1992 Peugeot 106 XSi - Strip, Respray, Rebuild OEM+
Discussion
Get some pics up, Guiness - Always good to see another one 
S1 Rallye Manifold is in the post. Think I'll be 3D printing an adaptor for the XSi throttle body.
Think I am happy with how everything connects up and what I want to do with my hoses etc.
As soon as I'm happy with the inlet manifold/ management etc - will pull the engine for rebuild
S1 Rallye Manifold is in the post. Think I'll be 3D printing an adaptor for the XSi throttle body.
Think I am happy with how everything connects up and what I want to do with my hoses etc.
As soon as I'm happy with the inlet manifold/ management etc - will pull the engine for rebuild
Thanks chaps - These cars seem to get a lot of love on here, which is great!
To be honest Tom; I'd be spending money to keep a Rallye standard and in tip top condition, I think.
I do like a standard, special edition and they're probably appreciating everyday at the moment.
I know people will call me boring but, as mentioned before on this thread, that's the exact reason I went for an XSi (certainly not appreciating at Rallye rates) and a cheap one needing saving at that.
Someone will always want a good Rallye, I am not sure people will always be looking for a ropey XSi
Still, my Clio V6 has only done 950 miles so I am not a shining example of 'using' cars as intended. But, I took on this project to remedy that
To be honest Tom; I'd be spending money to keep a Rallye standard and in tip top condition, I think.
I do like a standard, special edition and they're probably appreciating everyday at the moment.
I know people will call me boring but, as mentioned before on this thread, that's the exact reason I went for an XSi (certainly not appreciating at Rallye rates) and a cheap one needing saving at that.
Someone will always want a good Rallye, I am not sure people will always be looking for a ropey XSi
Still, my Clio V6 has only done 950 miles so I am not a shining example of 'using' cars as intended. But, I took on this project to remedy that
Kitchski said:
geeks said:
Looking at How Many Left we have half as many XSI's than Rallyes out there, I think they will begin to appreciate of their own accord over time!
They will to an extent, but they're 4th in line for 'most-coveted 106', and the XSi badge has never been that desirable. Being how hard Peugeot found it to shift S1 Rallyes back in the day, the surviving numbers are testament to this.
Even if it is the better car
Good articles those - Makes sense now why my XSi has the homologation plate!
Don't get me wrong, guys - I'd be the last person to talk down values but if this was a 50,000 miles Rallye, I wouldn't be touching it, other than to make sure it was perfect.
If you can keep the rust of them; none of these models will lose money but I'll probably lose a load if I try and sell this when it is finished BUT - It will be worth its weight in gold to me (hopefully) as a non-cat, non-ABS, non-power steering, back to basics car.
Should be getting close to the weight of a Rallye with close to the power of a GTi, which should make it a lovely B-road steer.
No presents from the postman today, so mocking up the inlet manifold arrangement will have to wait! Away this weekend as well so progress may be slow for a couple of weeks
Don't get me wrong, guys - I'd be the last person to talk down values but if this was a 50,000 miles Rallye, I wouldn't be touching it, other than to make sure it was perfect.
If you can keep the rust of them; none of these models will lose money but I'll probably lose a load if I try and sell this when it is finished BUT - It will be worth its weight in gold to me (hopefully) as a non-cat, non-ABS, non-power steering, back to basics car.
Should be getting close to the weight of a Rallye with close to the power of a GTi, which should make it a lovely B-road steer.
No presents from the postman today, so mocking up the inlet manifold arrangement will have to wait! Away this weekend as well so progress may be slow for a couple of weeks
127bhp is very do-able but I won't be going that far and I agree that we probably wouldn't match the torque.
https://web.archive.org/web/20110903072843/http://...
But weight and the short ratios will have a huge effect and my target is more like 110+bhp, which ought to be 'easy' on a 4-2-1, cam and S1 inlet.
This car isn't about bragging rights, it is purely for my own enjoyment on our local roads and maybe trips to Wales/ Scotland.
I'm hoping the cam and S1 inlet manifold may appear today, so I'll try and get my throttle body adapter drawn up in the next couple of weeks, then off to 3D printing!
Then I'll get some long overdue photos up
https://web.archive.org/web/20110903072843/http://...
But weight and the short ratios will have a huge effect and my target is more like 110+bhp, which ought to be 'easy' on a 4-2-1, cam and S1 inlet.
This car isn't about bragging rights, it is purely for my own enjoyment on our local roads and maybe trips to Wales/ Scotland.
I'm hoping the cam and S1 inlet manifold may appear today, so I'll try and get my throttle body adapter drawn up in the next couple of weeks, then off to 3D printing!
Then I'll get some long overdue photos up
mwstewart said:
Interesting stuff - keep it up! It takes me back to when I started in the late 90's/early 2000's, and tuning hot hatches at the time. It seemed to be far more common than it is now.
It'll be a blast when finished.
mwstewart - [Wayne's World] I am not worthy It'll be a blast when finished.
[/Wayne's World]Good to have you on the thread! I have been inspired by your projects and the chap building the 205 GTi Dimma.
Yeah, I was always a 205 GTi man back in the day and never had a 106, having been through a couple of Clio Williams and a 172 in the last year - The modifying bug has bitten again. I can't/ won't touch the V6 as it's one of the very rare, Phase 1 Illiad blue cars (chassis #002, 1 of 8 and even less remaining) so I needed a project.
The last one I did was the track day 996, back in maybe '09, and I'd love to do something like that again but with the O&G business the way it is; I have to be a little more careful with the pennies!
So, engine, 'box and chassis (respray, suspension refresh etc) this year and then assess the situation and maybe look at throwing a load of alcantara at the interior in the next phase.
Kitchski said:
110bhp is certainly do-able on those mods, but the gains aren't as easily found as many people think.
I think you've got the right approach though, where it's not just about numbers, more about how the finished product feels to drive. I suspect it'll be a lot of fun!
If memory serves, the VTS gearbox is the second closest-matched ratios behind the S1 Rallye's (though the final drive is longer than the XSi, and the AX GT etc). Might be worth hunting one down though?
There are some good threads on the 106 Rallye forum about gearbox ratios.I think you've got the right approach though, where it's not just about numbers, more about how the finished product feels to drive. I suspect it'll be a lot of fun!
If memory serves, the VTS gearbox is the second closest-matched ratios behind the S1 Rallye's (though the final drive is longer than the XSi, and the AX GT etc). Might be worth hunting one down though?
I would link to them but for some reason; that site is blocked at work!?
Anyway, I believe the 1.4 XSi 'box (as I have) is the second closest, only marginally behind the S1 Rallye.
I am tempted by a rebuilt Rallye 'box, Quaife ATB and then the VTR (and other 1.4/1.6 boxes) 5th gear as it drops on the end of the shaft, easily and gives a much, much longer 5th gear for motorways/ cruising etc.
The hijack is more than welcome! Will give me some inspiration!
The S1 Rallye inlet, Piper BP285 cam and new ICV are at home... but I'm down in Berkshire for the Easter weekend so no car stuff until next weekend, sadly!
Still, my credit card needed a break! Will outline my plans for the S1 inlet when I'm back!
The S1 Rallye inlet, Piper BP285 cam and new ICV are at home... but I'm down in Berkshire for the Easter weekend so no car stuff until next weekend, sadly!
Still, my credit card needed a break! Will outline my plans for the S1 inlet when I'm back!
Quick update after I've had my scrubbing brush out!
Cam, new ICV and some vernier callipers to measure up the various manifold holes and pipes have arrived.
Here is the S1 Rallye inlet:
It came drilled for an ICV. I'll use this hole to TIG weld a little 19mm hose connector on:
That will allow me to use the XSi management in its standard form. The one 'correction' I need to make is to fill these holes (either TIG or a bolt and a plastic plug), which were for a MAP sensor as I believe this inlet was to be used on a Saxo VTR:
The XSi does have a MAP sensor but it is in the ECU and takes a pressure signal via a small bore pipe. I can use the small brass connections (you can see one in the first pic) by the throttle body for this. I don't need two so I might join them for a slightly 'cleaner' signal, using a T-piece.
Then, it should run as Peugeot intended, on the standard management, though will likely need a remap to get the best from the Piper BP285 cam. I'm expecting a slightly lumpy idle to start with!
Next stage is to get the XSi throttle body adaptor template drawn up and get that made.
I did think I had bought a second XSi engine and 'box but when I saw pics, it turned out it was an SPi XS and wasn't any good, which is a shame. Hopefully a refund is on the way as the seller seems honest and did make a mistake.
Cam, new ICV and some vernier callipers to measure up the various manifold holes and pipes have arrived.
Here is the S1 Rallye inlet:
It came drilled for an ICV. I'll use this hole to TIG weld a little 19mm hose connector on:
That will allow me to use the XSi management in its standard form. The one 'correction' I need to make is to fill these holes (either TIG or a bolt and a plastic plug), which were for a MAP sensor as I believe this inlet was to be used on a Saxo VTR:
The XSi does have a MAP sensor but it is in the ECU and takes a pressure signal via a small bore pipe. I can use the small brass connections (you can see one in the first pic) by the throttle body for this. I don't need two so I might join them for a slightly 'cleaner' signal, using a T-piece.
Then, it should run as Peugeot intended, on the standard management, though will likely need a remap to get the best from the Piper BP285 cam. I'm expecting a slightly lumpy idle to start with!
Next stage is to get the XSi throttle body adaptor template drawn up and get that made.
I did think I had bought a second XSi engine and 'box but when I saw pics, it turned out it was an SPi XS and wasn't any good, which is a shame. Hopefully a refund is on the way as the seller seems honest and did make a mistake.
Edited by dom9 on Wednesday 30th March 18:09
Good man - maintain the momentum!
Mrs9 had us out gardening today, so missed the good weather to whip the throttle body off. Maybe tomorrow if it's dry.
However, I've ordered the ally hose connector to see if I can get that TIGed onto the manifold and... I also ordered a full set of Bilsten B4s for less than £100 using the 20% off code on ebay on Friday.
They're coming from Demon Tweeks, so there shouldn't be any problems. Also ordered -35mm springs with the saving.
So, other than the Group N exhaust - I think I've got all the major parts. There is a guy selling a short ratio 'box and ATB on the Rallye forum but he wants the same sort of money as it would cost to refurb mine with a new ATB and I think the ratios are a bit short, so I won't get that.
So, get it running on the S1 inlet, then engine out for rebuild and onto the tear down, repaint and rebuild. New tax year next week so I can start paying myself again and get on with it!
Get some pics up, Thomas!
Also ordered some white rattle cans for the steels. Will see if they look ok after that as getting someone else to do 'em is about £200 and the wheels only cost around £135 brand new, delivered! Then I need tyres... grrr!
Mrs9 had us out gardening today, so missed the good weather to whip the throttle body off. Maybe tomorrow if it's dry.
However, I've ordered the ally hose connector to see if I can get that TIGed onto the manifold and... I also ordered a full set of Bilsten B4s for less than £100 using the 20% off code on ebay on Friday.
They're coming from Demon Tweeks, so there shouldn't be any problems. Also ordered -35mm springs with the saving.
So, other than the Group N exhaust - I think I've got all the major parts. There is a guy selling a short ratio 'box and ATB on the Rallye forum but he wants the same sort of money as it would cost to refurb mine with a new ATB and I think the ratios are a bit short, so I won't get that.
So, get it running on the S1 inlet, then engine out for rebuild and onto the tear down, repaint and rebuild. New tax year next week so I can start paying myself again and get on with it!
Get some pics up, Thomas!
Also ordered some white rattle cans for the steels. Will see if they look ok after that as getting someone else to do 'em is about £200 and the wheels only cost around £135 brand new, delivered! Then I need tyres... grrr!
Brilliant - you superstar!
Where you had your ICV, mine I drilled for the MAP, so I'll fill that.
Looking on my Blackberry screen (will look properly when I stop watching Daredevil through the laptop, on the TV) - the one thing that stands out is you have one of the small bore brass hose connectors plumbed into the far side of the throttle body, effectively bleeding air in at all times. Any reason for that?
Should the ICV not have done that job? Just interested as it sounds like you got the idle spot on! Was the engine cammed or mapped?
This is great stuff, thank you!
Where you had your ICV, mine I drilled for the MAP, so I'll fill that.
Looking on my Blackberry screen (will look properly when I stop watching Daredevil through the laptop, on the TV) - the one thing that stands out is you have one of the small bore brass hose connectors plumbed into the far side of the throttle body, effectively bleeding air in at all times. Any reason for that?
Should the ICV not have done that job? Just interested as it sounds like you got the idle spot on! Was the engine cammed or mapped?
This is great stuff, thank you!
Edited by dom9 on Saturday 2nd April 20:08
t4thomas said:
I haven't got any recent pics, but I do have this one from last year:
This is what I've got planned for the next few months:
- Mintex discs and 1144 pads.
- Peugeot Sport group n exhaust with motorsport cat.
- Bilstein group n dampers and 155lb Faulkner springs.
- Suspension service, including bushes etc.
The car is in pretty good shape cosmetically now, but I still need to replace the decals; have these already, but I have been putting the job off.
I don't know what's on the cards after that, but I like the idea of a shouty little 8V with Cat Cam 4900645, GSXR/Jenvey throttle bodies and a good map. It's just hard to justify from a bhp/£ perspective.
Thomas
Looks great, Thomas! The engine should run nicely with a remap and a 1mm skim with the 645 cam, so maybe do TBs last.This is what I've got planned for the next few months:
- Mintex discs and 1144 pads.
- Peugeot Sport group n exhaust with motorsport cat.
- Bilstein group n dampers and 155lb Faulkner springs.
- Suspension service, including bushes etc.
The car is in pretty good shape cosmetically now, but I still need to replace the decals; have these already, but I have been putting the job off.
I don't know what's on the cards after that, but I like the idea of a shouty little 8V with Cat Cam 4900645, GSXR/Jenvey throttle bodies and a good map. It's just hard to justify from a bhp/£ perspective.
Thomas
I want mine to look OEM+ or I'd have gone with bike carbs - old skool!
t4thomas said:
Thanks Dom.
There's certainly no rush.
I guess I missed the opportunity when I had the head completely rebuilt last year, but it's running beautifully at the moment so can't complain.
I don't know much about the Piper 285, but will be interested to hear how you get on with it. Is it a straightforward job, or do you need to pocket the pistons etc?
If you've had it rebuilt, recently, and it's showing no signs of needing to be opened up (e.g. oil leaks, head gasket) - I would leave it alone.There's certainly no rush.
I guess I missed the opportunity when I had the head completely rebuilt last year, but it's running beautifully at the moment so can't complain.
I don't know much about the Piper 285, but will be interested to hear how you get on with it. Is it a straightforward job, or do you need to pocket the pistons etc?
Get any bolt-ons done and keep the body tidy
The BP285 is a bit more cam than I wanted but I'll give it a go
Pistons shouldn't need to be pocketed but we'll check when the head has been skimmed.gretsch drummer said:
I have absolutely no idea why I even did that...That must have been during my R&D stage (maybe the idle was low and not drawing enough air). But I've found a video of it running but with a different pipe set up so this must be the stage after:
http://vid60.photobucket.com/albums/h19/gretsch_dr...
Yeah, she was a tapper. Not cammed or anything and no mapping either.
Just picked this up at work so will have a look at the video, later - sounds like a fun project!http://vid60.photobucket.com/albums/h19/gretsch_dr...
Yeah, she was a tapper. Not cammed or anything and no mapping either.
Edited by gretsch drummer on Saturday 2nd April 20:49
My idle is a little high at the moment (standard inlet) but who knows whether that is air leaks (will have new gaskets), the dodgy induction kit (will build a new one) or a failed ICV (will have mine cleaned and also have a brand new one).
TheJoker said:
I had a 106gti running on hyabusa bodies. Mate, fantastic fun. How's this getting on?
That sounds interesting - any pics of the engine bay?I would have liked a black GTi on white steels and a few mods (Rallye 'box, 150bhp etc) but a 'good one' is getting pretty expensive nowadays.
Plus, I really, really like a screaming 8v, for some reason. I guess, at 37, I was brought up on them as we couldn't afford anything with 16v!
I also prefer the S1's looks but I can see a GTi in my future...
Hopefully a few parts will show up this week, including the hose connector for the inlet. Will then visit my local, friendly TIG welder!
Dampers and lowering springs are here... cam cover should be going for its VTEC finish next week and I finally pulled my finger out...
The one issue is that the ally hose connector turned up for the Rallye Inlet and they sent a 17mm one instead of 19mm, so that will have to go back before progress can be made.
Off to Mumbai for work next week, so there may not be many interesting posts for the next week or so!
Quick edit after 4 x 200ml cans (12 more ordered)...
The one issue is that the ally hose connector turned up for the Rallye Inlet and they sent a 17mm one instead of 19mm, so that will have to go back before progress can be made.
Off to Mumbai for work next week, so there may not be many interesting posts for the next week or so!
Quick edit after 4 x 200ml cans (12 more ordered)...
Edited by dom9 on Friday 8th April 13:32
Quick update - back from India so whipped the cam cover off and dropped it at Spooner Restorations for the full VTEC crackle red refurb - should look great when done!
The aluminium hose connector had to be sent back as it was the wrong size, so i'll be ordering a new one and then hopefully i'll get the inlet manifold welded up and then i'll get Paul @ Spooner to give it the crackle black finish so it looks smart and OEM-ish!
Some more parts arrived while I was away. Another head gasket 0.2mm thicker and with the 'irregular' bore shapes for valve de-shrouding, new suspension nuts and bolts and new head bolts.
Also got 12 more cans of paint so I can finish the wheels at some point!
The aluminium hose connector had to be sent back as it was the wrong size, so i'll be ordering a new one and then hopefully i'll get the inlet manifold welded up and then i'll get Paul @ Spooner to give it the crackle black finish so it looks smart and OEM-ish!
Some more parts arrived while I was away. Another head gasket 0.2mm thicker and with the 'irregular' bore shapes for valve de-shrouding, new suspension nuts and bolts and new head bolts.
Also got 12 more cans of paint so I can finish the wheels at some point!
Thanks Neil
Bought a load more stuff today, the major bits being:
- 4 x Toyo T1-R tyres in 195/45 R15 and valves for the steels
- New Pugsport Group N exhaust with 2in rolled tail pipe
- New tool set, roller cabinet, impact wrench and jacks
- New carbon induction kit to modify
- New gear rods
- New fuel pressure regulator (FPR)
- New fuel filter
- New oil filter
- Various silicon hoses etc
And I am going to try one of the French (most of the XSi tuning seems to go on over there) performance EPROMs/chips as the seller seemed pretty genuine and it's only £25.
So, I reckon I have 95% of all the 'small' parts I need.
The major things like getting the engine and 'box rebuilt and getting a refurbished axle are on hold until I get the new tools, stands etc.
Once all the wheels are painted and have the tyres on, the unbolting and refreshing will start in earnest!
Bought a load more stuff today, the major bits being:
- 4 x Toyo T1-R tyres in 195/45 R15 and valves for the steels
- New Pugsport Group N exhaust with 2in rolled tail pipe
- New tool set, roller cabinet, impact wrench and jacks
- New carbon induction kit to modify
- New gear rods
- New fuel pressure regulator (FPR)
- New fuel filter
- New oil filter
- Various silicon hoses etc
And I am going to try one of the French (most of the XSi tuning seems to go on over there) performance EPROMs/chips as the seller seemed pretty genuine and it's only £25.
So, I reckon I have 95% of all the 'small' parts I need.
The major things like getting the engine and 'box rebuilt and getting a refurbished axle are on hold until I get the new tools, stands etc.
Once all the wheels are painted and have the tyres on, the unbolting and refreshing will start in earnest!
Edited by dom9 on Wednesday 20th April 18:20
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