Miami xud. Phase rust

[martyn92]

Thought I had best start a project thread as its turning into one!

Bought it in July 2011 and it started off as an honest phase 1.
92000 miles
Bosch untouched
Decent bodywork
Plastic trims!
Loads of service history from 1994 upto 2007 65k miles

Paid a massive sum of £250



Then didn't stay standard for long of course!
Obviously turned up the fuel/turbo
'6 brakes/axle
b4 shocks + eibach springs
Every bush/joint replaced
A set of lovely yokohama ad08's

Pretty happy with how it was tbh

Then this year it visited the ring and travelled Europe.



And broke down in the Ring carpark. (proud moment)



And then the brake pad decided it did wasnt happy and tried to depart on the autobahn





Soon fixed

Other than that the car handled the journey no problem

And work began soon after return...







Td04 going on with the wastegate!





Really started enjoying the turbo! 30psi and found it wasnt as laggy as I expected tbh. Still feels lacking somehow though, but think that its down to the exhaust and the excessive blowby!! (silly mistake of not honing the bores and/or changing the rings ) And every oil seal was flooding out oil.

---

Had planned to fix that after the MOT. However, that turned out alot worse than expected!

Usual things like lights and excessive exhaust noise. Oh and rust. Alot of it! Only failed on this small patch on the chassis rail



Which is always half the story...





Just needs finishing off now.
But whilst I was doing that I started investigating...











Had decided that I was going to scrap it at this point. Been to look at a few 306's and no luck. haven't found anything in a month so decided to spend a few hours on it today and see what happens and see if I can love it again.





And this is where im upto at the minute!

[Dicky]

Holy rust batman..

Looks tidy though and good to see you haven't given up on it!

[Jtrigga]

Can't scrap it phase 1s are getting rare now and it's in one if the best colours and few days welding and you will love it again.

[Jenkosowls]

Must have got the one that slipped past peugeots quality control! Pretty much rust in places that are very uncommon! The down side of rust is a 50p sized hole soon becomes a 6" hole. But soon rectified then loads of stone chip and under seal lol!

[Piggy]

holy cow....looks as bad nearly as the ph1cossack grey I had.
ph1 starting to rot proper now

[martyn92]

The problem is I don't think it's uncommon, there are 2 holes under the bonnet that let water run the length of the car. You can see them in one of the pictures above. It's just phase 1s have had time to rust. Needless to say I'm going to be welding them up.
I went to see another phase1 and it was exactly the same, because it rots from the inside out you you can't really tell until the underseal underneath starts to split from the metal swelling

[mr_fish]

keep the ph1 era going! good project though!

[ozonehostile]

ooh thats some nasty rot, i found a few bits that were starting to go on the sedan when i was ripping it to pieces, but nothing that bad

[Eeyore]

christ thats a lot of rust! D: Best colour though! Really really like it!

[c.gerrard]

This car is pretty damn mint on the outside, it has to be said!

What lurks beneath is unfortunate, but good to see you're sticking with it!

Get in touch if you want some company one weekend

[Piggy]

those holes arent a terrible idea...but what gets blocked is the drainage holes underneath

dont forget the huge gaps behind the bumper on the chassis rail at front!

[Seid']

make a rat-style with him

[martyn92]

This car is pretty damn mint on the outside, it has to be said!

What lurks beneath is unfortunate, but good to see you're sticking with it!

Get in touch if you want some company one weekend

Cheers Carl

those holes arent a terrible idea...but what gets blocked is the drainage holes underneath

Sorry but I dont see how in anyway there a good idea ? Two holes that let water run straight through the chassis and big rust holes along the way shows that it is a terrible idea! When water enters that section the next time it can leave is near the back of the car, regardless of whether or not the drainage points are blocked or not (which they aren't).

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More progress..









The above welds are pretty terrible tbh. The welder is too weak and has no more power, the welds are too cold And then the odd gush of wind which ruins the bit that your doing! Either way cant be any weaker than it was!
Just needs finishing and painting/underseal.

[martyn92]

Ive finally finished all of the welding! Just have to paint/seam seal everything then it can start going back together







Does anyone know what type is sealant is used between the bulkhead and the black metal plate thing? Anything specific?

[Daniel306]

I would just use black sikaflex or such cant see why anything specific would be needed

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Should stonechip the bit under the wing

[martyn92]

Cheers that stuff should work and yeah it will get as much protection as it can!

[Eeyore]

good work! keep it up!

[Jonny81191]

I used cheap as chips no nails adhesive to seal over welds and such. It's very similar to what was on there as standard

[Niall]

I use RTV lol.
Looking good and great you didnt give up after discovering all that rust! Most people would of done!

[martyn92]

Pretty much the finished product!





Just need to decide what is going on top of that to protect it.

Now I need to work out how to put everything back together :/




Ive also got a strange water leak in the passenger footwell. When I first lifted the carpet there was about a half inch or so of water in there. Now that its dried out though there seems to be a small puddle of water that keeps reappearing from (I think) a joint near the centre console. It just keeps leaking water even after a few days of no rain!

[Jimbo]

Fairplay with carrying on with this. Most would have given up

[martyn92]

Sooo.. Tuesday morning:



Wednesday night mostly done and started the engine again!! :



And back on the floor



Then onto washing it. Made the stupid mistake of working too close to the car cutting metal etc and all the metal filings covered the car and started rusting on the paint work. Made the paint feel like sand paper! Tried to get a picture of the mess, was all over the car.




And this was just a very small section on the bonnet:




Going to book in it for MOT on Tuesday. Have a feeling it might fail on the rear brakes as it only just passed last time and now they've rusted quite a lot. Ill just get them hot when I take it

[Jonny81191]

Good work! Re the brakes, try reversing a bit with the handbrake on, it cleans up the pads.

[martyn92]

Passed its MOT with a few advisories start of this month Well worth getting it back on the road again. Glad I didnt scrap it!

Yesterday took it to the Yorkshire RR meet and did much better than I expected:

Would love to know why it sounds like it crackles?






Was hoping for at least 160 and it made 179hp and 270lbs/ft.
Really pleased it made that and feel like it could do more considering the blowby and part of the original exhaust is still there which is less than 2" in places.

[Jenkosowls]

Certainly had some grunt to its sound on the dyno! Healthy looking graph too!

[mr_fish]

Fair play with sticking at it!

bigger exhaust to free up some more horses?

[martyn92]

Fair play with sticking at it!

bigger exhaust to free up some more horses?

Hopefully, definitely cant hurt it!

[bobertmate]

glad you took one for the team and saved the miami mate haha

[mikey b]

Good to see you sticking at it what was the rear inner arches like my ph1s really bad that graph looks good nice and clean all the way up no spikes or anything

[martyn92]

glad you took one for the team and saved the miami mate haha

Good to see you sticking at it what was the rear inner arches like my ph1s really bad that graph looks good nice and clean all the way up no spikes or anything

Cheers The rear arches are fine as far as I know anyway! Next year I will be cutting/welding the passenger side of the car thats for sure