Twincharged, Wide-arched Convertible Peugeot 405
Discussion
Hi everyone!
After being a lurker on these forums for a while (and loving the project threads here!) I thought I should start my own which I can hopefully update semi-regularly.
I've owned this car for a long time as it's gone through various guises, it started off as a standard 1.6GL before I transplanted a 2.0 turbo engine from a Citroen XM into it about 10 years ago. A slight accident took it off the road a few years later and it's turned into a long-term project since then and never returned to the road. As is the case with a lot of these things the ideas get crazier and crazier, until it reaches the current state where it's essentially turned into a complete ground-up bare-shell rebuild.
The planned spec (as it stands!) is:
Exterior - convertible conversion with hydraulic roof, 2 door conversion, wide arches, vented bonnet, etc
Interior - Electric heated leather interior from Citroen XM, Peugeot 307cc dash + doorcards
Engine - 2.0 XU10J2TE from Citroen XM, fitted with 16v head, Toyota SC14 Supercharger, as-yet undecided Turbo
Drivetrain - Gearbox and 4x4 running gear from Peugeot 4007 - essentially a rebadged Mitsubishi Outlander, but the gearbox will fit the engine with very little modification (maybe a bellhousing adapter) and the wheelbase is exactly the same as the 405 (to the mm) so no prop shortening/lengthening required.
Suspension - Full air suspension front and rear
I'll let the pictures do the talking, but essentially there's very little of the car that hasn't been/won't be fettled in some way. I appreciate it's not to everyone's taste, but I love it and I've put a lot of work into it and learnt so much!
Here's a selection of progress pics:
Stripping the interior
Chassis restrengthening (more under sills, and the transmission tunnel will be replaced to allow for 4x4 running gear)
Roof removed
307 dashboard test fitment
Engine Bay Repainting
The roof I'll be using - from an E46 BMW 3 series convertible
Bonnet with vent from Toyota Rav-4 smoothed in
I'll try and get some more pics up ASAP.
After being a lurker on these forums for a while (and loving the project threads here!) I thought I should start my own which I can hopefully update semi-regularly.
I've owned this car for a long time as it's gone through various guises, it started off as a standard 1.6GL before I transplanted a 2.0 turbo engine from a Citroen XM into it about 10 years ago. A slight accident took it off the road a few years later and it's turned into a long-term project since then and never returned to the road. As is the case with a lot of these things the ideas get crazier and crazier, until it reaches the current state where it's essentially turned into a complete ground-up bare-shell rebuild.
The planned spec (as it stands!) is:
Exterior - convertible conversion with hydraulic roof, 2 door conversion, wide arches, vented bonnet, etc
Interior - Electric heated leather interior from Citroen XM, Peugeot 307cc dash + doorcards
Engine - 2.0 XU10J2TE from Citroen XM, fitted with 16v head, Toyota SC14 Supercharger, as-yet undecided Turbo
Drivetrain - Gearbox and 4x4 running gear from Peugeot 4007 - essentially a rebadged Mitsubishi Outlander, but the gearbox will fit the engine with very little modification (maybe a bellhousing adapter) and the wheelbase is exactly the same as the 405 (to the mm) so no prop shortening/lengthening required.
Suspension - Full air suspension front and rear
I'll let the pictures do the talking, but essentially there's very little of the car that hasn't been/won't be fettled in some way. I appreciate it's not to everyone's taste, but I love it and I've put a lot of work into it and learnt so much!
Here's a selection of progress pics:
Stripping the interior
Chassis restrengthening (more under sills, and the transmission tunnel will be replaced to allow for 4x4 running gear)
Roof removed
307 dashboard test fitment
Engine Bay Repainting
The roof I'll be using - from an E46 BMW 3 series convertible
Bonnet with vent from Toyota Rav-4 smoothed in
I'll try and get some more pics up ASAP.
looks bonkers so far - can't wait to see more.Thanks for the replies everyone - I'm aware it's pretty bonkers 
Progress has actually come on quite a bit further than the pics I've posted but my netbook's SSD has died and I've lost a few - I'll have to retake some when I get a chance.
As for using the 405 Mi16x4 drivetrain - the main reasons I've ruled it out are due to rarity of parts and the strength (or lack thereof). You can't really put much more than the standard power (or more accurately, torque) through the 4 wheel drive system, which wasn't particularly high to start with (155bhp). There are a few weak points, but mainly the splines on the transfer box were prone to stripping, and if you uprated them, it'd spit the diff out the back. It's a reasonable split of power front/rear, normally 53/47% but this can be changed by the viscous centre diff (which is also fairly weak).
In comparison, the 4007 drivetrain is largely the same as is fitted into the Mitsi Evo X, and therefore able to cope with far higher power outputs. It's true that the 405 Mi16x4 drivetrain could be obtained and the necessary parts upgraded, but then you're entering silly money territory, whereas the entire running gear from the 4007 can be picked up a for a few thousand.
I am however running the 405 Mi16x4 rear beam because without it the 4x4 conversion would be a nightmare with custom subframes/suspension etc. The Mi16x4 had hydraulic rear suspension like the Citroens, but I've ditched that system and am getting air shocks made to fit where the hydraulic shocks were, as well as overhauling the entire beam.
I'll try and get some more pics (probably this weekend) but in the meantime, here's some more old photos:
Painted S16 Rocker Cover
SC14 Supercharger being overhauled, though this may be scrapped as finding replacement bearings is next to impossible
S16 head rebuild
Front bumper being modified - originally a vertex-style bumper for the S14a 200SX
405 Mi16x4 Rear Beam ready for overhaul
Progress has actually come on quite a bit further than the pics I've posted but my netbook's SSD has died and I've lost a few - I'll have to retake some when I get a chance.
As for using the 405 Mi16x4 drivetrain - the main reasons I've ruled it out are due to rarity of parts and the strength (or lack thereof). You can't really put much more than the standard power (or more accurately, torque) through the 4 wheel drive system, which wasn't particularly high to start with (155bhp). There are a few weak points, but mainly the splines on the transfer box were prone to stripping, and if you uprated them, it'd spit the diff out the back. It's a reasonable split of power front/rear, normally 53/47% but this can be changed by the viscous centre diff (which is also fairly weak).
In comparison, the 4007 drivetrain is largely the same as is fitted into the Mitsi Evo X, and therefore able to cope with far higher power outputs. It's true that the 405 Mi16x4 drivetrain could be obtained and the necessary parts upgraded, but then you're entering silly money territory, whereas the entire running gear from the 4007 can be picked up a for a few thousand.
I am however running the 405 Mi16x4 rear beam because without it the 4x4 conversion would be a nightmare with custom subframes/suspension etc. The Mi16x4 had hydraulic rear suspension like the Citroens, but I've ditched that system and am getting air shocks made to fit where the hydraulic shocks were, as well as overhauling the entire beam.
I'll try and get some more pics (probably this weekend) but in the meantime, here's some more old photos:
Painted S16 Rocker Cover
SC14 Supercharger being overhauled, though this may be scrapped as finding replacement bearings is next to impossible
S16 head rebuild
Front bumper being modified - originally a vertex-style bumper for the S14a 200SX
405 Mi16x4 Rear Beam ready for overhaul
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