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Old 10-06-2010, 03:38 PM   #1
Cris B
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Cris Bloomfield - 106 Rallye S2 16v

I've decided that I might as well set up a progress blog on the Rallye here on the site. I've been maintaining one since buying the car on my own website, so there's plenty already written about it. It'll take a while to build up the posts from the origins of the car to where it is now. This is a summary blog so it covers all the main things that have been done, but doesn't go into all the little details that are still covered in my personal blog.

Having previously owned a white S1 Rallye, when I decided it was time to return to Rallye ownership, getting involved in the Rallye Register and using it to help find a new car seemed the logical place to start. After a bit of looking I found a great one in the ownership of Ian Hawxby from the North East members section. So made a viewing appointment and caught the train up to Durham. The Rallye wearing the H2XBY plates was in tidy condition having been recently machine polished and well looked after - see Ian's old blog for more details.







Inspection revealed the usual stone chips from a 10 year old car and quite a bit of rust on the underside, including splits between the rear arches and boot. Some further TLC was going to be needed. A deal was done and I ended up driving home after a trip to Newcastle and some fish and chips on the banks of the Tyne. It was a particularly appealing Rallye to buy because Ian had already spent quite a lot of money on the car in terms of putting a 16v engine in. I'm still amazed at how much money you can save by buying car someone has already carefully uprated.

Bye bye 8v.


Empty bay.


45k Saxo 16v VTS engine to go in...


It fits...


Prior to fitting the engine a new clutch and cambelt went in and then new gear linkages were fitted.


The car also came with various other goodies fitted to it, including:

Bilsteins and Eibach springs


Mocal Oil Cooler


Raceland Exhaust Manifold


Compbrake Quickshift


OMP Lower Brace


So the car with all these bits made up my Rallye when I bought it, but of course that's just the beginning of the story... Specification on purchasing:

Quote:
Series 2 106 Rallye, Bianca white with 119k on the car and 51k on the engine. 4 previous keepers.

Engine and Transmission
45k mile Citroen Saxo VTS Engine fitted at 113k with the following genuine Citroen parts during the transplant. Running on the stock Rallye gearbox, but with all three gear linkages being replaced along with the gearbox mount and a Powerflex lower mount. Both driveshafts replaced with new units in August 2008 along with drivers side wheel bearing.

* Clutch Kit
* Timing Belt Kit
* ECP Lambda Sensor
* Raceland 4-2-1 stainless manifold
* Twin exit Magnex stainless steel exhaust system with decat
* Simota Forced Air Induction Kit
* Polished Cam covers
* Mocal 13 row oil cooler with Thermostat sandwich plate
* Nissens radiator
* Compbrake quickshift

Suspension and Handling
* Bilstein Sprintline Front and rear dampers
* Eibach 50mm springs
* Torsion bar adjusted to match
* OMP lower strut brace

Wheels and Brakes
* 15″ Speedline Corse 2116 Chrono’s fitted with Michelin Exalto Pilot and Yokohama S Drive tyres
* Wheel stud conversion

Interior
* JVC CD/MP3 player
* Pioneer 6x9s in the parcelshelf
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Old 10-06-2010, 11:34 PM   #2
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So started making a few changes to the car once it came home. Fitted some Sparco pedals:


Made an alloy ECU bracket to replace the rusty steel one. It's a third the weight...


...and a heatshield to stop the exhaust melting/discolouring the rear bumper.


Ordered these from Spoox...


...but ended up sending them coolant hoses back and getting these instead.


Fitted the induction pipe into a tidied up engine bay


These also arrived in the post along with some new trackrod ends and drop links


So ended up getting fitted to the front end (rear beam still to be done)...




Car went off and had the tracking sorted out and then ended up getting driven around quite a lot. Went back up to the North East to pick up some OZ Superleggeras with brand new R888s. Bargain set of wheels for the track, but they'll going to get powdercoated before I use them.


Then bought some new bits for the interior, including a Sparco steering wheel


Streamline Carbon door and three-quarter cards...


...and some blanks for the dash


Took the dash out, lightened it by 1kg and took it over to Raj at Autoflock who did a top job on it
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Old 11-06-2010, 12:12 AM   #3
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Bought some GSXR 1000 throttle Bodies off Kiwi (planning ahead at this point)


Then I went nuts and bought an 106 GTI that had been used as a stage recce car by Richard Clews. Out came the Sparco seats and Safety Devices cage and harnesses and in the end it was all tidied up and sold on.


The car was then booked in to Paul Reaney at Ghost Developments for some body work repairs and to get the cage fitted, suspension strut top plates added and seat rails mounted. In the mean time I stripped out the interior including all the sound proofing materials. I also thinned out the interior loom of all the none essential wiring.


Came back and had a full interior respray. After which I started putting it back together.


My intial relocation of the washer bottle didn't work out with the 205 rear washer bottle in the photo below, but it did second time around with a different bottle that didn't leak and a pump that works French cars are great.


Bought some new OMP seat mounts and made them lighter


Prepped the scuttle for moving to an AX single wiper setup and then fitted that in.


Sorted out a co-drivers footrest, cage for a lightweight race battery and grip taped the footwells.


Finally finished the interior off with a Lotus gear knob


Replace the Magnex with a much lighter Pug Sport with the Motorsport Cat...


...and heat wrapped the manifold.


Did a bit of tarting it up


Then had the injectors refurbed as part of trouble shooting an engine problem.
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Old 11-06-2010, 03:44 PM   #4
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Next thing was to replace the alternator. This was identified as the cause of the engine problems. I went for an 8v unit and used poverty spec mountings, with the tensioner modified to fit the block. Coupled with some of Colin Satchell's alloy pulley wheels, this delivered a 5kg weight saving. Might have polished a few bits up whilst I was at it.







Whilst the car was off the road I fitted the silicon coolant hoses and a slimline fan as well as giving the slam panel a full respray. At some point when all this was going on Tommy Assen sold his Rallye, so I bought up all his braided fuel and brake lines. Then decided that I needed some decent brakes to connect them to. Marc Boni's group buy on his Hi Spec setup seemed to good to miss so I ordered a set and picked up a 23mm master cylinder off a Peugeot 406. Just need to get around to fitting this lot.



With the car back on the road, took it out for a blast and took some photos in the Peak District.






Ordered some roll cage padding, colour coordinated my zip ties and received my new lid...




...then I ended up having a hectic few weeks what with getting married and buying a new engine! A cracking deal came up on a recently rebuilt JP4 engine with cams, throttle bodies, Omex 600 management and a full loom. As I said there are some bargains to be had when people starting breaking their cars. This is now safely tucked away whilst I accumulate the time and other bits to fit it. The Saturday after I came back from honeymoon, I headed up to Mallory for PPC in the Park and my first trackday



The track day was ace! Coming off the M1 on the way there the car started making strange car noises. These turned out to all be down to the alternator belt. By the time I made it home the whole tensioner assembly had fallen off, but at least (and somehow) the belt had stayed on the pulleys despite being immensely slack. I’ve finally managed to source a replacement part and started to make up a new lower assembly again now. So that's the summary over!
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Old 13-06-2010, 08:19 PM   #5
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Did a bit of fettling over the last week and finally have the car back on the road for the first time since PPC in the Park. Chopped up a poverty spec lower alternator mounting to liberate the necessary section, then tidied it up, drilled the extra mounting hole and painted it up with POR15.

New custom alternator tensioner bracket:


Fitted (note that the zinc plated (gold coloured) adjuster that attaches to the alternator bottom mounting doesn't have enough thread on it naturally, so this has to be tapped so that it will mount as shown):
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Old 13-06-2010, 08:47 PM   #6
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Good read, good progress!
You got any more trackdays planned?
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Old 13-06-2010, 09:14 PM   #7
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Nothing certain yet, my weekends seem to be getting booked up really quickly at the moment so I'd better get my arse in gear and book some track time
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Old 14-06-2010, 07:36 AM   #8
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Looks well mate, have you got the Hi specs on yet?
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Old 14-06-2010, 10:12 AM   #9
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No they're still sitting in a box

I *think* I now have everything I need to do the install. I will need to make a mounting bracket for my Wilwood bias valve and also to get some brake fluid.

The reason they're not fitted is that I want to put this new Throttle Bodied JP4 engine in and the bay needs tidying up before that so the current plan is:
  • Take car off road
  • Strip interior and front half of cage.
  • Remove rear beam and send off to imaxle for a refurb
  • Remove struts and send off to Paul R for coilover conversion and refurb.
  • Remove engine and gearbox
  • Remove fuel tank
  • Remove all brake lines and master cylinder
  • Refurb engine bay
  • Refurb under rear beam and fuel tank (did under the boot this winter)
  • Refit beam and front struts.
  • Fit new M/C, braided lines through out and Hi Specs
  • Fit braided fuel lines
  • Fit race battery in interior and wire in with cutoff
  • Check release bearing on gearbox - makes a worn bearing type noise when the clutch is released so I'm hoping that it's this. A diff is on the menu, but I don't really want the box rebuilt until it's absolutely necessary.
  • Fit new engine, loom and ECU
  • Iron out loom wiring interface - power supply and dash inputs.
  • Put car back on the road.

Not sure the order is exactly right but there's a fair bit to do! The idea is that by waiting until the engine is out I can get the runs for the brake lines right and fit them in securely. To be honest the whole thing might have to wait until August as I have a lot on until then. We'll see. In the mean time I'm still amassing parts.
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Old 14-06-2010, 10:31 AM   #10
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Stunning car!
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Old 14-06-2010, 04:14 PM   #11
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That's quite a list dude!

Just spotted the alternator bracket, that's a fantastic idea. I think part of my power problems are due to the supercharger belt slipping, so that should help sort it.
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Old 14-06-2010, 10:04 PM   #12
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Rallye's looking spot on mate, dont suppose you'll be at pugfest with it will you?
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Old 15-06-2010, 01:05 PM   #13
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Maybe at PugFest
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Old 16-06-2010, 06:53 PM   #14
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Few bits have turned up recently.

Gearbox Oil Seals


Hub Nuts


Also I sent my steering column surround back to Raj at Autoflock.co.uk who's done a top job of reflocking it. I wasn't happy with it first time around.
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Old 17-06-2010, 12:37 PM   #15
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Lovely s2 you have there dude, I've nicked a few pics from your site for backgrounds on my work computer
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Old 20-06-2010, 05:11 PM   #16
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Well yesterday I decided I'd fit the reflocked dash surround. I went to removal the steering wheel and in giving it a wriggle to loose it on the splines one of the 6 countersunk bolts holding the steering wheel to the boss sheered. The head just pinged straight off and almost hit me in the face

Removed all the previous bolts and replaced them with some 10.9 rated bolts. I'm glad that happened when I was stationary and not out driving! So having done a few checks on the car last night, today took the car over to North Wales and might have touched on part of the Evo Triangle

I took the camera with me and had planned to take some photos, but to be honest I was enjoying the sound of the pugsport over 4k revs that I became too hooked on driving to stop and take any. A beautiful day in the mountains and empty roads (they are if you get up early enough to get out there and enjoy them) both made for a memorable drive. I still made it home nice and early, so took some pictures at the local Industrial Estate which is a spot I haven't tried before.









Drive was great put just emphasised the need to get the suspension sorted, so that is now the number one priority going forwards.
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Old 15-07-2010, 08:34 PM   #17
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Months ago I bought a second hand 23mm Master Cylinder off a Peugeot 406. With the 4 pot calipers that are to go on it should give a nice firm pedal feel. It came in a jiffy bag that was soaked with brake fluid and the brake lines had just been crudely snipped off. So tonight I took off the remains of the brake lines and gave it a clean up. I just need to get a blanking screw and this is ready to go. I’ve been contemplating stripping the piston cylinder and cleaning it up too before reassembling.



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Old 18-07-2010, 08:24 AM   #18
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Absoulty stunning
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Old 18-07-2010, 09:36 AM   #19
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Cheers

Some interesting bits turned up on Friday. I've picked up a set of OZ Ultraleggeras. These will be replacing the Speedline Chronos that are on the car. They're off getting refurbished right now.



Also the baffled sump from Constella which I bought as part of the Rallye Register group buy is here and will be fitted to the engine in the near future.



None of this helps on the big list of jobs, but I am slowly making sure I have all the bits needed

I took the father in law out in the car yesterday for a quick blast which he seemed to enjoy. I think that it'll now be coming off the road for a bit so that work can commence after the NW Peugeot meet on Monday.
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Old 20-07-2010, 12:46 PM   #20
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Ultraleggeras are back from powdercoating and refurb at The Wheel Specialist. Now looking rather amazing in Anthracite... I'll hopefully get some tyres on them next month...





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Old 12-08-2010, 08:33 PM   #21
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Right been a while without any updates due to holidays and other things. Tyres are being fitted to the Ultraleggeras on saturday morning. Some bits have arrived to...

Anodised P clips for the coolant hoses


Brake master cylinder blanking plug with crush washer from Speedflow. M10 x 1mm stainless steel niceness. I need this to blank off the redundant rear hose port on the master cylinder. Fitted finger tight at random for this photo.




Finally I ordered some replacements for the Goodridge hoses as they were the wrong fitment for the Hi Specs. Now have everything needed to fit the brakes except DOT fluid.
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Old 12-08-2010, 09:05 PM   #22
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Quite a collection there now.
Similar position as me, just need fitting!
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Old 12-08-2010, 09:06 PM   #23
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What length are the threads on those Banjo bolts dude? Does this mean the brakes are finally going on? I swear you and Mike have been keeping them under your pillows

Seriously though, I need those brakes in my life!
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Old 12-08-2010, 09:26 PM   #24
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Thread lengths are spot on for the calipers. Tested them out tonight. I'd guestimate it's about 10mm of thread on them.
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Old 12-08-2010, 09:41 PM   #25
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Arse! My 20mm ones are going to be waaaay too long then
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Old 14-08-2010, 04:56 PM   #26
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Whoop! Wheels are shod with Eagle F1s and fitted. I know wheel choice and colour is a very personal thing, but I am really pleased with these. They'll go very nicely with the Bank Holiday weekend surprise that's coming at the end of the month



The metal flake in the powdercoat on the wheels means they change colour a lot depending on the angle of the light (see photos further up the thread). They look darker in this photo that in natural light. Oh and the car needs a clean and polish!

In all this set of wheels are a whopping 14kg lighter than the Speedline Chronos that came off. I know it is often talked about but it really is noticeable on the handling of the car, especially on the steering.
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Old 14-08-2010, 06:38 PM   #27
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Holy moly that looks good!
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Old 15-08-2010, 05:43 PM   #28
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This car is stunning
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Old 17-08-2010, 09:52 PM   #29
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I like that a lot, but get those brakes fitted!
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Old 17-08-2010, 10:40 PM   #30
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It's coming off the road now for 6-8 weeks so I can do this lot:
  • Take car off road
  • Strip interior and front half of cage.
  • Remove rear beam and send off to imaxle for a refurb
  • Remove front suspension
  • Remove engine and gearbox
  • Remove fuel tank
  • Remove all brake lines and master cylinder
  • Refurb engine bay
  • Refurb under rear beam and fuel tank (did under the boot this winter)
  • Refit beam and new front struts.
  • Fit new M/C, braided lines through out and Hi Specs
  • Fit braided fuel lines
  • Fit race battery in interior and wire in with cutoff
  • Check release bearing on gearbox - makes a worn bearing type noise when the clutch is released so I'm hoping that it's this. A diff is on the menu, but I don't really want the box rebuilt until it's absolutely necessary.
  • Fit new engine, loom and ECU
  • Iron out loom wiring interface - power supply and dash inputs.
  • Put car back on the road.
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Old 18-08-2010, 11:43 AM   #31
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That's quite a list.
What's the turnaround on the axle?
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Old 22-08-2010, 06:16 PM   #32
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Turnaround at IMAxle was about 5 working days when I last spoke to them, I'm waiting until I get the new suspension at the end of September then I'll get them to fit the new bars at the same time.



Started working out the loom today. This is the full vehicle loom that came with the new engine. It's a full GTI engine and interior loom, including an alarm/immobiliser. Not shown is the OMEX engine loom that I have test fitted to the engine in the engine stand. There isn't much in this picture that will have any use to my setup, but it has confirmed the wire that controls the tacho/rev counter.

I've already partially stripped lightened my interior loom, but once I strip the interior out I'll remove a few more wires and gubbins that are now redundant. I've decided that I want to relocate the battery and engine fuseboxes to the interior before I do the other works so that way I can isolate any changes issues resulting from this on the electrics from the engine swap. Need to get a few bits and check a few things out.
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Old 22-08-2010, 06:37 PM   #33
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Have you had that loom above on the scales?
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Old 22-08-2010, 08:26 PM   #34
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Not yet, but I was thinking that I should weigh it whilst working on it today!

Just weighed it now, 8.5kg for everything you can see in the photo.

I've taken 1.66kg out of the standard loom that's in the car on the first phase of work. Phase 2 which will go with the relocation of battery and fuses will also see the heated rear window and some other soon to be surplus wiring go too so there should be another kg or two to go
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Old 22-08-2010, 09:14 PM   #35
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Hmm, interesting.
I'm still 'carrying' a full loom. Ironically I only need a brake light and rain light in the back. I certainly don't need central locking looms etc etc
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Old 02-09-2010, 11:21 PM   #36
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Progress at last. Car went up on my home made ramps yesterday as I need to strip all the suspension of it. I knew how the night was going to go when I couldn't get the gear box drain plug out and sure enough about half an hour later I called defeat for the night: I had a go at removing the hub nuts and it became clear they were not going to come off with my current arsenal of tools.

Not to be defeated, I opted for beer and an hour on here looking at advice in the forum and then online window shopping. After a lot of research last night on the web, I phoned up my local Engineering Suppliers today and they sorted me out with just the kit for removing hub nuts. 24" 1/2" drive breaker bar and a 60" piece of square section steel with 4mm walls all for 20. Halfords wanted 30 just for the breaker bar (I already had a 30mm hex socket).



So the DIY hub nut removal tool cracked the hubs nuts off like a hot knife through butter

Then I became concerned that tonight might go like last night, but I was feeling inventive and was not to be easily defeated, so created home made tool number 2. Driveshaft and Hub Separator:



The O/S drive shaft was to be separated from the hub. I made this up out of two off cuts of 3mm plate steel. Tightened up the M8 bolts a few times with different spaces on the drive shaft and out it popped

The Bilstein B8 shocks and Eibach spring based suspension is now all off the car and provisionally sold.







Roll on the weekend
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Old 04-09-2010, 01:19 PM   #37
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Quote:
Originally Posted by Cris B View Post

ahhhh i do love trawling through progress blogs and finding useful info!!!! i`ve been looking at these bottles on ebay and wondered if they`d be slim enough to fit in the 3/4 recess!!!


big hats off to whats been done so far.. some real nice touches and thought gone into getting this car to where it is now...





out of interest... do you post on the mig-welding.co.uk forum i use???
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Old 04-09-2010, 06:17 PM   #38
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Yes he does! I have seen his sneaky posts too!
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Old 04-09-2010, 08:00 PM   #39
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Quote:
Yes he does! I have seen his sneaky posts too!
LOL, Busted!

To be honest I wouldn't bother with the 205 rear washer bottles, mine was utterly useless so I got rid of it in the end! I bought one of these in the end:





100g lighter and leak free

Suspension sold, collecting my adjustable setup tomorrow...
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Old 05-09-2010, 06:50 PM   #40
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So with the Bilstein suspension sold yesterday, it was off this morning to pick up the replacements. I decided to go for something with adjustable settings...



ASTs with the camber adjustable top mounts. And to complement the front springs, a pair of 23mm bars for the rear end:



Finally I picked up that little extra I've been after for a very long time... an ultralight Streamline Carbon bonnet. A standard bonnet 13.4kg this one is only 4kg! It uses a honeycomb core for a stiff structure that won't flap.

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Old 05-09-2010, 07:24 PM   #41
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nice.... REAL nice...

did you get the bonnet brand new?? i was speaking to Bic the other day and he mentioned things were busy..
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Old 05-09-2010, 07:31 PM   #42
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Long story, but no it's brand new second hand
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Old 05-09-2010, 08:02 PM   #43
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ahhh i see... well either way having seen the stuff bic, actually no.. Mervyn! produces the quality is bang on hhaha..
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Old 05-09-2010, 08:08 PM   #44
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Yep, it's top notch gear. Have pretty much a full interior kit now too...
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Old 05-09-2010, 08:31 PM   #45
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Nice suspension dude! Are you going to fit strut reinforcement plates too?

Not a fan of the bonnet if i'm honest, but each to their own, that's an impressive weight saving!
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Old 05-09-2010, 09:10 PM   #46
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Yeah, the bonnet is a personal thing. May end up getting it sprayed to match the car at some point in future.

One step ahead on the struts, had the PSF reinforcement plates welded on last year:

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Old 05-09-2010, 09:53 PM   #47
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Aha! Very nice. Don't want domed strut tops, took me ages to hammer them flat again

Some kind of semi seethrough effect might look good on the bonnet? I like DannyGti's idea of painting around the outside and leaving a small section unpainted in the middle.
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Old 07-09-2010, 11:37 PM   #48
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I don't think that I mentioned that I wasn't too impressed to find that the droplinks which were fitted less than 1,000 miles ago are fooked. Both lower joint gaters have split. They were the First Line ones from 106parts. Not sure whether to try some more or stump up and try and get some rose jointed ones. Surely someone must be doing them...



Tonight I did a test fit of the HiSpec Ultralights on the new struts as I wanted to make sure I had the necessary spacer shims from Marc for them. They fit fine, so I'm happy with that. Did a little bit of other faffing including taking the cheap wheel studs off the hubs (I'll be putting my Motorsport Spec ones back on) and then spent some time just tidying up as the garage was a complete state.





Discs and pads are off. Tomorrow I'll drain the brakes and removed the front calipers. I've left the flex hose unions soaking in penetrating oil over night. I also hate the photos as they just show the state of the arches and how much work is needed to get the car cleaned up

It'll be a case of stripping back all the arches and doing a bare metal repaint starting with POR15 and hoping there's no rot... what are the chances?

Finally the weights of the Bilstein/Eibach setup struts that came off (fully assembled with hub, shock, spring and top mount) was 17.22kg each. The ASTs come in at 10.76kg each. That's a 12.92kg weight saving in largely unsprung mass.
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Old 09-09-2010, 11:16 AM   #49
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Update

Didn't get into the garage last night so no progress to report. I did have some success yesterday in finding a supplier for some high quality adjustable droplinks. So I'll start a group buy and see if there is enough interest to get some made up.

Adjustable droplinks group buy thread here
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Old 09-09-2010, 06:27 PM   #50
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Strange that your drop links have died so quickly, mine have been on for 10k or so including a fair bit of track work and they're fine.

Oh and I don't think your arches will be too bad, mine cleaned up really well with very little effort. Main spot for rust was under the chassis legs as they go towards the bumper as that must be where the water collects.
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