Boring Black Rallye

[wainwrightj]

feel like this isn't going to be very interesting to most as i don't have any wild plans for this and mainly plan to use this thread as more of a build log for myself to look back on.

I bought the car on the 26th of July 2016 from someone called Sam over on the 306gti-6.com forum for £1600 seemed like a half decent price to a 19 year old with only the other prices of Black Rallye's to go by. Cambelt needs doing, very small amounts of rust on the doors and the boot, couple of dents and dings here and there but that's about it.

To begin with I plan on replacing standard things such as filters, engine oil and generally just trying to make the car slightly cleaner. Oh also need new front speakers as I put a screw driver through one whilst sorting out a rattle behind the door card.

I passed my test on 19/02/16 and bought a 306 1.4 Meridian and have only have problems with it but I may have sorta fell in love with the 306 quite quickly, and after looking around realised there was a 3 Door version with a 2 litre 16 valve lump also known as the Gti-6 after looking at these and discovering the Rallye it wasn't long before I owned one.

I went to FCS this year and took my camera I still have alot of images and if anyone wants to know if I have a picture of their car out on the track just drop me a PM and describe your car and I'll happily send over the photos, I wasn't out for all the track time but I was there for an awful lot of it.

Also if anyone wants any photos of their cars edited to say a different colour or dropped just to see what it would look like again drop me a PM.

   

   

   

[Frosty]

Always worth getting a project thread up, looks like a tidy rallye. Look after it and i can only see they going up in value as they are getting hard to come by now.

Where abouts in somerset are you?

[Matt-Rallye]

Looks in fantastic condition! as a fellow black rallye owner I will be keeping a close eye on this!

[wainwrightj]

Always worth getting a project thread up, looks like a tidy rallye. Look after it and i can only see they going up in value as they are getting hard to come by now.

Where abouts in somerset are you?

About 15 minutes from Glastonbury in a small village

[C2K]

Nice car but surely insurance is mental on a rallye at 19 given you passed this year?

Needs to be in 306 projects!

[wainwrightj]

Nice car but surely insurance is mental on a rallye at 19 given you passed this year?

Needs to be in 306 projects!

Thanks it's been moved now thanks to whoever that was

If I try to insure it at the moment its £4000+ but after a years no claims it should drop to around £1500 which is cheaper than what I paid to insure a 1.4 306 Meridian so although it's not cheap it's still cheaper than what I paid the first time round.

---

Okay haven't really done anything on the car since the last post besides chucking on a new rear wiper blade as the old one was shot although the rear wiper doesn't work it looks alot nicer with out the rubber hanging down the back of the car. I also put on some team heko wind deflectors as I have them on my meridian that you can see in the background of the last shot and find they help an awful lot blocking the sun when it's low in the sky.

I gave the outside a proper wash and polished a car for the first time which was definitely way more effort than I expected it to be. I followed a video I found on youtube by someone called ChrisFix worked a dream took way longer than I thought but it was worth it. The second picture is my reflection from the bonnet the white blurry specs are stone chips but I'm super pleased with how it cleaned up.

I have a general idea of what I want to do now and I thought I'd start somewhere easy and start by cleaning up the engine bay a little there's some rust here and there that's worth getting rid of whilst I have the time just need to get hold of some paint.

   

   
^^Reflection from the bonnet^^
   

[Ben_w]

Get it up in the air and have a poke about the chassis rails at the bottom of the bulkhead.

MOT history last year talks about rot to these areas (described as subframe mounts on the failure sheet) and make sure they've been repaired well. Have a good dig about the sills too, make sure they haven't been attacked by a trolley jack. Be a good opportunity to check the condition of the main front to rear brake lines as well, especially up around the tank.

[wainwrightj]

Get it up in the air and have a poke about the chassis rails at the bottom of the bulkhead.

MOT history last year talks about rot to these areas (described as subframe mounts on the failure sheet) and make sure they've been repaired well. Have a good dig about the sills too, make sure they haven't been attacked by a trolley jack. Be a good opportunity to check the condition of the main front to rear brake lines as well, especially up around the tank.

Thank you I'll have a look the next time I get to see the car probably Tuesday/Wednesday I'll take pics and you can tell me what you think I'm fairly clueless as to what's what so I'm trying to learn as much as I can reading through forum posts although nothing comes close to doing something yourself.


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[Ben_w]

Have a read of the first page of my other rallye project. It will show you what you need to know/see about rust. This one was bad.....!

http://306oc.co.uk/forum/showthread.php?tid=32215

[Eeyore]

Another black rallye owner! I paid 730 for mine but then it wasn't on the road and not as good as yours. If you got any pictures of mine at FCS it will have been the black rallye with the smoke coming out of the back dropping fluid everywhere :/

[wainwrightj]

Another black rallye owner! I paid 730 for mine but then it wasn't on the road and not as good as yours. If you got any pictures of mine at FCS it will have been the black rallye with the smoke coming out of the back dropping fluid everywhere :/

I only had 2 decent ones the first one was as the first session I watched was ending

   

And the second was this 

   

I still have the full res images if you want them, only uploading smaller ones to save space for the fellas hosting the site.

[wainwrightj]

Went out today simply to fix the check door strap or whatever it's called. Only because the door *clicked* as it opened which was frustrating although it all worked fine.

Here are the tools I used   
   

Here is the pin before
   
   

And here is the new pin
   
   

To fit get the old knackered one out I hammered the nail up from the bottom in an attempt to slide the pin out this didn't work as the base of the pin had been bent and was larger than the hole so after bending the pin around with an old pair of secateurs to make it smaller than the hole the pin slide out. I then slid the nail the whole way through to hold the door hinge in place to then push the new pin from the top down using the nail as a guide worked perfectly and the door now opens and closes silently. Only problem is I bought a new hinge along with the pin and I didn't have to use the hinge so I may be stuck with a new original door hinge alongside being £30~ out of pocket if they don't let me return it.

[Eeyore]

Where did you get the pin from? Just a generic thing of fron pug?

[wainwrightj]

Where did you get the pin from? Just a generic thing of fron pug?

It's a genuine one, I got it from a small garage called Lintells 'Peugeot specialists' and they ordered it for me, I'm not sure if this is a part number or what but the number written on the bag is 918163.

[wainwrightj]

Okay I feel as if this project thread might need a name change. I haven't done anything major to the car since the last post other than a service which I may have already mentioned. I didn't buy an air filter at the time of the service, I recently bought one after looking at the filter currently in the car, when taking the filter out I noticed the air box was rusty and wanted tot take it out and clean it up. Anyways I couldn't get it off myself with the tools at home so dad brought some from work and took it off for me whilst I was at work. And after removing the arch liner this was uncovered..





Sooo it's pretty bad and this is only on the front passenger side I'm too scared to look at the other side but I'm really hoping it's not as bad. In an attempt to make it a little better I decided to start chipping away the loose rust and this happened...





It's pretty horrendous, my dad said he'd do the welding on it which makes everything alot easier for me, in a sorry attempt to save what was there I ground back to bare metal where possible and then covered it in Kurust not sure if this stuffs any good or not I found it lying around in the garage.



As much as this sucks I'm glad we've spotted it now rather than later as I'd hate it to find this further down the line when this is on the road at the moment I still have my 1.4 Meridian to drive around.

Not much of an update, but I wanted to get something worth while added to the thread.

[Matt-Rallye]

Welcome to the rusty black rallye club

Thats not an uncommon sight on them nowadays fella

As you say luckily your dad can weld it for you which will save you some pennies! Stick with her and have a look at my black rallye thread if you wanna see some real rust issues

[Ben_w]

Not seen one do an inner arch like that before.

To be honest, I'd have the other side apart and also get underneath, and check the bulkhead before starting any work. See what you are up against and make a decision from that. If the inner wing is like that, I suspect there will be more elsewhere....

[Matt]

My inner arches are exactly the same

[wainwrightj]

Not seen one do an inner arch like that before.

To be honest, I'd have the other side apart and also get underneath, and check the bulkhead before starting any work. See what you are up against and make a decision from that. If the inner wing is like that, I suspect there will be more elsewhere....

The other side is a heck of a lot better, there's still a hole it's fairly big but there's a lot of good bare metal around the hole which can easily be welded to, the bulkhead looks good from what I can see but I'll make sure I have a closer look when I can I plan on taking the skirts off, I'm praying that's not too bad, I already know I'm not getting rid of the car so even if it's a lot of work I'm keeping it ahah!

When I check I'll post pics and you guys can tell me how bad it is in comparison to what's normally seen on these things [emoji6]


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[Ben_w]

My inner arches are exactly the same

Maybe I just landed lucky with mine then.......Apart from a very small amount of rust at the bottom of one chassis leg, mine is very solid. Perhaps all that black crap actually did some kind of good!

Find out soon enough when she goes off to be blasted!

[Eeyore]

Im sure mine is like that but I havent dared to look yet! Will make a start on it this year!

[wainwrightj]

Not been up to anything exciting on the Rallye mainly been cleaning up the rust slowly but surely. decided to take off the front end to make sorting out rust around the bottom of the wheel arches easier. Whilst I was taking the the bumper of I noticed a smaller thinner radiator in between the dual fan unit and the main radiator, I'm assuming this is for the Air Con my main concern with this is that the thinner radiator is straight for 2/3 of its length then bends towards the front of the car for the last 1/3 I'm unsure if this is meant to be bent and just wondered if anyone else knew how this was supposed to look.



I also bought some Deox-C Gel in an attempt to make getting rid of the rust easier, it works pretty good, makes a complete mess and infuriates me when the directions state you need an even 4mm layer of gel over the affected area which feels impossible when the gel will barely hold on to itself let alone bare metal. Anyways I cleaned up the air box and was pleased with how well the gel works even if it's a little frustrating to use.









I know it's not the most amazing transformation and there's still small patches of rust but I have since removed these.

If anyone's interested I start by chipping/ hammering large flakes of rust away from the object i'm de-rusting.

I then move to a drill with a wire wheel to get the majority of the softer rust away from the surface. I sometimes use the grinder for particularly stubborn areas before returning to it with the drill and wire wheel to smooth the surface down a little.

My plan for the smaller parts are to cover them in deox-c gel, then coat in kurust, primer and spray with rattle cans. I'm hoping this will be enough if not overkill. For the body of the car I'm going to again use the deox-c gel, coat in kurust and then cover with hammerite.

[Eeyore]

Looks good thats a great transformation. I wasnt expecting there to be any metal left on that air box!

[wainwrightj]

Looks good thats a great transformation. I wasnt expecting there to be any metal left on that air box!

Me either to be honest shame the same cant be said for the rest of the car ahah

[tigerstyle]

Aircon rads are kind of bent probably normal, but if you're not using it anyway, get it out?

[wainwrightj]

Aircon rads are kind of bent probably normal, but if you're not using it anyway, get it out?

What else needs to come out for the aircon to be removed or is it worth keeping it in given it's a rallye


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[Matt-Rallye]

Aircon in a rallye was a optional extra! the engine driven A/C pump would need to be removed and also all the associated pipework & the A/C rad and condenser.

Good work on the airbox, im having every single bracket & bolt on part stripped, blasted and powdercoated on mine to keep the rust away for the forseable future

[wainwrightj]

Aircon in a rallye was a optional extra! the engine driven A/C pump would need to be removed and also all the associated pipework & the A/C rad and condenser.

Good work on the airbox, im having every single bracket & bolt on part stripped, blasted and powdercoated on mine to keep the rust away for the forseable future

I considered doing the same but given the need to save money it's cheaper doing it myself. I also have no facilities to get the engine out so I'm having to work on the parts of the car I can get to without removing the engine.

[wainwrightj]

Got some more done to the rallye yesterday. Began painting the air box and the slam panel which have turned out okay, I wasn't trying to make them perfect as you can probably see, I just wanted to make sure the rust wouldn't be coming back anytime soon. So to begin with I had them both to bare metal, deox-c gel on areas that needed it, kurust, slightly sanded the kurust back in places where it had globbed together and then, 2 coats of primer and 3 coats of top coat.





Sorta bodged a setup with too pea sticks jammed into the ground to hold up the slam panel but it held it up without fail and allowed me to paint all of it at once rather than one side at a time.





I also had the rusty bolts soaking in citric acid to remove any rust from the threads and the head. I bought the citric acid rather than the bilt & hammer deox bath stuff because someone said on a forum somewhere that it's basically the same thing and I thought i'd give it a shot and too be honest it worked pretty well, I haven't got a picture of the results but you can see it in action here.



Once I pulled the parts out of the acid bath and cleaned them using my patent pending protein parts bin sounds complicated I know but all it is, is a protein tub with a hole in the top big enough for my pressure washer head to fit in without having too much spray back, and a series of holes drilled into the bottom of the tub to allows the dirty water to escape all over the floor.




BEFORE


AFTER

As you can see it cleans the parts fairly well for how much it cost 

Plans as of now are to continue working on the front of the car itself which isn't fun in this weather but I can insure the car on the 21st and plan to have a lot of the rust sorted out by then; cleaning up the underside, wheel arches and any other rust I find, haven't pulled the skirts yet although I might make a regrettable decision and pull them off when the weathers better so I can spend a weekend fixing any issue they're hiding.

[Matt-Rallye]

That parts washer is fantastic