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Old 23-03-2008, 05:49 PM   #1
tommy_a
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Tom Assen - 106 Rallye S2 16v

I had another blog on here but ive not used it since june '06 !! so thought id start fresh !!

Any way here goes !!!

I bought the car back in July '05. It was completely standard apart from the Sparco alloys.
Some pics i took on the drive back home after buying it !!




It current spec:

Engine:-
1.6 8v TU5J2
QEP head
Catcam 4900646
GSXR 1000 bodies on Colin Satchell manifold
16v bottom end inc. valve cut outs on pistons
DTA S40 ecu
ITG filter
Nissen ali rad
Grp A engine mounts

Gearbox:-
Rebuilt S1 Rallye gearbox
OMP unsprung clutch plate
OMP reinforced pressure plate
Compbrake quickshift

Exhaust:-
Peugeot Sport GrpN exhaust
Heat wrapped Supersprint 4-2-1 manifold

Suspension:-
Front:
Struts converted to coilovers
Peugeot Sport Tarmac dampers
300lb 9" springs
Solid alloy topmounts
Powerflex wishbone bushes
Powerflex Anti-roll bar bushes
Rear-
23mm Peugeot Sport torsion bars
25mm Peugeot Sport anti-roll bar
Peugeot Sport France tarmac dampers
Powerflex rear beam bushes

Brakes:-
Front:
206 GTI 180 brake callipers
Mintex 1144 pads
Standard discs
Rear:
Standard callipers, discs and pads

Interior:-
OMP 6 point roll cage
Corbeau Forza sport bucket seats
Ricco Racing 6 Point harnesses
OMP Superquadro steering wheel
Completely stripped rear
Front carpets removed
Bulkhead sound-deadening removed
Odyssey PC545 battery mounted on exhaust tunnel

Exterior:-
Morrette Quad head lamps with inner lights removed
Standard body work
Wheels + tyres:-
15" Sparco Cromodora Wheels
Toyo R888 tyres all round

137 bhp @ wheels


Heres how it looks now:



Ive also got these waiting to go on aswell !!




I have also spent most of the weekend under the car trying to sort out some of the rust it has developed !! as you can see, its looking much better !!

before:




after:








still got to do a little bit on the inner wings in the engine bay before i can rebuild it. im going to be removeing the engine in the summer so i can do the whole engine bay !!! hopefully ill keep this thread up to date this time !!
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Old 23-03-2008, 06:32 PM   #2
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more pics ive found !!

at donnington !! whoops !!






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Old 23-03-2008, 07:20 PM   #3
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Dta s40 Ecu
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Old 23-03-2008, 07:31 PM   #4
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whoops !!
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Old 26-03-2008, 09:08 AM   #5
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Very very smart, I'm loving the single lense removal for the air filter. Get a battery box from a scrappy and make a heat shield for it and you'll be onto a winner!
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Old 19-04-2008, 09:22 PM   #6
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nice looking rallye mate
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Old 21-06-2008, 07:54 PM   #7
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Talking

A week or so ago i had a little trouble with the rallye. my brother took it out for a drive and shortly after he left i got a phone call from him. he said that the car was starting to make funny noises and had cut out!! there was very little petrol in it, so i ashumed it had just run out. when i got there i filled it up and tried to start it. thats when the fun began !!

once started the engine was rattling its tits off !! not a good sign !! i then drove it home, which could have possibly been a mistake !!

once i got it home i started to take it apart to find the problem !! first of all i jacked the car up, drained the oil, and removed the drive shafts as i was thinking the bottom end had gone !!



once id removed the head i found out what was wrong !! spot the odd one out !! lol


on closer inspection i found this:


this piston didnt escape damage either !!



and this is the little piece of metal that caused it all !!


and i still dont have a clue where it came from !!!

i then stripped the head down as it will need a rebuild, and on top of the inlet valve i found these other bits of metal!!


to say im pissed off is an understatement !! i really can not be doing with this at the moment !! but its happened so i have to make the most of a bad situation !! so its a good time for a full engine rebuild and upgrade !!

on speaking to a few people, i have decided to go for the 16v bottom end. apparently its got a higher compresion ratio than the 8v one and also it has a better breather set-up. the only problem with this is that the pistons would hit the valves. to over come this the pistons will need to have valve cut outs put into them, and Sandy has said he can do this for me !! and while hes doing my pistons hes going to supply me with an inlet manifold for my GSXR bodies !! woooooo !!

ive already got a 16v bottom end (thanks pye !! ), and ive already stripped it down and cleaned up the block !!




also as its going to take me some time to get everything sorted on the engine i have decided to give the engine bay an overhaul !! i started by stipping out what i could. i then gave the whole engine bay a good degreasing !!
under the grease and grime, i found that the bay was rusty in most places. luckily it was mainly surface rust and nothing too serious !!





as you can see its still in the red oxide primer awaiting a good coat of white !! just need to sort out the bulkhead and the front cross member first !!


ill try to remember to keep this updated this time !!
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Old 21-06-2008, 08:27 PM   #8
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need a 16v head now
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Old 21-06-2008, 08:29 PM   #9
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dont be silly !!
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Old 22-06-2008, 08:32 AM   #10
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The prep work looks good mate. Should look sweet when its done.
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Old 22-06-2008, 05:35 PM   #11
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Little bit of seam welding wouldn't have done any harm.
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Old 22-06-2008, 08:52 PM   #12
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i was thinking of having it done, but its just extra cost !! i doubt id really get the full benefit of having it seamwelded anyway !!
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Old 22-06-2008, 09:00 PM   #13
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Quote:
Originally Posted by Cyb3r View Post
need a 16v head now
he doesnt want a gti
what a ridiculous thing to say.lol...keep it 8v tommy! looking good mate!!
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Old 22-06-2008, 09:01 PM   #14
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16v is the way forward
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Old 24-06-2008, 01:16 PM   #15
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well ive finally managed to finish the engine bay !! and i must say it looks great !! id have liked to have had it done properly but i couldnt afford it !! but spray cans do a good enough job !!

anyway heres some pics !!

bay in red-oxide primer:


and the finished article:




and how the cars looking at the moment !!



have been cleaning the struts and brakes up aswell, so should have them finished and back together soon !! should look great !!
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Old 28-06-2008, 09:14 AM   #16
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more problems !!

after finishing cleaning and painting the front struts and brakes yesterday, i decided to fit it all back together and stick them back on the car. obviously the first thing to do is put them dampers back in. slid it in and tried to fit the damper cap. i tried to slide it over the damper, but it seemed like a tight fit and it wouldnt go on. i looked at the little rubber seal on it, and to my surprise it had fallen off slightly !! i then thought that sourcing new ones would be easy, i thought wrong !!


yesterday i phoned a few places and asked if they sell the damper caps, and each time they just say no!! they also tell me that Euro Car Parts are the mine/only uk importer.
i have just got back from there now and its not good !! they say that they dont stock or sell the caps seperately !! GAY !! i then asked them for the contact details for Bilstein (as they are the main importer you would ashume that they have them on file !!) well i ashumed wrong !! the answer i got was 'we just order them off the internet' thats when i walked out !! bunch of idiots !!

also id be unable to replace the seal with an aftermarket one as the original seal is actually part of the cap (kind of bonded to it !!)

so it looks like ill be getting some new ones from bilstein, if i can get in contact with them !!!
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Old 29-06-2008, 11:18 AM   #17
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Old 29-06-2008, 11:28 AM   #18
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surely you could rebond one on? put a pic up!
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Old 29-06-2008, 12:54 PM   #19
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Hi Tommy i think it was that 5p piece wot busted the engine
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Old 30-06-2008, 05:06 PM   #20
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well finally abit of good news !!

got hold of Bilstein Uk and spoke to a chap about the seals i need for the damper caps. he told me that the seals just press in (shows how much i know !! lol).

they do supply replacements ones which is great news !! then came the cost !! i was expecting it to be quite high, but to my delight it wasnt !! they are only around 5 per seal which i dont think is too bad !! i ordered 4 just incase !!

hopefully they will arrive tomorrow and ill be able to rebuild the front suspension and get it back on the car !!
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Old 30-06-2008, 06:14 PM   #21
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good to hear it's going back together now slowly still no idea where the metal bit came from then? you need the guys off CSI to do some metal test thing on it and see what it's made of!!
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Old 01-07-2008, 06:10 AM   #22
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Ideal! I've heard mixed reviews about dealing with Billie UK, it's good to hear your pleased with them
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Old 09-09-2008, 06:24 PM   #23
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right, finally some updates !! woooop !!

as im now using the 16 bottom end with my 8v head, the pistons needed to have valve cutouts put in them. sandy said he was able to do it. so as soon as i could afford to send them down to him i did !! i then received a parcel shortly afterwards containg these !!



once i got them back, i then sent them, and the bottom end off to the engine builders near me. a few days later, i went and picked it up, very excited that progress was finally happening with the engine !! once i got it home i bolted it to my new engine stand, and got to work finishing off rebuilding the bottom end. have only done a few minor jobs as im waiting on a few parts (gaskets, seals etc.) to finish it off.






while the car is off the road, i thought id re-new or upgrade my suspension. all i knew is that i wanted it alot stiffer than it was. firstly i bought some PTS Tarmac rear dampers, second hand, but shoukd be fine !!



i then cleaned and re-built the front suspension legs. they contained my Bilstein GrpN dampers and Eibach -30mm springs. also re-painted the claipers red !!



i then realised that if im using the PTS rear dmapers, id really want to upgrade the torsion bars too. this then would mean that the front would be too soft compared to the rear. i then made the decsion to convert to coilovers, again !! order the conversion kits from Rally Design, got the top mounts from a company on e-bay (basically there the compbrake fixed ones), also got 2 sets of springs off ebay too, for only 25 !! both are 9" long, one set is 300lbs, and the other is 350lbs. but it looks like they might be too long !! then came the decsion of which front dampers to use. i decided to use the PTS Tarmac ones, to match the rears. so i ordered a set from Skip Brown which arrived today !! well, heres the pics !!

heres the converted struts. not the prettiest welding but it will work !!





yellow are 300lbs x 9" and the blue are 350lbs x 9"


and the PTS tarmac dampers !! not very pretty, but function over form !!



well i think thats it for now. ill update in a few weeks once ive finished the engine build, and fitted the suspension !! cant wait to drive it, been over 3 months now !!
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Old 09-09-2008, 06:45 PM   #24
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More money than sense!
Whats the eta for getting the engine back together?
Hopefully get a ride in it soon.
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Old 09-09-2008, 07:16 PM   #25
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Quote:
Originally Posted by indigorallye View Post
More money than sense!
Whats the eta for getting the engine back together?
Hopefully get a ride in it soon.
shut it you !!

wish i had more money than sense !! im skint at the moment, thats why its taken a while !!

hopefully should be back on the road in around 4 weeks !! fingers crossed !! it would be sooner but i have to save before i buy more parts !!

yeah you can have a ride in it !!

edit: also, ive sent my head back down to QEP for them to try and save !! hopefully they will be able to do something with it and get it back up to me !! fingers crossed !!
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Old 09-09-2008, 07:36 PM   #26
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right, finally some updates !! woooop !!

as im now using the 16 bottom end with my 8v head, the pistons needed to have valve cutouts put in them. sandy said he was able to do it. so as soon as i could afford to send them down to him i did !! i then received a parcel shortly afterwards containg these !!


Is it me or is there a good reson why one of the pistons is missing a valve cut out?Flicking through the thread and it seams really well put together good luck man.
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[COLOR="Red"][SIZE="2"]Engine:[/SIZE][/COLOR][SIZE="1"]C2 VTS JP4 engine, JP4 cam covers, J4 cams, followers, valve springs and caps, Lightened flywheel, Pug racing gear linkages, heat wrapped 4-2-1 raceland manifold, 2" decat pugsport system, Pugsport group N engine mounts, powerflex exhaust mounts, 106 GTI airbox with K&N pannel filter, standard,S2 gearbox, [B]153bhp @ 7,310rpm 112ft/lbs @ 6,739rpm[/B][/SIZE]
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[SIZE="2"][COLOR="Red"]Brakes:[/COLOR][/SIZE][SIZE="1"]Front brakes:Godspeed brake set up consisting of Brembo Max disks (on order), standard calipers and mintex 1155 pads with braided flexi pipes. Rear brakes: standard S1 drums and shoes with goodridge flexi pipes[/SIZE]

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Old 09-09-2008, 07:39 PM   #27
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Which head is it? S1 or S2? I have a spare S1 should you need it.
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Old 09-09-2008, 07:43 PM   #28
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i didnt notice a cut out was missing until my engine builder noticed it and told me !! but as its an 8v head, only the 2 larger cutouts are needed !! so the other little ones arent needed, so the fact one is missing doesnt matter !! thats what i hope anyway !!

its an s2 head mike. but the head i have has already had work done to it !! has had work done to the combustion chambers, re-shaping or something !!
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Old 09-09-2008, 08:04 PM   #29
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Looking good dude!

How are you going to run those dampers - you gonna machine them down so there's more thread to take on the top nut if you see what I mean?
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Old 09-09-2008, 08:07 PM   #30
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Wow car is having some serious loving!

If you dont mind, how much did it cost to have the valve cut out work on the pistons?
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Old 09-09-2008, 08:14 PM   #31
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@ lewis - nah, im not having the damper machined down like yours (although id like to !!) im just going to shave down the spacer and top nut so theres less meat on them, and so they go further into the topmount, if you know what i mean !!!

@ curl - it cost me around 130. great value, and an awesome job by sandy as usual !!
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Old 10-09-2008, 07:24 AM   #32
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Where the hell did you find psf rear dampers second hand? Also those springs are too long and too stiff imo. Your going to run 23mm tbs I assume? And did you get the front dampers from france?? ?$£?$?

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Old 10-09-2008, 07:46 AM   #33
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Just looking at the engine damage, was it the tip of the spark plug that caused it?
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Old 10-09-2008, 09:58 AM   #34
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Where the hell did you find psf rear dampers second hand?
Keep watching out for peugeot sport items on ebay france, they crop up every so often!

I missed a set of PSF tarmac rear dampers for 80, i forgot about the time difference and auction ended no bids !
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Old 10-09-2008, 11:38 AM   #35
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@ george - i got the dampers off pye from on here !! yeah the springs are too long, but 300lbs is the about right i reckon mate. and yeah, im going to be using 23mm rear bars. no, i got the front dampers from Skip Brown mate !!

@ stugee - it wasnt the tip from the spark plug mate, as that was still attached to the plug.
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Old 10-09-2008, 11:44 AM   #36
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very nice, going to be a nice engine once its all done, keep up the good work mate...
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Old 10-09-2008, 03:02 PM   #37
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Please please give me another ride
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Old 16-09-2008, 06:39 PM   #38
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update time :

i decided to try and build up my coilovers, but found out that there was no way the nut would screw onto the damper. i thought id be able to just trim down the spacer and it would fit. once id had a proper look i realised that even with doing this, the nut was still no where near the tread on the damper.
i decided to have the dampers machined down a little to allow more room for everything to fit nicely.

before:


after:



going to build them up tomorrow and see how it all fits !!


and got some great news today aswell !! got a phone call from matt @ QEP who said my head was ready, and that it will be with me tomorrow !! wooooooop !!! cant wait to get it here and finally get the engine built up !!!

there should be quite a few updates and pics over the next few days, so keep an eye out !!
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Old 16-09-2008, 06:52 PM   #39
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Tommy, could you do me a favour? Could you take a pic for me of the strut with a Bilstein top cap screwed on (if you still have one lying around). I'm trying to figure out if the threaded tubes on mine are short enough for the top cap to screw down properly. I'll give you an e-mars bar
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Old 16-09-2008, 07:17 PM   #40
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sorry ponk, but ive not got a billie damper cap anymore !! but im pretty sure that they are the exact same length as the standard ones mate !!

btw, do you mean the threaded coil over tube is too long ?? it should land just under neath the tread for the damper cap !! i left a couple of mm gap just to be sure !!
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Old 16-09-2008, 07:25 PM   #41
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No worries, cheers anyway. At the moment the top of the tube is probably level with the last couple of threads on mine. I guess i'll have to either cut them down a bit or introduce them to Mr Hammer :-D
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Old 17-09-2008, 08:27 PM   #42
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recieved 2 parcels today, one containing some manifold heat wrap, and the other had my freshly refurbed head in !! wooooooooo !! its finally coming together !!

firstly the manifold. ive never bothered before heat wrapping my manifold as i thought it was a waste of money, but as all the engines apart at the moment i thought i might aswell do it !! and what a bastard of a job !! im still itching now from the fibreglass !! but it does look alright, and should keep bay temps down a little !!



and now for my head !! was really excited to see how well the head had been repaired, andi wasnt disapointed !! it looks great !!






decided to try and finish off the rebuild tonight, got quite abit done, came across afew problems !! but heres how the engine looks now !!



the main problem i had was when i came to fit the oil cooler and manifold !! i fitted the manifold first just to get it off the floor, then i tried to fit the ouil cooler plate. and as im using the 16v block, which has an extra breather pipe coming out of the block next to the dip stick, the oil cooler pipes fouled on this pipe, and once the dipstick is fitted there will be even less room!!

does the 16v have a different oil cooler plate thingy to the 8v ?? or i might just go for a mocal type set-up to solve the problem !!


well i think thats it for now. im nearly there with the rebuild, just need a few more parts and im sorted !! getting excited about finishing it now !!
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Old 17-09-2008, 08:53 PM   #43
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What headwork did you have done?

What cam are you going to run?

Looks good!
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Old 17-09-2008, 09:00 PM   #44
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headwork had already been done before the engine broke. that consisted of re-working the combustion chambers and doing other bits and bats !! the reason it went off to get worked on was that one of the combustion chambers had been wrecked !!
im using a CATCAM, the code for it is at the top of this page !!
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Old 18-09-2008, 04:51 AM   #45
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Looks like a nice finish on the head face
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Old 18-09-2008, 12:17 PM   #46
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I think i might still have the 16v heat exchanger take in the Saxo, i should also have an 8v one as well, i will have a look if they are the same at the weekend. You can have them both if you want?

Where are you getting the TB's from? Crossie?
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Old 18-09-2008, 03:24 PM   #47
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pye, if you could have a look and see what difference if any there is between the 8v and 16v heat exchangers i would appreciate it very much !!

not getting the tb's from crossie, should be having his 25mm anti roll bar, but im waiting on some money to come in first !!!
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Old 18-09-2008, 04:39 PM   #48
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The ones that Crossie has are the ones that i got with the rear dampers you bought!!

I will have a look and let you know.
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Old 18-09-2008, 05:44 PM   #49
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cheers mate !!

only one update today. finally after alot of messing around, i finished building up my coilovers. think the springs might be abit long, but i wont really know until i put them on the car !!



im also gathering a few other bits so hopefully ill make some more progress this weekend !! fingers crossed !!
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Old 18-09-2008, 07:49 PM   #50
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I can see it looking like a jet on take off lol. Nice work though, are the struts just painted with hammerite?
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