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Old 17-07-2009, 12:45 AM   #1
Lewis
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Throttle Bodied 106 Rallye...**Engine fitment write up now complete**

Right, well I haven't QUITE got my greasy paws on the car itself yet!!

BUT, I thought i'd start a blog so things are up and running, as i started to do a few bits to the engine tonight and managed to get some good pics of the ports/angle of the pug sport bodies etc etc.

Anyway here we go:

PART 1:

As i'd removed the inlet recently to get the Carbon Trumpets made by Streamline Carbon, I had to re-bond the bodies back onto the engine to seal them properly again. Below are a few pics of the engine with the intakes loosley bolted on, prior to the re-seal process, then pics of the bonding itself, then a pic of it all sorted.

Here she is unveiled again (it's almost like a statue than a race engine!):










Angle of the Direct to head Pug Sport Throttle Bodies:








Close of up of port down intake:




Intakes off:






Close up of Porting:






PART 2:

Work in progress:




Cleaned Face:




Cleaned face of intakes (Old sealant removed etc):




The Sealant:




Apply to both surfaces carefully:






All bolted back on, and none seeped into the ports either!:




And all done:





Next thing is to collect the car, fit the engine and box (with the help of Hank), get Bobby (wire wizard) to get it running, then fit my seat, brakes and steering wheel to it and we should be good to go **Fingers crossed**
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Old 17-07-2009, 01:28 AM   #2
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I so love this engine! Fancy a Honda Conversion?
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Old 17-07-2009, 07:48 AM   #3
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one thing boyo, check that the sealant hasn't splurged out inside the tract, easier to clean out now than when the engine's in
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Old 17-07-2009, 03:23 PM   #4
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Sure you've got a nice engine there mate - Would definitely be a shame to run it in a Saxo ..
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Old 18-07-2009, 10:09 AM   #5
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Lewis where is the blue line going to, off ur fuel pressure reg...
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Old 18-07-2009, 06:52 PM   #6
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Does the scuttle need to be cut?
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Old 19-07-2009, 01:35 AM   #7
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Quote:
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Lewis where is the blue line going to, off ur fuel pressure reg...
Just down the back of the engine. Think it's just where excess fuel which isn't returned to the tank drips out..or something like that!

Thanks for the comments guys!

James, I'm not going to cut the scuttle as I reckon it looks pikey as fuck. May do some neat hole saw holes as I have the LHD wiper motor but we'll see. Depends how much clearance there is. Should be ok. Trumpets are shorter than Tommy Rallye's current one's and he seems to have a reasonable amount of room.
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Old 19-07-2009, 06:28 AM   #8
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Looking good mate, whats all the gunk on the valve stems?
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Old 19-07-2009, 10:37 AM   #9
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i was gonna say the same dyno!!
it looks to me to be assembly lube, weird did longmans not run and map the engine mate.
all the same it looks absolutely awesome.
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Old 20-07-2009, 10:01 AM   #10
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Cheers Lads - there is a small secret to that, which I couldn't possibly tell you, and if i did, i'd have to kill you!

A few more pics from the weekend too - the Saxo is now out of the garage and i've moved the engine to the front so I can now see hat i'm doing when working on it!

Cam Pulleys:




Modified & baffled Sump:




All ready to be fitted now:




I am on holiday now for two weeks but once i'm back i'll get this updated again asap - looking forward to getting the Rallye now!

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Old 20-07-2009, 02:50 PM   #11
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I've read this on three different forums now, what a loser! lol. I can't wait to see the Rallye in the flesh, you will have to bring it to the next French car night at Ace Cafe.
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Old 20-07-2009, 03:16 PM   #12
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that blue hose is meant to be connected to a vacuum feed but i'm informed that if it's mapped disconnected then it's fine
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Old 20-07-2009, 03:41 PM   #13
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i must say the build quality and workmanship looks excellent on this motor!
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Old 20-07-2009, 08:50 PM   #14
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Oi! Nothing 'pikey' about scuttle cutting, you tart
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Old 21-07-2009, 09:46 PM   #15
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Nice work as usual.
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Old 10-08-2009, 12:04 AM   #16
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Proper write up now complete - see below
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Old 10-08-2009, 06:01 PM   #17
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one let down...the citreon badge

otherwise very nice
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Old 10-08-2009, 09:23 PM   #18
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Old 10-08-2009, 10:18 PM   #19
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I actually prefer the citroen rocker badge to the pug one, but alas, it WILL be changed lol!
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Old 13-08-2009, 12:58 AM   #20
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Right i've had a chance to do a bit more of a proper write up regarding the engine installation so here it is:

I loaded up the van on saturday with all the parts - engine, gearbox, Grp N wishbones, Steering, and other various nuts and bolts etc and then got up pretty early on the Sunday to head to Hanks gaff in Newport Wales. Bit of a debacle en route as I didn't have enough dosh for the severn bridge (assumed it would be about 3 and it turned out to 15!) So anyway they let me through and I just had to pay by post instead...and if you don't pay within the week it goes up to 90!!! Robbin' bastards!

That aside, I got to Hanks about elevenish and we made a start straight away.

First Job was to check all the hoses in the bay were ready, and to remove the old Fuel pressure regulator that Hank had installed for his engine - mine already has one so we did away with that. 2nd pic shows Hank modeling the latest fashion in Wales, otherwise known as the '106 Rallye Frock'!





2nd job was to mate the engine to the Gearbox - this was done without too much trouble once we had lifted the engine up a little using the crane, and then located the input shaft into the clutch. We then bolted everything up and checked it was all tight etc:







Next job was to try the brakes on the car to see if they fitted...needless to say they didn't, but the discs sure looked sexual regardless:



Next up was the actual engine fitment. ALthough the pics give the impresion that this was an easy task, while it was relatively straight forward there was a lot of heaving and fecking about to move it into postion while we lowered the car down onto it using the crane, all the while trying not to scratch or break anything (which we managed fine!)







We then 'simply' lowered the car to the ground, and pulled the engine up into place using the crane, then onto then bolted it all in:




We then had to modify the throttle cable to fit, which we did. Meanwhile Hank discovered he had somehow implaed himself with some braided hose in his leg - stings like a bitch!







After that we connected pretty much everything else, fitted the wishbones, checked it all and we were done! All that was left to do was admire our handiwork.








The car get's delivered to my house this weekend so more updates to come!


Watch this space......
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Old 13-08-2009, 01:13 AM   #21
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Nip on and get it running!
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Old 13-08-2009, 09:03 AM   #22
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Nice dude, Hank bringing it down? My 8v engine comes out on saturday, whole week booked off work, touch wood it should be done by next weekend!
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Old 13-08-2009, 03:41 PM   #23
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Keep going !!
The engine bay is actually ubersexual
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Old 13-08-2009, 07:22 PM   #24
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thanks Benje - now all I need to do is sort this brake issue!
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Old 13-08-2009, 10:02 PM   #25
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Swap for my 266s.........no?
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Old 13-08-2009, 10:16 PM   #26
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*cough* Enter swear word here *cough* off!
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Old 13-08-2009, 10:20 PM   #27
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just get some hi specs Lewis like Si had on their orginally
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Old 14-08-2009, 12:27 AM   #28
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looking good
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Old 14-08-2009, 06:50 PM   #29
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I am actually getting moist about getting this on sunday now, wooo! I am feeling drunk too (beer after work) .. She should turn up sunday if all goes to plan. It's all insured now too
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Old 14-08-2009, 08:09 PM   #30
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Loose the SL434's and get some White Comp 2's, the only wheel that truly suits a 106!!!
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Old 15-08-2009, 11:44 AM   #31
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Them wheels are sexy leave them be!!!! Top work guys i would give my leg for this car
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Old 16-08-2009, 09:50 PM   #32
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Well?!
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Old 17-08-2009, 01:58 PM   #33
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looking well nice mate

bringing it to trax or rallye day ??????? or both for everyone to perve at
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Old 17-08-2009, 07:06 PM   #34
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Right well I took delivery of it yesterday and got to work straight away. Steering wheel fitted, seat fitted (took a while) quickshift fitted and loads of bolts swapped for new one's everywhere. I will get some pics up when I get a chance!!
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Old 17-08-2009, 10:12 PM   #35
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Stop fannying about and drive it (I'm sure I've told you this before!)
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Old 18-08-2009, 12:23 AM   #36
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Right, a few updates tonight:

I have done a more comprehensive list of work but i haven't had time to do a proper write up, and my laptop is dead so currently using my g/f's cumbersome pc...anyways, that aside, here are some snaps and a list of work done so far:

All bolts changed for lightweight aluminum one's where safe to do so, otherwise stainless steel or black high tensile socket head bolts were used. I fitted the seat, steering wheel, harnesses, and quick shift, and roof ariel blank too, and swapped all the stainless bolts in the cabin for back one's to tone it down a little. Also removed the map pockets as I don't really like them, plus the flock was peeling too! I also washed it so it's like new again now. I cannot emphasise how pleased i am with the car - pics do not do it justice, it's absolutely stunning in the flesh! Also swapped the jubilee clips for proper strong motorsport items - pics to follow. Spent two days working on it so far and got most of the small jobs done that I had in mind.

Here it is on it's arrival:





I washed it and did some work that night, now onto the next day:

Coming out of 'bed' for the evenings work:



Seat Fitted:





Doorcards with black bolts & removed map pockets:



Overall quick snap:



Like I said i will do a proper write up when i get a chance!!

Things to do still:

*Buy new alternator
*Get exhaust system made
*Fit brakes/sort brakes out
*Get wiring loom done

These are expensive jobs so it'll be a while yet!

Lewis
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Old 20-08-2009, 10:32 PM   #37
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Right a few more updates tonight... I finally had time to upload my other pics onto photobucket, with the initial progress, so i'll get those up and then put the latest updated after that....

Steering wheel fitted:






Quick Shift fitted:




All bolts replaced with aluminum one's (where safe to do so of course):






Jubilee clips banished and replaced with proper fasteners:



OE cable retainers on pillar banished and replaced with tidy ones (you can also see i'm in the process of fitting black roll cage bolts instead of the stainless ones):







Stainless Steel Engine Mount bolts fitted:



Stainless bolts fitted on brake balance bar:




Gold bolts on engine all swapped for black aluminum ones (decided it's a cleaner more subtle look than the gold type!)

Before:



Take these:



And you get this:





Still a few to swap in this pic - not quite done yet as I ran out!



Also ground off this random stud in the bay using my good mothers dremmel (amazing tool this!) and touched it up with paint - looks better than a stud sitting there doing nothing but may get it smoothed over professionally eventually but it will do for now - no pic of it painted but it does look nice, I did a tidy job of it!



And that's about it for now - doing all the small detailing type jobs for now until I have enough dough to crack on with the exhaust and wiring!

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Old 20-08-2009, 11:07 PM   #38
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I would not use stainless bolts on any brake component or engine mounting, they are nowhere near the tensile strength of the original factory spec HT bolts which are 8.8 grade at the very least.
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Old 20-08-2009, 11:55 PM   #39
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i think these are 8.8 too? there isn't a lot of stress on these bolts anyway, it's mainly on the bolt underneath bearing the weight of the engine - what do you reckon?
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Old 21-08-2009, 08:09 AM   #40
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Don't do it Lewis. Stainless is weak ass shite and certainly well under the specs of 8.8. If you want good looks, corrosion resistance, lightweight and strength then the Ti Bolts from ProBolt are 8.8 equivalent spec but the cost will make your eyes water. Even then, there is a lot of discussion on other forums regarding the use of lightweight bolts. The general consensus is that you have to fully understand that engineering implications of changing them on certain components. Also note that the mechanical properties of Steel and Ti are not identical so it's not as simple as saying that they'll do the same job in holding things together. To be honest in most cases BZP or the black coated 8.8 steel bolts you'vve used elsewhere are the best bet.
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Old 21-08-2009, 08:53 AM   #41
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You whore, maxed your bandwidth again dude
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Old 21-08-2009, 09:53 AM   #42
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Don't do it Lewis. Stainless is weak ass shite and certainly well under the specs of 8.8. If you want good looks, corrosion resistance, lightweight and strength then the Ti Bolts from ProBolt are 8.8 equivalent spec but the cost will make your eyes water. Even then, there is a lot of discussion on other forums regarding the use of lightweight bolts. The general consensus is that you have to fully understand that engineering implications of changing them on certain components. Also note that the mechanical properties of Steel and Ti are not identical so it's not as simple as saying that they'll do the same job in holding things together. To be honest in most cases BZP or the black coated 8.8 steel bolts you'vve used elsewhere are the best bet.
Yea I take your point dude. The black one's i've used are high tensile one's from trident racing in silverstone so are proper 'motorsport' standard (strength wise) and i've used them most places. The reason I didn't use BZP is that still corrodes and they're a fucker to un-do if you ever need to. I may revert to using the black bolts instead of stainless..we'll see. I know Bic had these bolts in the same places in his car and didn't have any problems. I will check out those Titanuium one's from Pro BOlt...I only need 4 or so! Hopefully they're not too pricey! They say these are strong enough to use on brake calipers etc so should be fine on my application.
With regards to the alloy bolts I have considered where i have changed them, the only case they'd snap is if I crash, an there's not a lot I can do about that! Should be safe enough in a kevlar seat and preoperly welded in cage i'd like to think...
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Old 30-08-2009, 12:05 AM   #43
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Right lots of updates today. I fitted my AP's (total arse of a job) achieved with the help of 5mm spacers and a little grinding. Also installed my fuel lines in the bay, replaced my bonnet lifters as they were creaking, and removed my rear caliper as it was leaking like fuck (only realised when I pushed the car out of the garage and saw the stain on the floor from brake fluid, so that will need to be replaced at some point. Also perfected my throttle cable as it was a bit gammy before, and took a pic of my group N wishbones fitted too. Also fitted my carbon number plates, as the old one's were a little haggard! I will let the pics do the talking anyways.

Good morning little Rallye:



Old Bonnet Lifters removed:



New OE ones from Peugeot:



Linkage was fouling my fuel line fitting so i ground it down a little bit with a dremmel (such a handy tool!)

Before:



After (tiny corner ground off for clearance):



Throttle cable sorted:



Throttle cable secured to bulkhead:



AP's brakes ground down a little (still need to touch them up):



Pads in (very easy) At this point the caliper was upside down so I swapped it after - doh!):



Tight like a tiger!!:





All fitted:

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Old 30-08-2009, 12:05 AM   #44
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Mint new Earls Black fittings:



Fuel lines and filter installed (using hole already present in the bay, didn't have to drill anything!):





Return Line:



Group N wishbone:



New Carbon plates off Bic @ Streamline Carbon (thanks again!):



Leaking Caliper (Now removed):



New coilpack badge (there is a piece of paper on it here but you get the idea!)



Bay as it stands now:

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Old 30-08-2009, 12:59 AM   #45
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still can't get over how clean this car looks, dare i ask how much the carbon plates set you back?
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Old 30-08-2009, 09:13 AM   #46
Aleksandr
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You're a master with the grinder dude, I would have trashed those calipers trying to do what you have
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Old 30-08-2009, 09:39 AM   #47
7unner172
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absolute stunner mate
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Old 30-08-2009, 10:01 AM   #48
Cris B
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Good work on the brakes Lewis, it's looking the business now.
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Old 30-08-2009, 11:42 AM   #49
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Lol thanks guys. Funnily enough, I started to use the dremmel on the brakes, but ended up using my dad's age old hand file, it did a much tidier job, it almost looks factory! Just need to mask the area off and touch it up with some satin black spray paint now. Plates were 50 + VAT from streamline dude. They are worth it though, not only do they look sex but they are hella lighter than plastic!
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Old 30-08-2009, 12:12 PM   #50
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Have you considered 106 diesel bottom arms if your not runing a ARB. A lot stronger than the uprated arms at a fraction of the price.
What shafts are you runing?
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