Pugsley-Marie

[P-Courty]

Its bin a while so thought i'd make a progress thread, so here's the story so far.
Had a 1.1 saxo as my first car and when that died my cousin offered me her car for £400, 45000 miles, x reg, 1.4 meridian. Decided to buy it of her and use it as "just a work car, no messing with it". Didn't last long took it straight home and started seeing what i could utilise before scrapping the Saxo.
Get ready for a major pic whoring.

1st stop petrol station









Thats how i baught her now for the picture heavy updates ...

Debadged, dewipered

Induction from the saxo

Light upgrade 6500K

Magnex back box (yes looks huge but fits perfect)

Cut the old olive off

Weld it onto the new exhaust for a straight fit

Weld the old hangers on again for a straight fit

Decided to put the Saab Ronal alloys on with spacers and extended bolts, exhaust on aswel


A few pics
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Started a bit of painting with the old paint left over from the saxo.








A few subs won't harm too much

Couple more shots



Bye bye centre box


Left the car outside work and got the tire stabbed

Heading to a meet in preston an the coilpack gave in

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Just a big tree at Cheshire Oaks

Oil breather filter on

Dvd player from my old saxo

What the dash likes to do on cold mornings

Few photos after a good clean

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Oil breather filter ripped through its own hose (should of known really, Halfords)

New green cotton one will do also some nice stiffer Spax shocks

Oil breather fitted

Sticker bomb

Angel eyes

Decided to fit them as it was getting dark (as you do)

Found out why my car looked like a jeep, the spring clamps didn't work so had to use a hydrolic clamp at a mates garage to get them off

Looked a bit better, needed alloys again

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And then this happened fire started down at the gear box earth which, not until after this happened, i found out the crimps come loose which is common. It was sparking against the gearbox and must of lit something. It basically welded the driveshaft and gearbox together and melted the wiring harness and a bit of the inlet manifold.

So got towed home on a 17 mile journey by my mate who decided this sign would liven things up!

Thought that while the car was off the road would start changing a few bits of colour







I then baught a little Tigra to get around while i tracked down a gearbox, loom, inlet and driveshaft to get it back on the road. This took 6 months!! mainly finding the gearbox for the right price.

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Skip forward from 2012 to 2015-2016 (as can't be bothered trawling through the pics on the laptop of the other bits, only really painted the bottom grill purple to match, and baught an Escort estate for work, car was kind of on the back burner for sometime) I had white vtr wheels on which didn't look right, and then decided to start doing things a bit different.

Alfa Romeo 156 T-Spark (momo oem) did have the rears in aswel but took them out to make room for something else Had to remove the rails off the Alfa seats and use some lengths of steel to make a subframe to sit on the pug rails as the Alfa seats funnilly are wider but the rails are closer together, all in all the fronts were in in just a day the rears though took 2 weekends measuring, cutting, test fitting etc. will try and find a pic with them all in, and they would fold down aswel still fully functional. Also the fronts slide on the pug rails and height adjust on the Alfa lifter, also the seat belt tensioner fits on the side perfectly.




Got rid of the old springs after they snapped and upgraded a bit



Following on with the outside new wheels bolts etc all happened back in 2013








Inside




Still got the old drivers seat, made some great use of it

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Preparing for Pure Rally London to Edinbrough 2016






Also it has done this a fair few times since 2012 just thought i would add on, who needs a van anyway but rear beam is looking a little worse for wear now.

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Finally upto yesturday, this is what my day consisted of

Seens as the car overheated at the tip the other day and took a pee all over the floor i decided i've had enough of relying on the air con/blower/temp sensor to switch my fans on. This is the third time they have decided not to come on at a crucial moment.

So i have a print out of the wiring and parts, looks nice and complicated, so decided all i want is the fans to have 3 options, off, half speed, full speed, and will get rid of the air con rad (as like most of you know it never works!) and get 2 slimline fans instead.

So basically the fans are wired in parallel for full speed off seperate fused supplies and the crossover relay is there to switch them to a series setup (power split between both motors) creating half speed to both.<br />

On the phone i have an active trial circuit setup to work on how to have both half speed, both full speed and both off.

[pdg]

So, did you get a coat of paint on that rat-look rocker cover?

[P-Courty]

nope i really need to tidy up the bay again and paint the calipers so when i stop being lazy and get some high temp paint i'll get it done . At the moment the headlights seem really dim and with the fans not working properly i have a few wiring needs to attend to, just need a 3 postion switch for the fans and a few relays with 12awg cable for the lights.

[P-Courty]

On the lovely bank holiday i decided to get the fans wired up, but ran into a problem, battery was flat, while waiting i put my temporary switches in until i get the 3 position rotory switch to control off, low and high.

After charging it up i ran it so i could move it, left it running for a while to see what the fans would do, once up to temperature, right on cue, boiled its water and spat it all out but from somewhere at the bottom of the rad (suspected a new rad now ).

So time for test meters and links, all ok the meters and circuits. Started linking to get the fans running.
3 link pics at the bottom
1. no links, no fan (perfect)
2. links in, still no fan (ok somethings not right)
3. links it, tap the fan and away we go (fan was scraping on the housing so sruggled to start).

Right so the drivers side fan actually works but needs persuation, tryed the same with the passenger side fan after linking the crossover relay aswel and nothing, tryed all different layouts, 1 fan/ low speed 2 fans / high speed 2 fans and nothing, so looks like it's going to be new rad, pipes, slimline fans, and get rid of the air con aswel.

[P-Courty]

So definately need a new rad water is dripping straight out the bottom of the bottle
Also find out why the passenger fan wasn't working, i kind of forgot to put the fuse back in for it when testing [emoji4] still needed a knock like the other though, so tested single and 2 fan low and high speed all good so just rad needed

[insomaniac45]

have you not tried the aircon mod?

simply hit the aircon button to turn the fans on/off? if this is something you want to do, it is bridging a few pins in the plug behind the drivers side light on the aircon pipes, (cant remember what pins off hand) but its dead simple, and works really well.

If you were closer, i would say come round and get my spare rad and fans, as the rad is like 6 months old, and the fans worked (well they did on jims XSI :p )

Tony.

[P-Courty]

Cheers matey appreciate the kind of offer , i have been reading a few threads with people saying about the air con mod, i just have a slight problem, i can't see or press the aircon button without taking the face of the radio

So what i'm going to do is still be using the relay setup and running a cable from the dash fuse box to the switch so only has a supply on ignition, then from the switches will run 2 cables to the coils on the relays, which means the fans will still be able to draw a full load on their own supplies from the engine bay fuse box meaning i only need to run a little cable as current only required for coils not motors.
Basically using manual switches in place of the temp sensor and ac, so both fans will be on together in either slow or high speed. This is how it looks on paper... phone.
Both off

Both low speed

Both high speed

Both switched of again from high speed

[insomaniac45]

i have a great idea...









Fit a smaller stereo   

that is one huge ass system. but i can now see your issue on pressing the button

[P-Courty]

haha ye that is a good idea ... why didn't i think of that [emoji29] [emoji6]

I had a smaller one but was annoying when you try to watch anything or use the ps2 (missus always plays it on long drives, instead of kicking my ass she takes it out on good old Mortal Kombat [emoji106] ), also the output was low whereas this is 4x 80w, and rca outputs for all corners and sub [emoji41]

I kind of seen the details on it but didn't think of it being fitted before buying it haha.

[P-Courty]

So, the time has come, i did finish the fan setup with slimlines retrofitted to the original cowling but as of the start of this year the car has sat in a garage trying everything to get it to pass it's m.o.t on the emissions test but it just won't.

It's time to say goodbye to good old Pugsley after 6 years, i am gutted as although it has its days it's still been a great car.

The whole car is being broken to make way for something else French (hopefully), if you need anything let me know, preferably collection though as i am struggling to get a minute to strip it let alone box and post.

I will still be on the forum and shall post a thread of the new project once i actually get it.

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[Eeyore]

yehh definitely stay on the forum post a breaking thread up in the parts section.

[Mattcheese31]

that's why i broke my 1.6 as it wouldn't pass emissions and i didn't want to risk cost of a new CAT for nothing, still it's a nice starter engine, sure you're ready for something with a little more poke now anyway

[P-Courty]

Will post a thread up later.

And ye the missus is going to be driving soon so looking at another French car for her and something rwd for me.

I have changed lambda, cat, throttle body, icv, spark plugs and still sky high readings so time to give up.

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