My Indigo Blue Throttle Bodied 106 Rallye
Discussion
Ok, so I have quiet of late but I have been busy.
Few things, had to go to Earls and get some more bits to redo the rear brake lines as the thread was different on the replacement caliper I bought on ebay. Tangent - I took a day off work to go there, and at the trade counter I was confronted with the most mechanically knowledgeable woman ever (or at least that I have ever met in my lifetime). At first I wrongly assumed she was a receptionist, that was until she brought her hands up from under the counter, picked up the caliper whilst wearing mechanics gloves, and then proceeded to tell me in detail what thread they are and what i'd need etc - I fell in love immediately!
So now I have sorted the rear lines, bled the brakes (another arse-ache job, as when bleeding the new caliper it became apparent that the bleed nipple was blocked. The fools had used grease when screwing it in, which was in turn blocking the small hole for the fluid to pass out through. Had to remove it entirely, stem the leaking fluid from the caliper, clean and blow out the nipple with a cunning DIY device made from my bike pump, football valve and a piece of rubber tube, and once that was done I refitted it and bled that caliper without issue. I've also put in some new gearbox oil in, wired in the Wiper Motor (pics to come as they're not uploaded yet), put in some new engine oil, and drained out the old petrol. Another cunning little ebay tool (£10) and it worked a treat! Just need to dispose of the old fuel now - any ideas (keep it sensible lol!)
I just need to wire in my AFR, get some coolant, get a new battery and fit it, and hopefully it will be good to go. That's discounting mapping and any teething issues I may have.
Also not sure if i've said before but I will be moving and there was a possibility i'd have to sell the rallye. However, i've amanged to find a garage to rent so that's bonus. No lighting or power, but it's better than nothing. I will make do!
Here are some photo's anyways:
Brake line stuff (making them up):
Calipers:
New bits:
Cutting the hose and preparing the end for the olive:
Earls tool to push on the olive (requires serious force so I would suggest using assembly lube which I don't have)
Done (two in total):
Fuel drainage - excuse the pics, used my iphone:
Starting:
Getting there:
Will upload pics of the wiper motor wiring later on.
Few things, had to go to Earls and get some more bits to redo the rear brake lines as the thread was different on the replacement caliper I bought on ebay. Tangent - I took a day off work to go there, and at the trade counter I was confronted with the most mechanically knowledgeable woman ever (or at least that I have ever met in my lifetime). At first I wrongly assumed she was a receptionist, that was until she brought her hands up from under the counter, picked up the caliper whilst wearing mechanics gloves, and then proceeded to tell me in detail what thread they are and what i'd need etc - I fell in love immediately!
So now I have sorted the rear lines, bled the brakes (another arse-ache job, as when bleeding the new caliper it became apparent that the bleed nipple was blocked. The fools had used grease when screwing it in, which was in turn blocking the small hole for the fluid to pass out through. Had to remove it entirely, stem the leaking fluid from the caliper, clean and blow out the nipple with a cunning DIY device made from my bike pump, football valve and a piece of rubber tube, and once that was done I refitted it and bled that caliper without issue. I've also put in some new gearbox oil in, wired in the Wiper Motor (pics to come as they're not uploaded yet), put in some new engine oil, and drained out the old petrol. Another cunning little ebay tool (£10) and it worked a treat! Just need to dispose of the old fuel now - any ideas (keep it sensible lol!)
I just need to wire in my AFR, get some coolant, get a new battery and fit it, and hopefully it will be good to go. That's discounting mapping and any teething issues I may have.
Also not sure if i've said before but I will be moving and there was a possibility i'd have to sell the rallye. However, i've amanged to find a garage to rent so that's bonus. No lighting or power, but it's better than nothing. I will make do!
Here are some photo's anyways:
Brake line stuff (making them up):
Calipers:
New bits:
Cutting the hose and preparing the end for the olive:
Earls tool to push on the olive (requires serious force so I would suggest using assembly lube which I don't have)
Done (two in total):
Fuel drainage - excuse the pics, used my iphone:
Starting:
Getting there:
Will upload pics of the wiper motor wiring later on.
loving the work so far 
Max_Torque said:
If you didn't stick those sharp stainless steel braid wires into your thumbs at least 5 tines during making up a single hose end, you're not a proper race mechanic....... ;-)
In short, yes! This tool helps minimise spiked fingers, but you still do it! I only bled the once on this occasion..TB Rich said:
I cannot believe you haven't finished this yet! I've been through 3 cars now since I sold my TB'd Rallye (Rallye_Rich from the RR & SSC forums a good few years ago!), though some how now back in French tat again
Did Chris (Bic) ever finish his?
Ha ha....it is very close now honestly! Did Chris (Bic) ever finish his?
Bic sold his to another guy on the Rallye Reg, so hopefully it will see tarmac again, although it will be in a few years as it costs big money to build a motor like that (as you know).
Do you miss yours? That was the first throttle bodies rallye I ever saw!
Lewis, yes mate I sure do miss it! I need that kind of savagery back in my life! I don't think the Clio is going to cut it really as nobody is doing TB's for them, compared to the Rallye it's a good 40bhp/tonne less 
It's s
tty modern ECU's that seem to be the problem as you loose the dash if you go standalone.
You will be one lucky sod when yours is up and running, the love (and money!) you have lavished on it means it'll be quite the weapon I'm sure
Olly, that must have been my original 8v block then(?) as the 16v block and head ended up in Belguim!
It's stty modern ECU's that seem to be the problem as you loose the dash if you go standalone.You will be one lucky sod when yours is up and running, the love (and money!) you have lavished on it means it'll be quite the weapon I'm sure
Olly, that must have been my original 8v block then(?) as the 16v block and head ended up in Belguim!
Ok, haven't done anything for a while on this as busy sorting my wedding and house buying and moving out - full steam ahead.
Annoyingly I put the stack dash back in last night and saw that my internal rear brake lines are fking leaking again?! Cannot fathom how as they were pressure tested at earls and found to be ok....may nip up the connectors and just see whether that's the issue. I am fking hating brake lines now!
I also flicked the cable back onto the battery and there is still life in it - or at least enough to fire the dash up. Will try and wire the AFR to my fuel pump switch over the weekend. I am guessing I can just wire the live into the switch so that the AFR comes on when I flick the fuel pump switch?
Also put sealant on the panels where I had knocked them flat to accommodate the new steering arms too. And Tommy shortened them and sent them back to me so I have re-fitted them since.
Regarding wiring in of my AFR, the idea I had is to wire it into the fuel pump switch on the carbon panel where the radio was. I just need to find somewhere to connect the earth wire. I assume these switches will be fused somewhere?
Here are the pics and the idea:
Annoyingly I put the stack dash back in last night and saw that my internal rear brake lines are f
king leaking again?! Cannot fathom how as they were pressure tested at earls and found to be ok....may nip up the connectors and just see whether that's the issue. I am fking hating brake lines now!I also flicked the cable back onto the battery and there is still life in it - or at least enough to fire the dash up. Will try and wire the AFR to my fuel pump switch over the weekend. I am guessing I can just wire the live into the switch so that the AFR comes on when I flick the fuel pump switch?
Also put sealant on the panels where I had knocked them flat to accommodate the new steering arms too. And Tommy shortened them and sent them back to me so I have re-fitted them since.
Regarding wiring in of my AFR, the idea I had is to wire it into the fuel pump switch on the carbon panel where the radio was. I just need to find somewhere to connect the earth wire. I assume these switches will be fused somewhere?
Here are the pics and the idea:
Quick update tonight, had a busy and productive weekend on the Rallye. Wired in AFR properly and got that working, did coolant, discovered teething issues as follows:
1. Rad appears to be leaking - will use rad weld I think for now until I get a new rad (unless anyone recommends against it on my engine?)
2. Brake lines are leaking again inside the cabin (rear t piece as before). No idea how as they were pressure tested at earls and came back ok. However, they defo leak but have a day off tomorrow so will go to earls and get more hose to redo them.
Finally, I only went and got it working today! Took it for a blast up the road but was a bit sketchy with no brakes and no PAS (another thing I need to sort). Otherwise I love it. Seriously insane I forgot how fun a small extremely noisy car is!
More to come, and will get pics up tomorrow.
Lewis
1. Rad appears to be leaking - will use rad weld I think for now until I get a new rad (unless anyone recommends against it on my engine?)
2. Brake lines are leaking again inside the cabin (rear t piece as before). No idea how as they were pressure tested at earls and came back ok. However, they defo leak but have a day off tomorrow so will go to earls and get more hose to redo them.
Finally, I only went and got it working today!
Took it for a blast up the road but was a bit sketchy with no brakes and no PAS (another thing I need to sort). Otherwise I love it. Seriously insane I forgot how fun a small extremely noisy car is! More to come, and will get pics up tomorrow.
Lewis
shalmaneser said:
Don't use radweld on a Longmans engine!
No I decided against it!!Ok so I have had a productive few days. Also highlights how heinous my luck has been with a lot of stuff. On my (2 minute) maiden voyage I only managed to get a fecking puncture - can you believe it??!! Pulled a big shard of metal out the tyre this afternoon. Anyway, I can get it repaired so no biggie. Just annoying.
So this weekend and today as I had the day off work (woo), I investigated the leaky rear brake line, made up a new one as I think it was just one side at fault (we shall see). Wired in my AFR which I pretty much did already but needed a fuse and a few small bits to sort, removed my fan assembly and ripped out the leaky rad. It was definitely leaking as you pour fluid it, it pisses straight out again at the bottom. Every goddamn thing I have pretty much replaced now. Also hoovered her out and gave her a clean and wax as she needed some love. Dusty and haggard she was.
Also put some carbon vinyl on the door bars of the cage to stop it getting bashed and scuffed when getting in and out (with my long pins swinging about it's unavoidable)!
Here are pics of the work anyway:
First up is in line fuse for the STACK AFR:
Connected:
Cable tied up behind dash complete with 3A fuse fitted as per instructions (excuse the snakes wedding in the back it's all out of sight when the carbon panel is back on):
Earthed behind dash support bar - cunningly hidden:
Working:
Carbon on door bars:
Cleaned out inside:
Looking hard:
Wax 'curing'
Leaky Rad:
Removed:
Redoing the rear line:
The big ass bit of metal in my tyre:
And lastly, my current Nissens rad had this piece of alloy bonded over the top making it look very tidy. Not sure if Hank fitted this or what, but the new models don't appear to have it on the photo's so I chiseled it off (was tough) and cleaned it a bit to bond on the top of the new rad. Unless spending £500 on a prop alloy rad, most of them appear quite ugly so this should at least aid to make it look cleaner and neater:
So next up is the following:
Buy new rad
Buy more coolant
Buy brake fluid
Bleed brakes
Flt new rad and fan and fill with coolant
Mapping
Maybe fit a battery isolator so I can just disconnect it that way to stop the battery running down, as at the moment I am undoing the terminal all the time. Can't believe it started on that battery. It hasn't been run in years (the battery), and the previous ones I had died after a short period of inactivity. Sweet. I am feeling excited about it again now. That short drive yesterday made me realise how awesome it is. God damn the noise it makes is unbelievable!
That's all for now,
Lewis.
Edited by Track_Cit on Monday 14th July 23:15
Looks much better, not surprised that drive spurred you on.
In the first 300 miles of a fully rebuilt car I've had an engine blow up, punctured tyre and many many other annoying problems so I fully sympathise with your pain. That puncture is just typical!
Taxed n tested for the last bit of summer?
In the first 300 miles of a fully rebuilt car I've had an engine blow up, punctured tyre and many many other annoying problems so I fully sympathise with your pain. That puncture is just typical!
Taxed n tested for the last bit of summer?
MrMoonyMan said:
Looks much better, not surprised that drive spurred you on.
In the first 300 miles of a fully rebuilt car I've had an engine blow up, punctured tyre and many many other annoying problems so I fully sympathise with your pain. That puncture is just typical!
Taxed n tested for the last bit of summer?
Thanks! Hopefully I don't experience the blown engine problem that would NOT be cool! In the first 300 miles of a fully rebuilt car I've had an engine blow up, punctured tyre and many many other annoying problems so I fully sympathise with your pain. That puncture is just typical!
Taxed n tested for the last bit of summer?
Ok, so more work on this last night.
I took the supposedly punctured tyre/wheel to a tyre place on the way home from work yesterday and apparently it wasn't punctured after all? So he pumped it up a bit and just need to keep an eye on it. It's possible that it lost pressure being sat around for ages - we will see.
After my little outing on Sunday I also noticed that i'd caught my exhaust clamp while reversing into the garage. At first I wondered what the hell it was, as was trying to reverse in and it wouldn't budge. Then after a few seconds I realised that the clamp must have been catching the floor lock. Sure enough, it was.
This is the culprit:
And it caught just here:
It's pretty much buggered the clamp so will buy and other and position it differently. I also cut the bolt down to allow this, as it's far too long as standard:
Cutting down the bolt (ps: if you don't own a vice buy one - invaluable tool)
Finishing it:
So much shorter now and will fit to a new clamp (yet to buy):
Meanwhile I did the same on the rear clamp and turned it round so it's not likely to catch anything. Although it's not that low really, did it just as a precaution:
I have never been a fan of the Spoox Motorsport logo on my rad hose, it looks a bit chavvy, so a it was off I took the opportunity to lose the logo. Used the wife's nail varnish remover that stuff is evil. I have used it in the past to take logos off bikes frames etc, really strong.
Before (already taken one logo off):
After (OEM and subtle):
Finally, gratuitous manifold shot while the rad is off - looks awesome!
Bought a rad today so that should land shortly, then just need brake fluid, new exhaust clamp and a few other bits. Also have to wire and fit my speed sensor still too, but a little unsure as the ones I have (kindly supplied by a mate) have three wires and my current one only has two?
More to come soon!
Quick teaser. Got it fired up again tonight to check the new rad and add more coolant. Also bled the brakes but still have air in the system but so far the lines don't seem to be leaking which is good. I will add all the photo's of the work tomorrow, but here is a teaser vid for now. Got the AFR working too which is cool. As you can see she is running really rich. Almost intoxicated myself with it running in the garage lol :idiot:
Also I must apologise in advance for the heinous portrait video - I only realised this after i'd taken it - sorry guys!
Onto the car, you can hear she revs up super quickly with that lightened flywheel. It's a real beast. The wife was not happy and said it was vibrating the glasses in the kitchen cupboard upstairs - sweet
https://www.youtube.com/watch?v=1meFcfk50zo&list=UUW0X695QQxiMsqwQqpTkgJA
That'll fix it.
https://www.youtube.com/watch?v=1meFcfk50zo&li...
Lovely car by the way, I had a VTS on Bodies and I still miss the 'bwaaarp'
https://www.youtube.com/watch?v=1meFcfk50zo&li...
Lovely car by the way, I had a VTS on Bodies and I still miss the 'bwaaarp'
Crowds said:
rallye rich, bic, blasts from the past pgac days haha! really tempted to buy myself another rallye these days.
I must stop looking at this thread.....
Paul.
For me too. I was on the PGAC maybe ten years ago plus. Early 00's. Myself (Paulr) and a good mate Joe (Longun) went to most of the shows back then and pretty much constantly on the forum. haha! really tempted to buy myself another rallye these days.I must stop looking at this thread.....
Paul.
It's funny looking back on forums. I'd love to read a few of my old posts. Probably talking utter s
te.Nikko 40691 said:
That'll fix it.
https://www.youtube.com/watch?v=1meFcfk50zo&li...
Lovely car by the way, I had a VTS on Bodies and I still miss the 'bwaaarp'
Thank you mate https://www.youtube.com/watch?v=1meFcfk50zo&li...
Lovely car by the way, I had a VTS on Bodies and I still miss the 'bwaaarp'
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