1991 Peugot 309 2.1td conversion
Discussion
This thread is legit inspiring, thanks Lawbags. It makes me miss my old crappy and brilliant Xantia with this same engine, and also think about giving some attention to another jalopy "project" of mine that's been rotting away for a few years....
The slippers though are something else. They deserve their own thread
The slippers though are something else. They deserve their own thread
Spinakerr said:
The Pistonheads event in august at bicester...last year there was a readers cars section and it was fantastic to see all the stars of this forum (and the owners!). I'm hoping the same again this year... thought I may annoy everyone by bringing the Insight...
Ahhhh. Just found the post about it.Typically it's my rents golden wedding anniversary that day.
No chance of getting out of that!
Jodyone said:
This thread is legit inspiring, thanks Lawbags. It makes me miss my old crappy and brilliant Xantia with this same engine, and also think about giving some attention to another jalopy "project" of mine that's been rotting away for a few years....
The slippers though are something else. They deserve their own thread
Cheers!The slippers though are something else. They deserve their own thread
Got more to do this weekend so should be able to give some good updates!
And yes, the slippers rock
More progress today and lots of little things ticked off the list.
Which incidentally is nearly all done!
So the car was supposed to go for the exhaust and turbo relocation pipe on Wednesday but the guy who made the flanges only made 2 and then totally messed up the 3rd when I reminded him that I needed 3
Then by total chance, as I was telling someone at work about it, one of my colleagues said that her other half worked laser cutting stuff and could do it for me.
So the exhaust is now delayed by a couple of weeks.
Anyway, I cracked on and relocated the battery to the boot.
I couldn't figure out how to run the 0 gauge from the engine bay to the boot. Tried a couple of grommets but they were just too small.
So I think I'll run it under the car, with the brake lines, but I need some protective sleeve first, so ordered that up.
I then spent ages trying to utilise the original coolant hoses but after an hour or so and seeing how persihed they are, gave up and ordered various silicone pipes, reducers and joiners.
Then I went to connect up the throttle cable and realised it was too short.
So cut down the metal sleeve.
Another job that took far too long.
Then fitted the boost gauge which automatically turns it into a race car and adds 50bhp.
Wires to be tidied later.
I'll be winding up the boost once its all running so need this.
The inlet system is also shocking on the XUDs so I need to keep an eye on any boost leaks
I also tidied up some of the wiring andremoved the cold start module, not realising how big the spring is inside, and them found out that it holds it one way.
By removing it, the lever thing has gone the other way.
I assume it holds it in the position for cold start so left it as is.
Nothing a cable tie won't sort if its in the wrong position.
Once all the coolant bits arrive and I get them fitted, thats all I can do till the turbo relocation and exhaust have been made!
Which incidentally is nearly all done!
So the car was supposed to go for the exhaust and turbo relocation pipe on Wednesday but the guy who made the flanges only made 2 and then totally messed up the 3rd when I reminded him that I needed 3
Then by total chance, as I was telling someone at work about it, one of my colleagues said that her other half worked laser cutting stuff and could do it for me.
So the exhaust is now delayed by a couple of weeks.
Anyway, I cracked on and relocated the battery to the boot.
I couldn't figure out how to run the 0 gauge from the engine bay to the boot. Tried a couple of grommets but they were just too small.
So I think I'll run it under the car, with the brake lines, but I need some protective sleeve first, so ordered that up.
I then spent ages trying to utilise the original coolant hoses but after an hour or so and seeing how persihed they are, gave up and ordered various silicone pipes, reducers and joiners.
Then I went to connect up the throttle cable and realised it was too short.
So cut down the metal sleeve.
Another job that took far too long.
Then fitted the boost gauge which automatically turns it into a race car and adds 50bhp.
Wires to be tidied later.
I'll be winding up the boost once its all running so need this.
The inlet system is also shocking on the XUDs so I need to keep an eye on any boost leaks
I also tidied up some of the wiring andremoved the cold start module, not realising how big the spring is inside, and them found out that it holds it one way.
By removing it, the lever thing has gone the other way.
I assume it holds it in the position for cold start so left it as is.
Nothing a cable tie won't sort if its in the wrong position.
Once all the coolant bits arrive and I get them fitted, thats all I can do till the turbo relocation and exhaust have been made!
Edited by Lawbags on Sunday 17th March 14:58
So I finished work in good time today so cracked on with the car.
I'd sort of forgotten about the intercooler and having bought one a while back, decided to check it fitted.
Which it didn't.
So got a smaller one which I could mount in front of the rad. But this means moving the rad back and down, so I can run the hoses over the top.
And also running slimmer fans.
So I had a rummage through the scrap at work and found that a dentists delivery unit scaler module mounting plate works just fine.
A couple of slithers of it and a couple of holes- job done
I fitted a quick shift a while ago and realised that it only reduces the side to side movement so got one that shortens the front to back too
I wish I'd have my workshop built, cause I could make this sort of thing easily!
Anyway, I got it fitted and the gear stick feels brand new now.
Then fitted some of the new coolant hoses.
With a heap of reducers to make them fit
As I'm moving the battery to the boot, obviously I need to run a cable from the boot to the engine bay.
The plan was to run it inside the car as per normal.
But the only grommet I could use is right behind the glove box. And being 0 gauge, I couldn't get it to bend down into the footwell as the gap was so small.
There is no way I was removing 32 year old French plastic, so have decided to run it under the car, along side the brake lines.
But obviously needed to sheild it.
So fed it into steel reinforced walled fuel hose.
Not as easy as that though!
But nothing a bit of washing up liquid didn't help.
All that's left to do except fit the oil coller before going off for the exhaust is to run the cable under the car. But that's a job for Sunday.
Also after being messed about for 2 months trying to get the flange made for the downpipe, I finally have it!!
I'd sort of forgotten about the intercooler and having bought one a while back, decided to check it fitted.
Which it didn't.
So got a smaller one which I could mount in front of the rad. But this means moving the rad back and down, so I can run the hoses over the top.
And also running slimmer fans.
So I had a rummage through the scrap at work and found that a dentists delivery unit scaler module mounting plate works just fine.
A couple of slithers of it and a couple of holes- job done
I fitted a quick shift a while ago and realised that it only reduces the side to side movement so got one that shortens the front to back too
I wish I'd have my workshop built, cause I could make this sort of thing easily!
Anyway, I got it fitted and the gear stick feels brand new now.
Then fitted some of the new coolant hoses.
With a heap of reducers to make them fit
As I'm moving the battery to the boot, obviously I need to run a cable from the boot to the engine bay.
The plan was to run it inside the car as per normal.
But the only grommet I could use is right behind the glove box. And being 0 gauge, I couldn't get it to bend down into the footwell as the gap was so small.
There is no way I was removing 32 year old French plastic, so have decided to run it under the car, along side the brake lines.
But obviously needed to sheild it.
So fed it into steel reinforced walled fuel hose.
Not as easy as that though!
But nothing a bit of washing up liquid didn't help.
All that's left to do except fit the oil coller before going off for the exhaust is to run the cable under the car. But that's a job for Sunday.
Also after being messed about for 2 months trying to get the flange made for the downpipe, I finally have it!!
Edited by Lawbags on Friday 22 March 20:47
Edited by Lawbags on Friday 22 March 21:19
I made some decent progress today.
Finished making the brackets for the bottom of the rad...
Then using some more dentist chair parts, made the brackets for the top
I don't have a workshop, or anywhere to make things like this, so utilised the table I made for the engine last year....
Then made some more brackets and mounted the oil cooler.
The engine comes with a water cooled oil cooler, but the take off plate is very thick and where I've moved the rad back, it would interfere, hence the air to oil cooler
Then offered the turbo up. And wished I'd have done this before all the hassle I had getting the flanges made.
Due to the cold side inlet and outlet angles, I've had to clock the turbo, which means the waste gate bracket doesn't line up.
So I'm now going to need to get that made somehow.
If I'd have realised before getting the flanges made, I'd have sacked this turbo off and gone with a T25 which has much better angles to work with.
I reckon I'll also now need to move the header tank too.
Marvellous.
I'd hoped to get the power cable run aswell today but the brackets took so long to make I ran out of time.
Regretting this project?
100%
Finished making the brackets for the bottom of the rad...
Then using some more dentist chair parts, made the brackets for the top
I don't have a workshop, or anywhere to make things like this, so utilised the table I made for the engine last year....
Then made some more brackets and mounted the oil cooler.
The engine comes with a water cooled oil cooler, but the take off plate is very thick and where I've moved the rad back, it would interfere, hence the air to oil cooler
Then offered the turbo up. And wished I'd have done this before all the hassle I had getting the flanges made.
Due to the cold side inlet and outlet angles, I've had to clock the turbo, which means the waste gate bracket doesn't line up.
So I'm now going to need to get that made somehow.
If I'd have realised before getting the flanges made, I'd have sacked this turbo off and gone with a T25 which has much better angles to work with.
I reckon I'll also now need to move the header tank too.
Marvellous.
I'd hoped to get the power cable run aswell today but the brackets took so long to make I ran out of time.
Regretting this project?
100%
So, turns out the stock turbo won't work where I want it to.
So, Saab T25 it is!
A little bigger, but has the usual type of inlets/outlets, making it work above the gear box.
You can see the size difference here
I also mounted the fans.
Due to the intercooler, I had to mount one on the front and one on the rear....
I'm hoping the fans run off the stock relays, so they will cut in and out as required, but if not, I'll just run them from a switch in the cab.
Having mounted the oil cooler previously without the starter fitted, I went to fit the starter and realised that the sandwich plate side elbows fouled it.
So had to spin that round 90 degrees to get the clearance.
That also meant I needed longer hoses, which obviously I didn't have.
So once they were here, got that fitted.
Off for the exhaust and turbo relocation pipe next Wednesday
So, Saab T25 it is!
A little bigger, but has the usual type of inlets/outlets, making it work above the gear box.
You can see the size difference here
I also mounted the fans.
Due to the intercooler, I had to mount one on the front and one on the rear....
I'm hoping the fans run off the stock relays, so they will cut in and out as required, but if not, I'll just run them from a switch in the cab.
Having mounted the oil cooler previously without the starter fitted, I went to fit the starter and realised that the sandwich plate side elbows fouled it.
So had to spin that round 90 degrees to get the clearance.
That also meant I needed longer hoses, which obviously I didn't have.
So once they were here, got that fitted.
Off for the exhaust and turbo relocation pipe next Wednesday
Edited by Lawbags on Monday 22 April 19:30
Jhonno said:
Could you not have just drilled the required hole for the battery cable and fitted a grommet? Seems it would be a better solution than running it under the car like that..
Theres no way I'd drill behind an old French plastic dashboard 
One slip and the thing would disintegrat into 4 million bits
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