Ben306 Rallye Thread

[ben306]

Please bear with me, as I'll be copy/paste from other forums so they might be all over the place.

I'll try and start from when I bought it all the way back in May 2006 in standard form.

Anyhow, here we go. Please give me time as Im sure it will be a few posts lol

Car was completely standard when I bought it in May 2006

The locks had been done (barrels buggered) and the car had been keyed down both sides. The bodywork was actually pretty shabby but the engine was a minter, which is what I wanted

Car when I 1st bought it.



They just before I lowered it I had fitted the single wiper, Magnex, powertec induction kit, decat.



Then a couple of hours later after a 60mm/70mm drop and a swap to AVO adjustable setup.



It has then had a trip to the bodyshop where it has had the locks removed (to stop the theiving scum trying again), where it had been keyed all taken out, and all the side strips colour coding.

It was then time for French Car show where it would make its 1st Track appearance and the car lived up to and exceeded my expectations.

By this point, the dtm mirrors have been added along with my 1st buckets and harnesses.





After the track action there wasnt much left of the tyres so the white BK racing rims have now gone on it along with a new front strut brace.













Then I stripped it right out and this actually left the back sitting pretty high again



Spent 2 weeks of work and it was sporting a new smooth front end, crystal headlights, lowered a little more and stripped interior.





And just how low it really is!!!

Next to a standard 306, you can really see the 80 / 100mm plus drop front and rear



Id swapped over to GAZ adjustable, along with OMP group N pads, Brembo disks and had the middle box removed.


I then got asked to have the car in the PGAC annual calendar so had a photoshoot done.

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[ben306]

Gave the car one of many proper detailing/polish/wax in prep for the shows of 2006.

Before


After




By this time Id added a Nissens Alloy rad, Tarmac Sump Guard, Uprated suspension top mounts, Mintex M1144 pads and group N grooved discs all round, OMP Record seats and further stripping of the interior.

And Ive also got a new camera to take lots more pictures.






Had a play with the new camera as well.








Also been on the rolling road with it, managed 181 bhp at the fly and 163 at the wheels, proper chuffed with that.

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[Just Sean]

I'm sure this was in PFC not so long ago?

[ben306]

And the next mod for it was.......... thermostatically controlled Mocal oil cooler to solve the problems of high oil temp on the track.




Well I fitted the oil cooler a month later in time for the track at Donny!!




Refurbed my wheels again (1st time was when I 1st fitted them to the rallye)

before


During


After


And also dropped the spare steelie and cage from under the car, now have this

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Then in true form cooked my brakes at donny, been having this problem constantly, and tried a few brake setups as I really do drive the car hard, so decided on a full caliper refurb and DS2500 pads



Oil cooler pipe split on me



Then the driveshaft went



Then driving down the road with a loud knocking, ended up being only 2 nuts left in the wheel, almost fell off hock:

So decided its trying to kill me!

So went to full race spec, aircraft twist release 3 inch 4 point harnesses

Before



Now




Bumper started peeling following my inner arches shooting out at donny on track



Wheels got refurbed again but it was a crap job on them

[ben306]

Anyhow, I sorted them out, rubbed em down and buffed them up, and they dont look to bad.

So had bonnet resprayed, bumper resprayed and boot smoothed (Stone chips from the airfield trackdays hammers the front of the motor)

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With FCS on the cards and being selected at top25 I got to work on minting the car out.

Got busy underneath, sealed, cleaned and repainted as well as polished the exhaust up.

Before


After



Also done some new rally/race doorcards

Before


After



And done the back to match.


Then came along the.....

Powered by Maltesers, lol. Think we all remember this, tho it didnt last to long before it got binned





And polished up the inlet manifold.

Pic from USC Show and Shine last weekend


Had a busy last few months then.

Done the engine bay out, polished rocker covers, battery cover, fuse box cover and powersteering res cover, painted manifold, braided fuel lines and a general good tidy up under the bonnet.





Then it spat a driveshaft (its probably done half a dozen lol)



Put a new gearbox and clutch along with group N engine mounts, engine chocks and a group A lower mount, turns out the reason for the bust driveshafts was a shot top mount



Then it was looking something like this

[ben306]

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And it was in Novembers 2007 issue of Performance FrenchCars Magazine




Hammered it around a few more tracks aswell

Resulted in me spraying my cyclones black, just cos I could and didnt have to bother with the brake dust lol




Ended up like this




Anyhow the results of the feature





And some of the tracks I have done.

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Bruntingthorpe

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Mallory Park

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[ben306]

Donington







Elvington



York Dragway

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Then along came the cage

Was just placed in the car to get it home, got it cheap from up in scotland, was worth the drive for some epic roads





And some of the brakets I made up ready to fit it



Then spent a saturday modding it and fitting it





All in and painted up









Managed to test it out with a few sessions at Donny, was surprised how much difference it makes in stiffening up the whole car.

[sam]

Got to say this is my favourite rallye! Love the work put into this

[ben306]

Also sprayed up all the interior floor





Decided to change the track rims (and one I use as a spare) to white

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Rubbed down ready





Primed



Layering the coats on



Final coat



And the finished article with laquered finish



Repaired the drivers seat with a pair of new patches (not the best but 100 times better than before)

Before



After



And tonight, fitted the new wing, gonna need to give the car a good going over to get the colours matching lol.





Rust on the old copy panel



Original pug panel now fitted

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[Grant]

Absolutely love this. So fresh. Great work here!

[ben306]

Few more from out on track

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Few from Anglesey from Oct 2008

So a few from Anglesey back in October










And then pretty much how it looked before it went into storage for my time away in canada

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[ben306]

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well 9 months stood still has took its toll

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Anyhow

Well its got jet washed and thats about it, just been enjoying being back in it,

Anyhow, its already mucky from some of the 'rally' roads Ive been playing on lol.



Then trying soming a little different, out on the 'rally stages' lol



And abit of flameage



And was experimenting with different camera locations for when Im back out on track in the new year

not sure if it works tho with the wind noise etc

http://www.youtube.com/watch?v=cSK-lA7952o

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Out in the snow earlier today, but wouldnt managed to move the car now as the snow is about an inch or so up the front bumper.

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Been out in the snow some more.

Last week



And today. Got a little sketch a few times

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I'll get one of the footrests fitted next time I give it a good going over.

As for the detailing, i do it myself, tho need a proper machine polisher to do a few bits of paint correction.

Now I have the DT I may get chance to spend some time back on the rallye and getting it back out on the track where it belongs.

Its in need of a full detail tho, just need a dry/mild weekend where Ive nothing planned so I can give it the full once over.

Anyhow, the latest one of it from earlier this week with its older/smokier brother lol

Bit of a difference

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[ben306]

Think I still prefer the white wheels, might just use these through the winter and put the white ones back on next spring, use these on trackdays then.

Thinking the HG is defo on the way out as well, so hopefully it will survive Trax this weekend then I'll be getting messy again.

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Was great until the last lap. hahaha

Few of the only photos I've managed to find.

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We'll unfortunately I've only managed to get about 5 minutes of footage from my tracktime at Silverstone. I'd never recharged the batteries in the camera . wasnt my day anyhow when it come to track time!

clicky

Found traffic to be a bit of an issue all day, people not moving over/ others forcing past, suppose thats the issue with these 'sessions' at shows as full on trackdays seem to have a total different attitude to drivers around you etc.

Anyhow, I didnt even get my 'incident', which happened after about 4 laps of playing with the cossie.

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RR at 184bhp at Waynes/chip wizards.

The incident was a wheel coming loose and trying to make a bid for freedom at Silverstone. Luckily Id felt it and had slowed right down before it actually come off, got away with minimal damage really.

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Well finally managed to make a start on the rallye over the weekend. Got the head off and found a mountain of other things that needs sorting, in true Peugeot form. Big thanks to my bro for his help so far.

Before we started, as you can see, all the staining from the coolant pressuring up past the rad cap



Then with the manifold off



Can see in the left most cylinder where the water had been passing the gasket, always good to confirm the failure.





From the colour of the valves it looks as tho water has been getting in the 1st 2 cylinders. We had real issues getting on of the sparkplugs out.







We had planned to leave the manifold in place but found a few cracks in it thats going to need welding up this week.









Finally, the head all ready for sending off to be tested and skimmed.


The list so far is,

Head sending off for testing and skimming

Weld up manifold

New gaskets all round

New top mount and buffers

New Powersteering ram

Waterpump

Thermostat

Head studs

Cambelt kit/pulleys

Fan belt

Full service.

Its an expensive week lol.

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Decided to make up a new sump guard while the old one was off, the old one had taken a proper battering over the 4 years its been on, so decided on the new one to put some strengthening into the weaker points I found.

Anyhow, here it is ready to go on at weekend when it all get put back together

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Well the rallye is back on the road and it feels so good to have it back running right again.

Once again, big thanks to my Brother for all his help, Saturday was a long day putting it all back together.

The block cleaned up

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[ben306]

The Head back from the engineers







Head gasket on



So much easier with the use of a ramp



The head on and torqued down



Plugs, coilpacks and exhaust back on



Manifold and everything back on



Finally, the new sump guard on



All in all its had

Head tested and skimmed
All new head related gaskets
New super 4 spark plugs
New top engine mount and new chocks made up.
Exhaust manifold welded up
New sumpguard with additional strengthened sections
Full service, oil, water and filters
Cambelt, pulleys, tensioners
Waterpump
Fan belt
Thermostat
Probably more but cant remember.

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well it managed 2 days /140 miles before I started getting a knock, so its been parked up waiting investigation.

Managed to get it back on the ramps last night and its spun a bearing.

Looks like all the hard work is gonna have to be done again, this time with a bottom end rebuild.

luckily I heard the knocking straight away and the car didnt do more than about 3 or 4 miles at low revs.

There isnt too much in the way of damage to the crank or cups, very little marking, waiting to see if you have any tolerences in the shells. Measured 50mm on the crank and 49.9mm on the one that spun, the cups where all the same.

But the way my luck has been Im not expecting it to be that easy.

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Well the rallye was finally alive again over the weekend. Massive thanks to my brother (Jack aka top mechanic) who did the rebuild for me, I pretty much watched and got in the way.

All in all its had the top end refurbed, then the bottom end died so its had a full engine rebuild.

From memory its had all of the below. Most items have been increased performance/upgraded items where possible

New super 4 plugs
Head skimmed, tested, polished and cleaned up
New head gasket (2 times round )
New head bolts
New inlet/exhaust/thermostat housing gaskets
New fire ring and exhaust fitting kit
New oil (2 times)
New coolant (2 times)
New power steering fluid
New gearbox oil (2 times)
New gearbox driveshaft oil seals
New clutch kit
New thermostat
Fresh bottom end from Birk which turned out to be knackered, I managed to salvage the crank and thats it.
Fresh piston and rod
Fresh crank, polished, balanced and checked
New big end bearings
New shell bearings
New crank oil seals
New waterpump
New piston rings
New bottom hose
New powersteering cooler pipe
New sump guard
Engine bay steam cleaned
Rust in engine bay treated and painted (needs final touching up)
New cambelt kit, pulleys/tensioners
Various engine bits painted
New Aux belt
New top mount and chocks
Wheels re done
New Ferodo ds2500 pads
Will be re painting the calipers etc
Towing eye straightened (Following wheel coming off at silverstone and car being lifted by track recovery)
Front bumper insert refixed (Following wheel coming off at silverstone and car being lifted by track recovery)

Probably alot more that I cant think off.


Load of boring photos now (and not in the right order but I cannot be fussed to sort them). Its at FCS in the Top 25 in less than 2 weeks so need to tart it up

[ben306]

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And today Ive had new wheel nuts land, so hopefully the wheels will stay on now

And also had my 1st bits land for tarting it up, set of small circuit stickers, dunno how they will look but thought Id see.

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Well its almost fully detailed now.

Got a last few panels to do if we get a nice evening before the weekend, plus got the interior to give the once over.

Repaired the rip in my seat and re painted the calipers, also got my stickers on now.

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Well its almost fully detailed now.

Got a last few panels to do if we get a nice evening before the weekend, plus got the interior to give the once over.

Repaired the rip in my seat and re painted the calipers, also got my stickers on now.

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Well was in the Top 25 at FCS but the rallye was probably one of the only ones thats driven regularly/properly going off the fact some turned up covered in masking tape. Anyhow, felt like I should have been out on the track, was only the fact that Im still bedding in the engine that stopped me getting giddy.

Anyhow, spotted a few photos of it so thought Id post some of the better ones up, some of the rare occasions its actually quite clean.

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Right, well got Blyton on Saturday so trying to get the car ready for that now but the weather isnt on my side. The throttles been sticking and Ive found that to be the cable, appears to be splitting so got myself a new one to see how it is.

Also gone and got myself so Roller bearing bushes to go on this week, see what difference these make to it.

Photos thank to Rich W's for sale thread. Mine are actually second hand from Andy who was breaking his track car.

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so fitted my new oil cooler, will have my old one for sale soon if anyone is interested









Full oil change after the rebuilt engine was bedded in, gone for castrol edge this time



Also trying a new brake set up with M1166's



Again I will have my old pads (practically new DS2500, only covered 500 miles) for sale soon if anyone is interested.

Finally some of the more recent photos of it













Hoping to have the cable and bottom arms swapped tonight, and get the brakes bled up. Fingers crossed it will sort a knock Ive got, but in reality I know its not the bushes.

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Few of my day at Blyton on Saturday. Will get some vids sorted when I get chance.

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Ive uploaded a few vids from Blyton. Ive more from later in the day but will see If I can be fussed to sort them

Clicky Vid 1

Clicky vid 2

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Went and picked up the wheels on Sunday.

Fitted them as soon as I got back.

Still prefer my white ones, but after an 8 year relationship with them, haha, its time for a change and these are what Ive got. I will be selling my old set (set of 8 with 5 goot wheels) on once Ive got the tyres off.



And fitted



Still prefer my white ones but the front still needs to come down a bit on the coilovers which I think will help make it look right, but they are coming back off to get sent to AVO anyhow.
I've not had silver wheels on the rallye with the exception of about 3 weeks after I bought it. Just dont think it suits silver, hoping its that and not the wheels (although still going to keep an eye out for other wheels)

Thinking of going this style with a white centre cap and red 'Raceline' stickers.



Firstly, what do you think of it as it is? Can any one photoshop it for me. One pic with white wheels, another pic with red wheels and maybe another with graphite grey wheels?

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The coilovers 'were' on but have been taken back off as it turns out they wont adjust and need to be set off for repair. Need to send them off to AVO so they wont be ready for Anglesey next week now, but hopefully its getting sorted now and me and the seller.

Ive put my original GAZ set up back on with the new wheels, they are growing on my but will need to go a colour.

Quick picture with it sat back down again on the new wheels.



Just need to swap some pads over and might put some mud flaps on it ready for anglesey! Wanted to run some brake cooling ducting but struggling to find any.

Ohh and it needs a blast with the jet wash, green bits are growing again.

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Few from anglesey.

Got a vid of me on an open track so some good laps, and another with Sean for a good few laps.

Had to swap the oil cooler after the 1st session as I had a leak, so that was fun for an hour.

Start with the excuses, I had different road tyres to what I usually run, strugled alot with them, had the car all over the place until you got decent heat into them. Usuauly took about 3-4 laps and then they seemed pretty good until they got too hot and dropped right off. Didnt have the confidence in them like I usually do. Getting sideways at 90mph on the quickest corner slows you down haha. Dont know if anyone got to see how bad it was on cold tyres?

Anyhow, good video with Sean.

Clear laps

http://www.youtube.com/watch?v=2kb4vPPYo1c

With Sean and his 182 clio

http://www.youtube.com/watch?v=GYwyq6WIc0A

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Well in the process of trying to get the Brembo's on, I'll probably regret it as everyone goes on about how bad they squeel, but we will see.

Still need to work out the best discs to go for and pick up some pads yet. Only tried them on for clearence checks and Ive shaved the calipers down a tad and made some 3 mm spacers up so that they fit without catching the wheels, though Im nothing more than a hairs width away, they are so close.

I need to get hold of some decals now and then discs and pads.

As I picked them up



1st trial fit



With the gti6 disc, wrong offset.



They caught the wheels



So they ended up being shaved a little



2nd trial fit after 1st coat of fresh paint, close with the 3 mm spacers







Final coat of paint

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Well Ive finished the refurb of the calipers.

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Also these group N peugeot sport gear rods which should give a cleaner/ more crisp gear change.

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Well the brembos are all fitted now, running Ferodo DS2500, 40 grooved discs which I get machined up for me. and touch wood, not any squeal yet.



Before on standard calipers







Bigger discs







Chamfered edge I cut into the pads









Anyhow, decided to get out in it today and have a proper drive, nice to get back out in it on a decent afternoon. Got a few new photos



The new brembo set up on!







And a few from my drive out.

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Just picked up my wheels, freshly powdercoated in white.

Quick sneaky pic



Should look ok once on I hope. Hoping to turn upto my wedding in it, lol.

Imagine this but with the wheels white (and the mudflaps gone)

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Now on the car, quick crap pic from the phone.



Definately need the Raceline decals back on them, just order them.



Think they need to grow on me, still prefered my old ones I think!

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Some better photos although taken on the phone

I think it looks much better with the decals.

Will sort out some decent photos once I've given it a clean and dug out the camera

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Latest update for you.

From our recent wedding on the 17th August 2012





Got another feature of the rallye in the next issue of Performance French Car Magazine, Out 7th Feb.

If anyone is interested in picking up a copy for a read. No idea what the write up will be like, but its titled 'Budget Track Car' so no idea how to take it yet. It could paint me in all sorts of different ways

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The latest feature

[Kimmie]

This car is f*cking gorgeous <3 Didn't you use it as your wedding car?

[Seid']

love it dude. realy! It's awesome, if it was mine, did not change anything!

[Piggy]

Ben, gorgeous. Nice to see a rallye used on track.

[procta]

fuckin hell a blast from the past! hows thing ben! nice to see you have the car still!

[Rich306]

Thought i'd recognised the Rallye from PFC!!!! Good drills on using it as the wedding car

[ben306]

Yeah, had it 7 and half years now.

TBH its not had much love these past 12 months and hasn't seen a track for the past 18 months due to us still trying to recover from the cost of the wedding last year.

Anyhow, I've started with some TLC again now.

Last weekend it had

New braided Teflon fuel lines
New front discs
New M1166 pads for the brembos
New M1144 pads for the rears
All the front inner arches treated and painted
Sumpguard straightened and repainted
New oil cooler and hoses
New bottom rad hose
New alloy radiator

Needless to say I was knackered from it all, but I want to get it back out on a circuit for October/November with a view to getting back out regular again.

Currently on the look out for an 18mm passenger hub as the threads don't appear great in the one Ive got.