Matts Onyx Rallye. 182.1bhp & 154.5ft/lb Wilwoods & axle arrived! Welding finished!

[Dum-Dum]

Awesome, hurry up rallye frwiend

[Matt-Rallye]

I thought the bonnet was ruined, turns out i had forgotten just how good i am with paintwork





Booked it in for an MOT test tomorrow. i know its gonna fail but i need to know how badly so i dont have the hassle of thinking its finished in time for pugfest then discovering its really not

[Orta]

Bonnet looks lush mate. U can give mine some of the same treatment!! What you think it's gonna fail on?

[Matt-Rallye]

Rot, axle and strut top mounts, possibly brake balance / performance

Recently had new tyres & new wishbones so should be ok on that front

[Dum-Dum]

Good luck. I hope the fail sheet isn't too long.

We could have a nice set of rallyes at pugfest with me, you orta and rowell

[Matt-Rallye]

Black rallyes are only more common now than ever because they are the most desirable ones and are well worth hanging onto pugfest should be decent

[Niall]

Looking good mate. Need to get them Rallye stickers replaced to finish it off!

[RetroPug]

What did you do to that paintwork?

[7057sam]

Paint work looks great matt

Come and do mine

[Matt-Rallye]

Well well well..

So it failed MOT on the rot i already knew about, the axle i already knew about and the missing headlight bulbs i forgot i had pinched for another car

So i get motivated.. got it straight in the workshop and ready for a beam swap and some major welding...

Failed epically at the first hurdle. whilst jacking the car the sill disintegrated around the jacking point and gave way, upon closer inspection the rust has severely spread throughout the inner sill Definitely no pugfest for the old girl now! but i don't mind as it has now been decided for a proper strip down and refresh / repair of any and all rust on the car.

As she currently stands: (working forwards from the back end)

No bumper
No arch liners
No exhaust
No fuel tank
No spare wheel / cage

Unfortunately i am having to leave the axle on for now untill the sill has been repaired as its the only solid bit of the car to support it while im underneath!

Im taking loads of pics to show progress and shall hopefully get alot done now i have a proper man cave Hopefully have it ready for some shows next year.. Wish me luck! Update with pics to come on monday when i can get to a pc

[Piggy]

good to see a decent effort will be made to keep a black one on the road

[ozonehostile]

The most annoying thing about that sill collapse is that there's nothing to put it on the ramp with without making an external cage or something aha. 

I'll be around later hopefully if you need bigger axle stands or the big jack  

[Orta]

Mate this sucks big time. Keep us updated

[Ben_w]

Whilst you've got all that lot off, have a damn good look around/poke about.

The fuel tank area on my Rallye had the beginnings of rust, and mines been looked after. Surface rust where the top of the tank had been rubbing, and a lot of surface rust around the edges of the tank recess.

Bump stops and the openings behind them are proper rust traps too. A pig to get at with the beam in place as well, so give them some love.

Last bit would be to look at the edges of your sills and take the time to straighten them out where its been trolley jacked in the wrong place. Did it on mine. Bit fiddly, frustrating and time consuming but definitely well worth it.

Depends how far you want to go on it really. Not sure if you've seen my project thread but I bare metalled the whole of the underside of mine.

[Matt-Rallye]

Whilst you've got all that lot off, have a damn good look around/poke about.

The fuel tank area on my Rallye had the beginnings of rust, and mines been looked after. Surface rust where the top of the tank had been rubbing, and a lot of surface rust around the edges of the tank recess.

Bump stops and the openings behind them are proper rust traps too. A pig to get at with the beam in place as well, so give them some love.

Last bit would be to look at the edges of your sills and take the time to straighten them out where its been trolley jacked in the wrong place. Did it on mine. Bit fiddly, frustrating and time consuming but definitely well worth it.

Depends how far you want to go on it really. Not sure if you've seen my project thread but I bare metalled the whole of the underside of mine.

Thanks for the hints and tips your project thread has been an inspiration (and im a fan of kerrys old car!)

Ive forgotten my camera lead but will update with plenty of pics tomorrow

---

Also the plan underneath the car (and to steal a cool idea from the rallying boys) is to paint the entire underside in brilliant white Shows any and every imperfection as soon as it appears! Will also be doing a few subtle upgrades and re-designs of the underside of the car over the standard items, already noticed a lot of bits that could easily be improved!

[Matt-Rallye]

Muchos thanks to work for a generous chrimbo bonus plus many hours overtime! been ordering alot of parts for this and im adamant it will return to the road this year miss driving it so much!

Parts being ordered include:

30mm bilstein B4 suspension
Stef beam set to 30mm
Caliper refurbs front & rear
Oil cooler kit

Shes booked in for welding at Jamtech motorsport in january so once thats done i can concentrate of getting it serviced and cambelted up then MOT'd hopefully then it'll be a case of saving for respray & new decals.

[ozonehostile]

Excellent sir

[Matt-Rallye]

Excellent sir

check your whatsapp dude

[Piggy]

Good lad

[Matt-Rallye]

Good lad

Looking forward too you overtaking me at the next track day i hope

[Dum-Dum]

Woop Woop, booked for welding

[Matt-Rallye]

Woop Woop, booked for welding

In truth i also had an offer i couldn't resist on the 106 turbo, Was getting overwhelmed with projects all over the place so going to just make the rallye priority #1 and get the old girl back out so i can enjoy it   the 106 sale has sufficiently enough covered the cost of returning this too the road hopefully.

Gonna book my FCS tickets now in fact while i have money in the bank for once

[Stef205]

dont forget your new wheels too

[Matt-Rallye]

dont forget your new wheels too

And the lovely Federal 595RS-R's i have ordered to wrap them in once they have been blasted and coated anthracite

[Orta]

Great to hear this project is getting going again!!

[7057sam]

dont forget your new wheels too

And the lovely Federal 595RS-R's i have ordered to wrap them in once they have been blasted and coated anthracite

Wheels? What wheels 

Definitely get it on track if you have them

[Stef205]

speedline chronos 15" et15 direct fit from our 106

---

In progress.....

[Matt-Rallye]

i believe these are the wheels

Beams looking good stef! just let me know when its ready for collection

[Stef205]

thats them matt, ill keep you informed

[Matt-Rallye]

Dropped the tank off in preparation for some major welding works. The rust is bad but not as bad as first thought!













Started removing rust out of the drivers rear arch also:



Started sanding down parts ready for powdercoat like the fuel tank cradle:



Decided to refurb my spare set of 6 brakes, heres a before / during / after shot then a few progress pics:













And ordered these bilsteins to match the new beam says in the add they are actually 30mm on a 6 / rallye hence asking for the beam to be 30mm not 40mm.




So yeah progress is finally being made