Project_5AXO - Reliving my youth!
Discussion
mwstewart said:
Great job. What are BE hubs?
BE is the gearbox designation. BE gearbox's were fitted to things like Picasso's. Saxo's came with MA designation gearbox's. They share the same bolt pattern of my Saxo block but most importantly they are rated to much higher power (~450bhp). They do this by using much larger shafts. It means some custom mounts and drive shafts to suit but it'll mean it's next to bullet proof. Evo Sean said:
BE is the gearbox designation. BE gearbox's were fitted to things like Picasso's. Saxo's came with MA designation gearbox's. They share the same bolt pattern of my Saxo block but most importantly they are rated to much higher power (~450bhp). They do this by using much larger shafts. It means some custom mounts and drive shafts to suit but it'll mean it's next to bullet proof.
Ahh, very nice to have that option.
mooseracer said:
Enjoying this, thanks.
What management are you planning to use?
At the moment, its my understanding that the std ecu can be remapped. However, i havent ruled out an aftermarket solution. What management are you planning to use?
I used a KMS setup on my last build that proved successful. More thinking to do on that.
A busy few evenings on the car this week. Now the engine is out and before I crack on with the welding work needed I wanted to get the removable components refurbished. First part of this was the power steering system. I did toy with going to a non PAS setup for simplicity. However, it's a road based car that will see the occasional race track therefore usability is key. I decided to retain the PAS. Pics do the talking I guess;
Before;
Stripped down and cleaned everything;
Just waiting on paint to turn up before reassembly this week. Of course I've done all the usual zinc plating of hardware and new rubber boots will be fitted. Should look brand new.
All this will feature is Ep20 next week with some luck.
Before;
Stripped down and cleaned everything;
Just waiting on paint to turn up before reassembly this week. Of course I've done all the usual zinc plating of hardware and new rubber boots will be fitted. Should look brand new.
All this will feature is Ep20 next week with some luck.
Edited by Evo Sean on Wednesday 13th October 08:28
Small update. As Christmas approaches and the projects funds are stretched I'm having to do jobs which don't cost a lot of money. (How do people fund project cars!).
That for me means welding! A few jobs I need to do;
1. Passenger side inner wing repair - DONE
2. Drivers side inner wing repair under ECU
3. Drivers side inner wing repair above chassis leg
4. New front bumper brackets to weld on
5. Chassis strengthening kit to add on - more on this shortly.
All this needs doing before I can think about painting anything to look nice. However, once these jobs are done then I can apply the raptor and have a shelf full of lovely shiny bits to bolt on.
I'm no fabricator/welder but I'm determined to do a better job than what is shown below!
Onto item 3 in the list. I knew this was a repair from when I bought the car but having the engine out the way I can really see the extent of the work done. Firstly, Ive taken back the paint to see what was underneath, this is what i was met with;
As you can see, it's a good sized patch. The welding, while solid and sturdy, is a bit errmmmmm....yea!
Additional, the patch was put in place to cover a rust spot. And rather than cut out rust it was just patched over the top, see view from the opposite side;
This is clearly bad, so I wanted to cut out that repair. Great care must be take here as the drivers side engine mount is part of this section and I really didn't want to cut into that. So, slowly, slowly I started to cut it out and ended up with this to path up;
and from the inside of the engine bay;
Pretty straight forward from here on in. It's double skinned in some places which I've managed to retain, well it will be when I've made the plate to go on top which overlaps the chassis leg.
Once I've sorted this i'll fit the other repair panel on the drivers side as per Episode 21 and can then move onto item 5. A known area for improvement on the Saxo/106 shell is the front struts. Satchell have developed a kit to sort this out. The pictures below are owned by Satchell so thanks to them for taking them.
At £100 it's pretty reasonable.
Still lots of stuff to get on with but hopefully for minimal cash! More progress to follow
YouTube link here for all episodes.
https://www.youtube.com/channel/UCVfBHJ0QkE6XUeTnU...
That for me means welding! A few jobs I need to do;
1. Passenger side inner wing repair - DONE
2. Drivers side inner wing repair under ECU
3. Drivers side inner wing repair above chassis leg
4. New front bumper brackets to weld on
5. Chassis strengthening kit to add on - more on this shortly.
All this needs doing before I can think about painting anything to look nice. However, once these jobs are done then I can apply the raptor and have a shelf full of lovely shiny bits to bolt on.
I'm no fabricator/welder but I'm determined to do a better job than what is shown below!
Onto item 3 in the list. I knew this was a repair from when I bought the car but having the engine out the way I can really see the extent of the work done. Firstly, Ive taken back the paint to see what was underneath, this is what i was met with;
As you can see, it's a good sized patch. The welding, while solid and sturdy, is a bit errmmmmm....yea!
Additional, the patch was put in place to cover a rust spot. And rather than cut out rust it was just patched over the top, see view from the opposite side;
This is clearly bad, so I wanted to cut out that repair. Great care must be take here as the drivers side engine mount is part of this section and I really didn't want to cut into that. So, slowly, slowly I started to cut it out and ended up with this to path up;
and from the inside of the engine bay;
Pretty straight forward from here on in. It's double skinned in some places which I've managed to retain, well it will be when I've made the plate to go on top which overlaps the chassis leg.
Once I've sorted this i'll fit the other repair panel on the drivers side as per Episode 21 and can then move onto item 5. A known area for improvement on the Saxo/106 shell is the front struts. Satchell have developed a kit to sort this out. The pictures below are owned by Satchell so thanks to them for taking them.
At £100 it's pretty reasonable.
Still lots of stuff to get on with but hopefully for minimal cash! More progress to follow
YouTube link here for all episodes.
https://www.youtube.com/channel/UCVfBHJ0QkE6XUeTnU...
dom9 said:
May I ask where you ordered you shiny steering rack rubbers from? Need some for my 106 XSi! Steering rack refurb (+ quick rack) has been on my bench waiting for me for months! Great progress!
Just Euro car parts mate. Wasn't expensive and both of those can be changed/replaced with the rack on the car. Albeit awkwardly. Minor update on the rust repairs;
I got the patch made up to rectify the horrible repair seen in my last post. Got that welding in nicely too. I'm not a welder by any stretch but my work is far prettier than what was there before. Once it's all been under sealed it will hopefully blend right in, sadly not after pic but here's the patch I made;
I managed to replicate the the contours of the inner arch and the oval hole
Next I needed to replicate the Inner arch panel as per the passenger side. Unluckily for me, these are usually very easily removed by drilling out spot weld and a cut or two with the cutting disc. However, this side had been "repaired" before;
So, with that eye sore in place, it was time to cut it out. This was difficult as it was tucked right up into the edges and corners off the turret;
New panel fits snugly in place;
Welded in;
Sadly, during removal I noticed the strut was a bit soft, So i poked it and removed soft bits until I got to solid metal;
It's a tricky area to weld in with a flux core welder so I made a simple patch to go over the top. I had to extend the engine mount plate. This is usually held with two spot welds onto the panel I've just fitted. So I seam welded that in place and welded to the engine mount where the previous person had cut it.
Lots of DeOx went on too of course.
With that, both sides are now done.
The original welding list;
1. Passenger side inner wing repair - DONE
2. Drivers side inner wing repair under ECU - DONE
3. Drivers side inner wing repair above chassis leg - DONE
4. New front bumper brackets to weld on - Need to purchase 1 and electrolysis the other which is salvageable.
5. Chassis strengthening kit to add on - TO DO.
Next up is the stiffening kit which should be here this week and then re weld on the bumper brackets (4 spot welds each). Then I can degrease, treat any further bits of surface corrosion before getting the raptor out again. I am nervous about welding in the much thicker plates to the top struts. Hopefully my cheapo flux core will be up to the job!
I got the patch made up to rectify the horrible repair seen in my last post. Got that welding in nicely too. I'm not a welder by any stretch but my work is far prettier than what was there before. Once it's all been under sealed it will hopefully blend right in, sadly not after pic but here's the patch I made;
I managed to replicate the the contours of the inner arch and the oval hole
Next I needed to replicate the Inner arch panel as per the passenger side. Unluckily for me, these are usually very easily removed by drilling out spot weld and a cut or two with the cutting disc. However, this side had been "repaired" before;
So, with that eye sore in place, it was time to cut it out. This was difficult as it was tucked right up into the edges and corners off the turret;
New panel fits snugly in place;
Welded in;
Sadly, during removal I noticed the strut was a bit soft, So i poked it and removed soft bits until I got to solid metal;
It's a tricky area to weld in with a flux core welder so I made a simple patch to go over the top. I had to extend the engine mount plate. This is usually held with two spot welds onto the panel I've just fitted. So I seam welded that in place and welded to the engine mount where the previous person had cut it.
Lots of DeOx went on too of course.
With that, both sides are now done.
The original welding list;
1. Passenger side inner wing repair - DONE
2. Drivers side inner wing repair under ECU - DONE
3. Drivers side inner wing repair above chassis leg - DONE
4. New front bumper brackets to weld on - Need to purchase 1 and electrolysis the other which is salvageable.
5. Chassis strengthening kit to add on - TO DO.
Next up is the stiffening kit which should be here this week and then re weld on the bumper brackets (4 spot welds each). Then I can degrease, treat any further bits of surface corrosion before getting the raptor out again. I am nervous about welding in the much thicker plates to the top struts. Hopefully my cheapo flux core will be up to the job!
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