Matts £200 Cherry Rallye shell rebuild & tidy up project. Xsara goodies landed!

[Matt-Rallye]

For those of you not on the mighty facebook..

Drove 70 miles with a trailer on my new landy the other evening and came home with this.. 



So what did i have for my money?

Cherry rallye shell (complete with all panels, logbook and even MOT'd untill march next year!)
Full rallye interior in mint condition
OMP steering wheel & boss (already sold)
Few other goodies like powerflex bumpstops 

This is the car in its previous form.. 



And this is how it stands now...



Dragged it back too Zakks (Ozonehostile) unit as he has an incredibly handy 2 post ramp! All of the underneath work will hopefully be carried out here by myself and Zakk. 

Plans so far are as follows but are subject to change at any given time. 

- Strip, clean, repair, paint and protect the entire underside.
- Repeat process in engine bay / inner wings etc.
- Get all brackets / mounts / subframe etc powdercoated.
- Refresh spare engine I already have, new gaskets & seals, new clutch etc and full service inc belts.
- Fit rebuilt 30mm lowered beam I have been hoarding.
- Refit full standard interior.
- Purchase some decent shocks & springs to match the beam.
- Fit wilwood 4 pots (also hoarded)


Aim is just for a nicely fettled OEM+ rallye, Will see if i end up falling in love but in honesty at the moment its mostly about saving one rather than see it go to the scrap heap maybe even make a penny or two but who knows.

[PocketFighter]

good god... i want it lol

and the spec! i want that spec too!

[Eeyore]

it was that spec. not that now. great to see it being saved!

[DeeTurbo]

Looks to be a great project.

Looking forward to seeing updates on this.

Sent from my Nexus 4 using Tapatalk

[roland rat]

Well done mate,saw this up on facebook for sale and si nice to see it being saved

[ozonehostile]

Better stock up on sanding discs and thinners again then haha

Not overall a bad shell, just had some badly executed rust repairs in a previous life, I'll be chopping all this out and plating it properly, should be a very nice example by the time it's done

[Matt-Rallye]

Better stock up on sanding discs and thinners again then haha

Not overall a bad shell, just had some badly executed rust repairs in a previous life, I'll be chopping all this out and plating it properly, should be a very nice example by the time it's done

I cant wait to get my teeth into it

Also need to get you on that welding before the missus finds out how much cash im going to be parting ways with

[ozonehostile]

Better stock up on sanding discs and thinners again then haha

Not overall a bad shell, just had some badly executed rust repairs in a previous life, I'll be chopping all this out and plating it properly, should be a very nice example by the time it's done

I cant wait to get my teeth into it

Also need to get you on that welding before the missus finds out how much cash im going to be parting ways with

Remember, when the girlfriends are concerned, everything only costs £50 ;

Set of new tyres, £50
Set of Bilstein shocks £50
Complete restoration and rebuild, £50... 

Haha

[Matt-Rallye]

Better stock up on sanding discs and thinners again then haha

Not overall a bad shell, just had some badly executed rust repairs in a previous life, I'll be chopping all this out and plating it properly, should be a very nice example by the time it's done

I cant wait to get my teeth into it

Also need to get you on that welding before the missus finds out how much cash im going to be parting ways with

Remember, when the girlfriends are concerned, everything only costs £50 ;

Set of new tyres, £50
Set of Bilstein shocks £50
Complete restoration and rebuild, £50... 

Haha

You certainly know the score sir

[Ben_w]

£200?

You jammy devil. Where did you get that from? Wish I could find a few more bargains. The only one I had was my other red rallye which I paid £300 for......

[Matt-Rallye]

£200?

You jammy devil. Where did you get that from? Wish I could find a few more bargains. The only one I had was my other red rallye which I paid £300 for......

You paid £300 for a running and driving rallye! i think you still retain the bargain crown dude

I just always seem to be in the right place at the right time! or the wrong place and the wrong time if your asking my girlfriend

[Ben_w]

well, it ran, and drove, if you like driving with absolutely no brakes....

I ended up chucking another £400 ish into it to get it done.

I think Carl Chambers still has it to be honest. Might look at buying it back next year and tracking it

[Matt-Rallye]

well, it ran, and drove, if you like driving with absolutely no brakes....

I ended up chucking another £400 ish into it to get it done.

I think Carl Chambers still has it to be honest. Might look at buying it back next year and tracking it

Tbh £700 for a fully functioning rallye is a bargain price

I think you should have an OEM cherry rallye and a track slag cherry rallye, epic driveway!

[procta]

why was it dismantled?

[Matt-Rallye]

why was it dismantled?

It was a high spec ITB engined beast and as always, worth more in bits so was broken down to a shell which i managed to scoop up last minute

[Ben_w]

well, it ran, and drove, if you like driving with absolutely no brakes....

I ended up chucking another £400 ish into it to get it done.

I think Carl Chambers still has it to be honest. Might look at buying it back next year and tracking it

Tbh £700 for a fully functioning rallye is a bargain price

I think you should have an OEM cherry rallye and a track slag cherry rallye, epic driveway!

Thats ultimately my plan. Just don't tell the wife.....as long as I don't park both on the driver at the same time, shell never know.......!!!!

[Ben_w]

Thanks Oz but two things:

1) it's way too much money for what it is and with its MOT history (several references to rot by the subframe mounts and generally the underbody)
2) I haven't got the money at the mo!

[roland rat]

Oz that's far too much money for a not mot'd bumped rallye!

[Matt-Rallye]

Has a post been deleted? :/

EDIT: Just found this, guessing by the ebay username it was something to do with this shed?

http://www.ebay.co.uk/itm/306-Rallye-85k...SwFe5X1bJH

[Mattcheese31]

Has a post been deleted? :/

EDIT: Just found this, guessing by the ebay username it was something to do with this shed?

http://www.ebay.co.uk/itm/306-Rallye-85k...SwFe5X1bJH

yeah, my doing, 1st post and trying to sell so i extended my size 10

[Matt-Rallye]

Has a post been deleted? :/

EDIT: Just found this, guessing by the ebay username it was something to do with this shed?

http://www.ebay.co.uk/itm/306-Rallye-85k...SwFe5X1bJH

yeah, my doing, 1st post and trying to sell so i extended my size 10

My detective skills are 2nd too none

[Mattcheese31]

Has a post been deleted? :/

EDIT: Just found this, guessing by the ebay username it was something to do with this shed?

http://www.ebay.co.uk/itm/306-Rallye-85k...SwFe5X1bJH

yeah, my doing, 1st post and trying to sell so i extended my size 10

My detective skills are 2nd too none

*to . . . . .  

[Matt-Rallye]

My grammar skills however are evidently 2nd to* yours

[Matt-Rallye]

Well last night me and Zakk (ozonehostile) got cracking with this. 

Firstly we needed an excuse to take his gti6 out for a spin... cue a milk and biscuit run to the local garage! 



Many bwarps and much diff & quickshift action later we find ourselves back at the workshop, brew in hand and no idea where to start!

So decided to remove the rear bumper, fuel tank, brake lines, fuel lines and rear arch liners. Get in there with the grinder & wire wheel then liberally apply some white hammerite



















Stay tuned for more exciting (boring) updates!

P.S. Massive thanks too zakk for all his helpful hard work going into this

[Ben_w]

Looks about right for underneath a Rallye!

They are a sod for the rust round the edges of the fuel tank bay. Mine was exactly the same. Try and get as much of the shite/crap/rust out of the open box section behind the bump stops as you can. I can see these areas being a pain in the ass in the future although I'm surprised we haven't seen any cars with issues in these areas yet considering the crap nature of the design of this bit.....

looks like a good job under there though bud.

[Matt-Rallye]

Looks about right for underneath a Rallye!

They are a sod for the rust round the edges of the fuel tank bay. Mine was exactly the same. Try and get as much of the shite/crap/rust out of the open box section behind the bump stops as you can. I can see these areas being a pain in the ass in the future although I'm surprised we haven't seen any cars with issues in these areas yet considering the crap nature of the design of this bit.....

looks like a good job under there though bud.

Its a similar state to my black one, wish i had had the foresight to do this when i first had that! would of saved me alot of hassle

The fuel tank seems to be a dirt trap on these, glad to report its solid although if it had been left unattended i wouldnt like to estimate how long it would of lasted. The section by the bumpstops is a pain! Going to invest in a dremmel or wire brush attachment for a drill and do the best i can.

[Ben_w]

Looks about right for underneath a Rallye!

They are a sod for the rust round the edges of the fuel tank bay. Mine was exactly the same. Try and get as much of the shite/crap/rust out of the open box section behind the bump stops as you can. I can see these areas being a pain in the ass in the future although I'm surprised we haven't seen any cars with issues in these areas yet considering the crap nature of the design of this bit.....

looks like a good job under there though bud.

Its a similar state to my black one, wish i had had the foresight to do this when i first had that! would of saved me alot of hassle

The fuel tank seems to be a dirt trap on these, glad to report its solid although if it had been left unattended i wouldnt like to estimate how long it would of lasted. The section by the bumpstops is a pain! Going to invest in a dremmel or wire brush attachment for a drill and do the best i can.

that's pretty much how I attacked them.....

You might find there are surface rust spots where the tank rubs the body. There was on mine. I bought some sticky backed neoprene sheet from ebay and cut it into sections to apply to the tank where it had been rubbing to stop it doing it again.

[Dum-Dum]

Wow that white is bright, not sure I'd have gone for such a bold colour underneath. That said I reckon black would be too dark if you wanna show it off, red wouldn't necessarily look right on a red car and I'm not sure about silver.

[Eeyore]

so what was the reason for the white apart from dum dums suggestion? And how much did you use to do what youve done in the photos?

[ozonehostile]

so what was the reason for the white apart from dum dums suggestion? And how much did you use to do what youve done in the photos?

As a finished job, all white undersides look great and overall make the entire car look cleaner, the rally boys do it to cars so when it comes in to service you can immediately see anything broken underneath as it stands out like a sore thumb. 

We've used a 1l tin so far, I finished it off today ready for the petrol tank to go back in, to do the whole car it'll probably take about 4l of paint as white needs a few coats to conver it as a solid colour.  

I personally prefer silver on my cars as it covers better and has the same effect but it's the customers choice at the end of the day!