've got to spend.

I personally wouldn't touch a French car again but that's just me.

Let me know if you need anything, I have a 1400 block, crank, rods, head gasket (new) , pistons. All bargain price.

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I'll be in the Scottish road classes with a 16v S1. Regs change next year so will be in mod prod A2! Best thing to do is go to a sprint and talk to the existing competitors, you'll get a lot more helpful advise as oppsed to trying to decypher the MSA blue book!
Rules are different in South East.

You aren't allowed motorcycle helmets here, but you are in south-west.
The classes here don't match with the British Sprint Championship either, which is annoying.

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Old 13-05-2008, 04:52 PM   #49
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some cool track photos there!

love the pic with the TVR behind you
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Old 13-05-2008, 05:58 PM   #50
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Why do you think an XSI would give me any advantage over the rallye as it stands. I mean its already at least half way there. Would be alot of effort to change it over. Ive already spent the initial extra on the rallye itself. Ive already got an approved helmet, not a prob. How far do you think id need to go with a 1.3 to be competitive?
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