1992 Peugeot 106 XSi - Strip, Respray, Rebuild OEM+

1992 Peugeot 106 XSi - Strip, Respray, Rebuild OEM+

Author
Discussion

Jerry Can

4,424 posts

222 months

Friday 20th January 2017
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Having recently rebuilt my 106 Rallye, I would suggest you stick it up on axle stands and remove the engine, front slam panel, struts, d/shafts etc etc. It really is a piece of piss, even I was able to do it in less than a weekend ( and my experience before doing this was removing a gearbox which I found far harder). Once you are down to the inner wings, subframe etc, clean it all up, and start fitting it back together, replacing and cleaning as you go.


pics for whoring purposes

Edited by Jerry Can on Friday 20th January 20:11

dom9

Original Poster:

8,040 posts

208 months

Friday 20th January 2017
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It's that crossmember that the radiator sits on that annoys me. Would be nice to unbolt the engine and 'box and just wheel the shell off it smile

To be honest; pulling the engine out doesn't phase me too much... It's how my missus reacts when she sees 3 engines in the garage!

The plan is evolving: I think I am going to get the front suspension, brakes, steering etc sorted, get the rear beam swapped, pull the engine and 'box out and then send it off to the paint shop like that.

That way they can tackle the engine bay and colour match with the body. While that is happening, I have the garage back to put the engine(s) together, get the gearbox rebuilt etc. I just don't have the space to do it all with the car in there.

I've also received permission for an ultrasonic cleaner large enough to get a cylinder head in biggrin

Scalino

121 posts

88 months

Saturday 21st January 2017
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Just read the whole thread, excellent work OP keep it up!

dom9

Original Poster:

8,040 posts

208 months

Saturday 21st January 2017
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Scalino said:
Just read the whole thread, excellent work OP keep it up!
Thanks Scalino - No progress today as I've been hiding in the woods with the dog most of the day!

Mrs9 seems to have turned the house into some resembling a WI meeting!

p4cks

6,885 posts

198 months

Sunday 22nd January 2017
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Looking good Dom bow

GuinnessMK

1,608 posts

221 months

Sunday 22nd January 2017
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Why do five minute jobs escalate?

Investigating a squealing auxiliary belt this afternoon, found that the alternator was already at the maximum range of adjustment, so it looks like I need a new belt (this one is only 130 miles old!). Can't order online, as the parts databases seem to be pointing me back to the same size as I have now, so I'll have to pop into an actual factors tomorrow and see if I can find a slightly shorter belt.

Not that it matters, as I managed to shear the lower bolt into the alternator off at the same time. So what should have been a five minute adjustment is now going to take at least a couple of days to put right!

Doh!


gowmonster

2,471 posts

166 months

Monday 23rd January 2017
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GuinnessMK said:
Why do five minute jobs escalate?

Investigating a squealing auxiliary belt this afternoon, found that the alternator was already at the maximum range of adjustment, so it looks like I need a new belt (this one is only 130 miles old!). Can't order online, as the parts databases seem to be pointing me back to the same size as I have now, so I'll have to pop into an actual factors tomorrow and see if I can find a slightly shorter belt.

Not that it matters, as I managed to shear the lower bolt into the alternator off at the same time. So what should have been a five minute adjustment is now going to take at least a couple of days to put right!

Doh!
Majority of my cars are old, anytime I go out to work on them and tell my wife i'll be 2 hours, she says, remember and come in for dinner. old bolts, either gonna sheer or seize...

dom9

Original Poster:

8,040 posts

208 months

Monday 23rd January 2017
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Thanks Scalino, p4cks and chaps smile

Thankfully nothing seems too seized (for my impact wrench wink ) on this car.

That alternator belt issue sounds very annoying. I have the engine joys to come. Hopefully engine no.3 will find its way to me this week.

Little progress at the weekend as we had a friend (of Mrs9) down to stay so I was on dog and cleaning duties for the most part.

I have ordered an ultrasonic cleaner. I have convinced myself that £200 on that will save me £150 in new brake calipers as well as cleaning loads of parts.

It should be big enough to get some good size castings (even an XSi cylinder head) in, so I ought to be able to make things shiny. Will be interesting to see.

The plan now is to get it to paint sans engine and 'box, while I build the engine and have it back together and on the road before we move house in April.

Oh, possibly frustratingly, this has appeared on ebay:

http://www.ebay.co.uk/itm/282334943163?_trksid=p20...

Non-sunroof, low miles and looks (the photos don't show much detail and the description doesn't say much) to be in great condition.

It is not, however, cheap with a £3,200 starting price, which feels 'strong' to me. My car with all the engines etc will cost less than that to be mechanically 'perfect' (or as close as I can get) and I'll have some bits to sell. Where mine will go over this though is the paint.

I must say... I do like it... Regardless, I won't leave this unfinished/ sell it on.

227bhp

10,203 posts

127 months

Monday 23rd January 2017
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Looking forward to seeing this featured on 'Car SOS' in a few years time.

dom9

Original Poster:

8,040 posts

208 months

Monday 23rd January 2017
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227bhp said:
Looking forward to seeing this featured on 'Car SOS' in a few years time.
LOL - Had the same thought myself at the weekend, whilst on my 3rd hour of sub-zero dog walking! biggrin

It'll get done... My (real) work will start to slow down in the next couple of weeks and there isn't anything else yet (irons in the fire).

I am intending on having the front end done in the next couple of weeks or so (want the ultrasonic cleaner here), refurbished rear beam on and engine out by the end of February.

I can then send it off to paint as my birthday present to myself at the start of March and hopefully have it back together at the start of April. If I can compress that a bit to make sure the engine is in before we move, so much the better.

To be honest; I think I am only a couple of days from having it running and driving with new front suspension and brakes but I want to get everything 'perfect' before paint so it's a relatively quick rebuild once it's back.

I've put this in writing now so you can all hold me to it wink

Engine No.3 is on a pallet and on its way to me, since my last update this morning, and I dropped the owner of the red one a few questions.

The only part I am really missing now is the standard XSi airbox. If anyone hears of one or sees one in a breakers - let me know!

I think I am going to tackle the Rallye inlet and cold air induction once the car is 'finished', back on the road and MOTed etc. I'd hate for it to all be back together but not roadworthy because I'm messing about with the induction.

dom9

Original Poster:

8,040 posts

208 months

Monday 23rd January 2017
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Since 227bhp car-shamed me this morning wink

I thought I'd use 30mins at lunch to pop the corner off and show some progress... It was only 6 nuts away!

Drop link out:



Steering track rod off:



Internal wishbone mount released:



Damper top mount dropped:



And this is where the problems started... Did not oil the lower wishbone bolt and it's seized:



It's soaking in WD40 now but I think it may be too far gone after being attacked with the impact wrench.

I can get to it with the Dremel so I may just take the head off it, once I've had another look. I have all new bolts, nuts and washers so I can afford to kill a few.

2nd issue is both the disc retaining screws were obviously seized and had sheared, before I got the car, and need drilling out, which is annoying. I could 'not bother' but that wouldn't be in the spirit of this build:



So, I'm a mere 10mm of nut unwinding away from one corner being off and ready for cleaning, painting and rebuilding! I'd like to get those hubs cleaned up (and the brake calipers etc), which may mean waiting on the ultrasonic cleaner but I can do the other corner in the meantime (with plenty of WD40) and get everything prepared, cleaned, painted and ready!

GuinnessMK

1,608 posts

221 months

Monday 23rd January 2017
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dom9 said:
Oh, possibly frustratingly, this has appeared on ebay:

http://www.ebay.co.uk/itm/282334943163?_trksid=p20...

Non-sunroof, low miles and looks (the photos don't show much detail and the description doesn't say much) to be in great condition.

It is not, however, cheap with a £3,200 starting price, which feels 'strong' to me. My car with all the engines etc will cost less than that to be mechanically 'perfect' (or as close as I can get) and I'll have some bits to sell. Where mine will go over this though is the paint.

I must say... I do like it... Regardless, I won't leave this unfinished/ sell it on.
Wow! Strong money! There are a few details that differ from my car, but not sure if that's because it's a J plate or a 1.4 (mine is an M plate 1.6), but the interior is in a different fabric, the mirrors aren't body coloured and there isn't a black strip at the bottom of the front bumper.

dom9

Original Poster:

8,040 posts

208 months

Monday 23rd January 2017
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Yeah, seems very strong money to me... The owner hasn't got back to me yet.

The seats look good and are the same material as my two sets here. Unique to the 1.4 I think.

Bumpers look ok to me (bearing in mind I am not expert) and the mirrors too though (it may just be the angle) they do look a bit funny to me.

I guess there will have been a few detail changes between the 1.4 and the 1.6 XSi.

I'm wondering whether I should just get new hubs - They're pretty cheap.

That way, I can get the hubs and bearings out of the upright, clean and paint it and rebuild with new bearings and hubs.

dom9

Original Poster:

8,040 posts

208 months

Tuesday 24th January 2017
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Well, today's lunchtime calamity...

The ultrasonic cleaning machine arrived, so I thought I would whip off a caliper and put it through, test the machine out and all that jazz.

The problem was that I rounded the brake hose (and cut it, braided were already on the way) and then the bleed nipple sheared!

Threw it through the ultrasonic cleaning machine anyway to give it a test after popping the piston out with an air line. It didn't look too pitted i.e. the caliper was serviceable.

Have to decide whether to get that bleed nipple drilled out or give up on the caliper. The other side could also be a pain. The annoying thing is that the rest of it seemed good and they were cleaning up nicely (without the correct cleaning fluid and pre-scrub should be even better).

Anyway; here are some pics:










dom9

Original Poster:

8,040 posts

208 months

Thursday 9th February 2017
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Quick, picture-free update while I have a break from work.

My contract is up at the end of this month so I've been trying to get all my real work and documents closed out. March and April are looking quiet, which is good for this project, if not my bank balance.

However, the car has been progressing, slowly and quietly.

New, OEM headlights (glass) arrived and look great (bargain old stock as well).

When I held them up to the car; I needed to order indicators as well, so they arrived to smarten up the front end.

The brakes were boxed up and sent to Bigg Red for a full refurb as I didn't want to tackle those sheared bleed nipples. They should be back soon.

I also have 2 x new front hubs and 2 x wheel bearings... So when the front suspension goes back together, it'll literally be brand new, top to toe.

It wasn't worth trying to get the sheared bolts out of the hubs when a new pair and bearings etc were less than £50 all in.

I had a chap round to look the car over for a glass-out respray and he reckons £3k (bear in mind we're in surrey and he's local), so off it goes next month.

This list now looks a bit like; need to put it all back together with the new suspension, brake etc parts (engine and 'box will come out), send it to paint, I'll build up one of the engines, send the 'box for a refurb with the Quaife ATB diff that arrived last week (YAY!), then hopefully it'll be a case of putting it all back together in April!

If I have a new job (perhaps even if I don't an am bored) then I may hit The 'Ring in May biggrin

GrandAndrew

871 posts

149 months

Thursday 9th February 2017
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Nothing to add aside from that I've enjoyed reading the thread! Nice to see a little Peugeot being saved.

t4thomas

394 posts

165 months

Thursday 9th February 2017
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Hey Dom,

Looks like you're starting to make some progress.

I am actually thinking about selling my little Rallye, with a view to buying a different toy this summer.

Thomas

dom9

Original Poster:

8,040 posts

208 months

Thursday 9th February 2017
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Thanks guys smile

Progress has been 'sporadic' over the last year but I'm getting there now. I have the time and the incentive to get it finished!

What will you replace the Rallye with Thomas? The more I think about the project, the more I think I'm doing the right thing. My 996 that was built for trackdays etc just had limits that were way too high for the road and I have the V8 BMW and V6 Clio so I need something I can actually peddle.

Anyway, here's a teaser pic for you:


t4thomas

394 posts

165 months

Friday 10th February 2017
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I know that you will really enjoy the car when it's finished.

The Rallye has been the perfect car for local spirited driving. The reason I am looking to change, is that I would like to make some longer trips with friends this year. Perhaps Wales or the Lakes and even jaunts on the continent. The Rallye is a pretty unpleasant place to be on a motorway.

I reallly fancy an Evo VI TME, but haven't found the right example. I won't do much mileage, but still want something that can be driven rather than a red garage queen.

dom9

Original Poster:

8,040 posts

208 months

Friday 10th February 2017
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I sometimes harbour dark thoughts of an Evo...

Is a TME really a much better place to be on the motorway? I honestly don't know. Always assumed it was light in the sound deadening department and probably fairly low geared?

Have you considered the VTR 5th gear mod to the Rallye 'box? I might do it to my XSi as it may well be used for B-road 'commuting' at some point.

Basically you just (and apparently it really is as simple as) pull the end cover off the transmission and drop the 5th gear gears from a VTR (and other 'long gear' MA 'boxes) on the shafts and voila; you have a cruising gear.

Obviously you retain the same 1-4, close gears but get say a 500-1k rpm break when cruising on the motorway. Or something like that! Apparently it saves the ear drums to some extent.