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NadiR
597 posts
16 months
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Probably the most bonkers project I've seen on PH. You got a Peugeot and you're adding on some BMW, some Nissan, and probably more car manufacturers to come! Absolute madness (in a good way).
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davetibbs
Original Poster
132 posts
15 months
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NotDave said: Makes sense to me, as the whole frame would have strength, and line up to roof. Scuttle could be adapted to suit  It's a good idea, but the whole frame wasn't available. I'll probably give it a good go with the bits I've got and the 405 windscreen frame and see if I can succeed with that. If not I'll hunt down an entire E46 windscreen frame.
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NotDave
20,951 posts
26 months
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davetibbs said: It's a good idea, but the whole frame wasn't available. I'll probably give it a good go with the bits I've got and the 405 windscreen frame and see if I can succeed with that. If not I'll hunt down an entire E46 windscreen frame. BMW scrapyard, angle grinder. Off you go? Can't see there being much "demand" for that part, as most are gonna be crushed with the rest of the shell ain't they?
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davetibbs
Original Poster
132 posts
15 months
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True enough. However, I forsee "difficulties" with getting the bottom curve of the E46 windscreen frame joined to the 405 bulkhead - it could actually be a lot more work than the way I've planned. Since I've already got the windscreen top I'll probably stick with the "strengthened 405 frame" plan for now, and if it doesn't work I can lob it off and try and use a full E46 frame.
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NotDave
20,951 posts
26 months
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Fair point.
How many additional tonnes of welded in metal are being added?
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davetibbs
Original Poster
132 posts
15 months
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A lot! As I understand it, it's not uncommon for factory convertibles to have an extra 200kgs of additional weight over the saloon/coupe model. I'll probably end up with quite a bit more than that. In fairness I haven't weighed the extra metal I've added as I've prioritised chassis strength over weight saving, with the idea that if it affects performance too drastically, my engine isn't powerful enough. I might take the completed car onto a weighbridge out of interest though.
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NotDave
20,951 posts
26 months
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If it's too heavy, just add more power  You strengthening sills/door appetures (sp?) and such?
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davetibbs
Original Poster
132 posts
15 months
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Yes, the sills already have a lot of additional strengthening (essentially box section) both inside and outside the car. The door apertures will be strengthened at the hinge end with the same strengthening for the windscreen (to provide support for longer - and therefore heavier - doors), and at the latch end to restore rigidity to the (shortened) B pillars which will also double up as support for the roof. I'll try and get some drawings up at some point to highlight where all the strengthening has gone.
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NotDave
20,951 posts
26 months
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Makes sense.
Any "under chassis bracing"...... I.e. E36 cabriolets had that X brace that bolted on?
Plus, shock to shock OMP type bracing?
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davetibbs
Original Poster
132 posts
15 months
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Yep, the list above isn't exhaustive. There's a front strut brace (just bolt-on though), and a welded cross-brace in the rear behind the seat. Plus I'm currently beefing up the front and rear chassis legs.
I'm considering an X-brace but not sure of the best way of approaching it at the moment.
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NotDave
20,951 posts
26 months
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Cool.  X brace...... BMW ones are good, BUT fetch a premium. So I'd be tempted if you have the skills, to fab one up
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doogz
18,721 posts
56 months
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Amazing project! I love old Peugeots as well.
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Whitean3
1,375 posts
67 months
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When I first skim read the OP, I thought we were about to see a Peugeot 406 coupe to cabrio conversion (which could look pretty damn good). Then I saw it was a 4-door 405.- now that is a LOT of work! Seem to remeber one of the Max Power type mags featured a 4 to 2 door conversion on a Pug 306 saloon a few years back...
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rhinochopig
16,058 posts
67 months
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So does anyone else have mental image of a cabrio version of this? 
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davetibbs
Original Poster
132 posts
15 months
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Whitean3 said: When I first skim read the OP, I thought we were about to see a Peugeot 406 coupe to cabrio conversion (which could look pretty damn good). Then I saw it was a 4-door 405.- now that is a LOT of work! Seem to remeber one of the Max Power type mags featured a 4 to 2 door conversion on a Pug 306 saloon a few years back... I actually had a 406 coupe which I was tempted to do the conversion on, but couldn't bring myself to chop that beautiful body so chose the 405 instead. The irony is that it's now being broken for parts in my back garden  Maybe I could do it in the future I remember the 2 door 306 saloon - it was an Ecosse job I think, I suspect they used the parts necessary (such as rear wings) from a 3 door hatch, but I have no such cheats available 
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BDR529
3,167 posts
43 months
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You Sir are nuts. 
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richard300
692 posts
78 months
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This thread has got me thinking about finding a 405 Mi-16 as a bit of a retro daily. Hopefully though when i head to the classifieds there are either non for sale, or they have hit that 'inflated price' retro bubble. As i already have to many cars and not enough room.
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davetibbs
Original Poster
132 posts
15 months
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Just a small update: Making the mounting brackets for the airbags   Cleaning suspension turret mounting plates (still needs a polish)  Wishbones painted with all new bushes  Adapting Spax PSX Adjustable shocks to fit airbags: First, cut off spring mounting cup  Then, strip paint  and weld on coilover conversion tube:   Once welds are tidied up and bottom mounts are finished, the shocks can be painted. I also started stripping 406 Coupe Brembo calipers for seal replacement and painting:  And ordered some badge lettering on a whim  
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mwstewart
812 posts
57 months
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Interesting project. Did you weld those sleeves on with the damper assembly still inside?
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davetibbs
Original Poster
132 posts
15 months
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mwstewart said: Interesting project. Did you weld those sleeves on with the damper assembly still inside? Yes. I was in two minds whether to do so but didn't really fancy dismantling the shocks, which would have presumably required them to be regassed afterwards. As such we were very careful with the welding that it didn't get too hot, and I figure the fact that they still move afterwards means that they'll probably be fine
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