1992 Peugeot 106 XSi - Strip, Respray, Rebuild OEM+
Discussion
We're seeing houses at the moment and once the 106 is on the road, I'm not sure I see a way of keeping 4 cars 
I think the V8 Touring will be the first to go as the pipe dream of taking the dog on holiday with us all the time just isn't 'working'.
No progress this weekend... have my little siblings staying!
I think the V8 Touring will be the first to go as the pipe dream of taking the dog on holiday with us all the time just isn't 'working'.
No progress this weekend... have my little siblings staying!
t4thomas said:
I wasn't aware of the VTR gear modification, but that does sound interesting.
I am not sure that the Evo itch is going to go away though.
I may keep the Rallye and still get an Evo; it's just the space implications.
If you have a s1 rallye gearbox in good condition that's at least £300 of box you got there. Rather than buggering about with it, buy a VTR gearbox and fit that to your existing car and sell the box. Although if you do that you take at least £500 out of the value of your Rallye. Best to leave as is. 5k rpm @ 85mph is the way!I am not sure that the Evo itch is going to go away though.
I may keep the Rallye and still get an Evo; it's just the space implications.
Gaaaaaaaaaaaaaaaaaaaaaah!
Just been to look at my gearbox code after finding the head wasn't an XSi... It's a 20CE09.
Google suggests that is a 1.1 'box. Bugger.
Well, at least I have found a spare.
So, cylinder head and gearbox look 'wrong'... what are the chances of the block being correct?
At least I can pick the new box up, drop it at the reconditioners with the Quaife, drop the whole engine and 'box and bin them (or sell them but they're barely worth it) without worrying about damage etc. Makes life slightly easier!
At least I have spare engines etc!
Just been to look at my gearbox code after finding the head wasn't an XSi... It's a 20CE09.
Google suggests that is a 1.1 'box. Bugger.
Well, at least I have found a spare.
So, cylinder head and gearbox look 'wrong'... what are the chances of the block being correct?
At least I can pick the new box up, drop it at the reconditioners with the Quaife, drop the whole engine and 'box and bin them (or sell them but they're barely worth it) without worrying about damage etc. Makes life slightly easier!
At least I have spare engines etc!
Kitchski said:
On the plus side, I'm pretty sure the 5th gear cog on the 1.1 box is the same as a VTR box 
You are the man! I had not thought of that! 
Means I need to get that 'box out before I deliver the 'new' XSi 'box for rebuild then.
Well, I guess they're at the end of the case, under the cover, so I could do it after it's back but I should have time to attack it first!
Kitchski said:
Double check it first an all that, but pretty sure they're both 0.77.
0.85 is the sports-gearset version.
I'll have a read up on the 5th gear mod again and count the teeth if I have to.0.85 is the sports-gearset version.
I have a feeling that you're right and it's only the FD that was changed on the non-Sport 'boxes so the actual clusters are the same.
i.e. I think it should work! I guess that's saved me £50-100 on finding an old 'box to steal the 5th off, which lessons the pain of not having an XSi 'box.
Man maths
A lot to do before it goes for paint in 3 weeks but work finishes in 13 days so it'll get 3hrs a day attention, which should be enough.
I know with the sports sets, the F/D was the only difference. So the AX GT, 106 XSi & GTi, Rallye S1 and S2, Saxo VTS etc....all the same ratios. The final drive was wildly different on some of them though.
The VTR was s
t, and just used normal gear ratios, as per the 1.1 and 1.4, only with a taller F/D. I *think* that's how it worked. I know you can get 40mpg from a VTR with ease on a run! Apparently there are some VTRs with a S2 Rallye-spec box though, but have never seen one. Mind you, I drove a 98bhp version of a VTR years ago and it seemed to zip along pretty well, so you never know! I know the 98bhp version had the same size valves as a Rallye, maybe they had the gearbox too?
Diesels and some oddball stuff was different again.
The VTR was s
t, and just used normal gear ratios, as per the 1.1 and 1.4, only with a taller F/D. I *think* that's how it worked. I know you can get 40mpg from a VTR with ease on a run! Apparently there are some VTRs with a S2 Rallye-spec box though, but have never seen one. Mind you, I drove a 98bhp version of a VTR years ago and it seemed to zip along pretty well, so you never know! I know the 98bhp version had the same size valves as a Rallye, maybe they had the gearbox too?Diesels and some oddball stuff was different again.
Than K - looks like that'll all work out!
Quick lunchtime update...
After soaking in WD40 for days, the wishbone bolt gave in to the impact wrench!
That's a good thing as the Dremel and a hacksaw were getting me nowhere!
One corner off - I'm hoping the other one will be easier! 2.5 weeks to paint so need a wriggle on!
Spring compressors should be on their way to me and the brakes should be back next week. They've been gone 2 weeks+ now!
Excuse the bad pic:
Quick lunchtime update...
After soaking in WD40 for days, the wishbone bolt gave in to the impact wrench!
That's a good thing as the Dremel and a hacksaw were getting me nowhere!
One corner off - I'm hoping the other one will be easier! 2.5 weeks to paint so need a wriggle on!
Spring compressors should be on their way to me and the brakes should be back next week. They've been gone 2 weeks+ now!
Excuse the bad pic:
Been ages since I last updated this - Sorry!
So, work has been progressing but I was busier through February and March than expected between finishing a project at work, starting a new business, having a birthday and savage, savage man-flu!
In the last update you could see one corner off and all the rusty suspension bits. Well, corner 2 was stripped off and the dampers/ struts/ uprights etc all stripped. They are currently being cleaned of rust, ready for painting this week and then all the new parts will go back together.
Will get some pics up when I have some clean parts to show and it's finally going back together.
Received my brake calipers back from Bigg Red and the look great and they gave me a fair discount due to the delays (paid about the cost of 1 new caliper).
The car should have been in paint this week but it still has the engine and 'box inside it! However, I have new wings, bonnet, lights etc all here and hopefully the suspension will be back on this week, engine out next week and then it'll go and we'll then move house!
Here's a sneak peak of what I finally got done today:
Look out for lots of updates over the coming days before it goes to paint!
So, work has been progressing but I was busier through February and March than expected between finishing a project at work, starting a new business, having a birthday and savage, savage man-flu!
In the last update you could see one corner off and all the rusty suspension bits. Well, corner 2 was stripped off and the dampers/ struts/ uprights etc all stripped. They are currently being cleaned of rust, ready for painting this week and then all the new parts will go back together.
Will get some pics up when I have some clean parts to show and it's finally going back together.
Received my brake calipers back from Bigg Red and the look great and they gave me a fair discount due to the delays (paid about the cost of 1 new caliper).
The car should have been in paint this week but it still has the engine and 'box inside it! However, I have new wings, bonnet, lights etc all here and hopefully the suspension will be back on this week, engine out next week and then it'll go and we'll then move house!
Here's a sneak peak of what I finally got done today:
Look out for lots of updates over the coming days before it goes to paint!
Edited by dom9 on Wednesday 22 March 13:50
Glad this got bumped so i got the chance to see it! Great work you're doing there to what is sure to be a lovely little b road blaster! An old friend of mine had a 1.4 XS as a first car and i was a big fan of that so I'm looking forward to seeing a complete project here hopefully some time soon!
Thanks jsmims1
Right - I have fallen behind as usual but with a house move on Friday... It just has to go to paint and be out of the way.
So, the suspension bits have been soaking in rust remover in the ultrasonic cleaner for a few days and came up pretty good.
Will pull it all apart again when it gets back from paint and get them powder coated etc. Consider this a 'test fit' to get it back rolling.
the other issue is that I haven't pulled the engine and 'box so the paint shop won't get at much of the engine bay but we can cross that bridge at a later date.
All went back together quite easily, really, as you might expect with all new parts.
What you can see in the pictures are:
- New wheel bearings
- New hubs
- New dampers
- New springs (-30mm)
- New top mounts
- New top mount bearings
- New nuts and bolts
- New wishbones
Probably not worth installing the new drop links or steering rod ends before it goes to paint as it'll need to come apart anyway after that.
However, I'll see how much time I get on it in the next day or so and may build it back up with the calipers etc so it all looks nice.
Right - I have fallen behind as usual but with a house move on Friday... It just has to go to paint and be out of the way.
So, the suspension bits have been soaking in rust remover in the ultrasonic cleaner for a few days and came up pretty good.
Will pull it all apart again when it gets back from paint and get them powder coated etc. Consider this a 'test fit' to get it back rolling.
the other issue is that I haven't pulled the engine and 'box so the paint shop won't get at much of the engine bay but we can cross that bridge at a later date.
All went back together quite easily, really, as you might expect with all new parts.
What you can see in the pictures are:
- New wheel bearings
- New hubs
- New dampers
- New springs (-30mm)
- New top mounts
- New top mount bearings
- New nuts and bolts
- New wishbones
Probably not worth installing the new drop links or steering rod ends before it goes to paint as it'll need to come apart anyway after that.
However, I'll see how much time I get on it in the next day or so and may build it back up with the calipers etc so it all looks nice.
Ah ha - Do you mean what looks 'black' in the picture and irregular in shape?
That's just the colour the metal has gone where the cleaner has reacted with rust and turned it black, a bit like charcoal. Basically, I didn't wire brush it enough in my excitement to get it back together!
No holes on any of those parts, thank goodness.
Wheel bearings were a pain though; needed a lot of heat to get the old ones out - seized right in!
Also, both dampers were completely dead and one of them had basically burst and fluid was everywhere.
Car should be night and day from how it arrived, soon.
That's just the colour the metal has gone where the cleaner has reacted with rust and turned it black, a bit like charcoal. Basically, I didn't wire brush it enough in my excitement to get it back together!
No holes on any of those parts, thank goodness.
Wheel bearings were a pain though; needed a lot of heat to get the old ones out - seized right in!
Also, both dampers were completely dead and one of them had basically burst and fluid was everywhere.
Car should be night and day from how it arrived, soon.
dom9 said:
Ah ha - Do you mean what looks 'black' in the picture and irregular in shape?
That's just the colour the metal has gone where the cleaner has reacted with rust and turned it black, a bit like charcoal. Basically, I didn't wire brush it enough in my excitement to get it back together!
No holes on any of those parts, thank goodness.
Wheel bearings were a pain though; needed a lot of heat to get the old ones out - seized right in!
Also, both dampers were completely dead and one of them had basically burst and fluid was everywhere.
Car should be night and day from how it arrived, soon.
Ah yes, I see it now! For a minute I thought......That's just the colour the metal has gone where the cleaner has reacted with rust and turned it black, a bit like charcoal. Basically, I didn't wire brush it enough in my excitement to get it back together!
No holes on any of those parts, thank goodness.
Wheel bearings were a pain though; needed a lot of heat to get the old ones out - seized right in!
Also, both dampers were completely dead and one of them had basically burst and fluid was everywhere.
Car should be night and day from how it arrived, soon.
It's slowly coming together... wishbones, droplinks etc all back on and threw the discs and calipers on as well:
Managed to get the driver's side steering rod end on no problem... the pass side just won't budge so it's the one thing outstanding to get it rolling for paint.
Can leave the old one on but it's a bit battered and getting the nut back on is proving to be a pain.
Still, by 11am tomorrow it should be rolling on 4 steels and off to the paint shop shortly after! Will get a pic on the trailer.
Fitting the new wishbones was not as easy as I thought though! Lots of hammer action, levering and swearing! It's all tight now, thank goodness.
The ultrasonic cleaner is about big enough for the XSi/ Rallye head. It's the ~£200 one on ebay, must be about 50cm x 25cm but I don't remember exactly.
It takes time to get the really rusty stuff clean (like days of soaking and hours of ultrasonic death rays) but they come up really well. I'm surprised how little rust there was, really. Didn't stop almost every single nut and bolt being seized though (and wheel bearings etc).
Don't worry Kitchski - rust free since 1993 (well, 1992). More pics tomorrow - should look smart on the steels!
Managed to get the driver's side steering rod end on no problem... the pass side just won't budge so it's the one thing outstanding to get it rolling for paint.
Can leave the old one on but it's a bit battered and getting the nut back on is proving to be a pain.
Still, by 11am tomorrow it should be rolling on 4 steels and off to the paint shop shortly after! Will get a pic on the trailer.
Fitting the new wishbones was not as easy as I thought though! Lots of hammer action, levering and swearing! It's all tight now, thank goodness.
The ultrasonic cleaner is about big enough for the XSi/ Rallye head. It's the ~£200 one on ebay, must be about 50cm x 25cm but I don't remember exactly.
It takes time to get the really rusty stuff clean (like days of soaking and hours of ultrasonic death rays) but they come up really well. I'm surprised how little rust there was, really. Didn't stop almost every single nut and bolt being seized though (and wheel bearings etc).
Don't worry Kitchski - rust free since 1993 (well, 1992). More pics tomorrow - should look smart on the steels!
dom9 said:
It's slowly coming together... wishbones, droplinks etc all back on and threw the discs and calipers on as well:
Managed to get the driver's side steering rod end on no problem... the pass side just won't budge so it's the one thing outstanding to get it rolling for paint.
Can leave the old one on but it's a bit battered and getting the nut back on is proving to be a pain.
Still, by 11am tomorrow it should be rolling on 4 steels and off to the paint shop shortly after! Will get a pic on the trailer.
Fitting the new wishbones was not as easy as I thought though! Lots of hammer action, levering and swearing! It's all tight now, thank goodness.
The ultrasonic cleaner is about big enough for the XSi/ Rallye head. It's the ~£200 one on ebay, must be about 50cm x 25cm but I don't remember exactly.
It takes time to get the really rusty stuff clean (like days of soaking and hours of ultrasonic death rays) but they come up really well. I'm surprised how little rust there was, really. Didn't stop almost every single nut and bolt being seized though (and wheel bearings etc).
Don't worry Kitchski - rust free since 1993 (well, 1992). More pics tomorrow - should look smart on the steels!
looks like you are running shorter springs to lower the ride height? if so mount your track rod ends upside down onto the strut, it will reduce bump steer. The passenger side nut for the steering rod is a PITA!Managed to get the driver's side steering rod end on no problem... the pass side just won't budge so it's the one thing outstanding to get it rolling for paint.
Can leave the old one on but it's a bit battered and getting the nut back on is proving to be a pain.
Still, by 11am tomorrow it should be rolling on 4 steels and off to the paint shop shortly after! Will get a pic on the trailer.
Fitting the new wishbones was not as easy as I thought though! Lots of hammer action, levering and swearing! It's all tight now, thank goodness.
The ultrasonic cleaner is about big enough for the XSi/ Rallye head. It's the ~£200 one on ebay, must be about 50cm x 25cm but I don't remember exactly.
It takes time to get the really rusty stuff clean (like days of soaking and hours of ultrasonic death rays) but they come up really well. I'm surprised how little rust there was, really. Didn't stop almost every single nut and bolt being seized though (and wheel bearings etc).
Don't worry Kitchski - rust free since 1993 (well, 1992). More pics tomorrow - should look smart on the steels!
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