1992 Peugeot 106 XSi - Strip, Respray, Rebuild OEM+
Discussion
Hi everyone,
I have been fancying another little project for a while as the Clio V6 is in the garage over winter. I was looking for something small, light and revvy - The complete opposite of what manufacturers seem to be releasing.
I'd have loved to get back into a 205 GTi but with good ones appearing to start around £10k now, with reasonable mileage, I felt that there may be more 'value' in the 106.
Originally I was looking for a black S1 Rallye but good ones are few and far between and also appreciating rapidly. I didn't fancy a GTi as I don't like the S2 face lift and I wanted to stick with an 8v engine.
So, I am now the proud owner of a little, S1 blue XSi. It has the 1.4 iron block engine, which basically has the Rallye head and produces over 90bhp in standard trim.
The plan is to strip it down to its nuts and bolts, repaint it and build it back up with new components and a little fettling!
I paid £800 for the car with a blown HG and some ugly alloys. When it arrived (back of a loader) the rear box was hanging off so I picked up a standard one (just £20, new) to get it running, which will be swapped for a full stainless system as the build progresses.
The windscreen washers (I think the bonnet had been changed recently) were also missing as well as the bonnet stay clip, so I have been picking up parts and putting that back together.
It also needed a new battery terminal and battery, so that's now all sorted and it runs nicely... minus the headgasket!
I also ordered some new, steel wheels from Tyre Leader to give it the Rallye look - so they'll be painted white, shortly.
The engine will be torn down and rebuilt with a CatCams 4900602 fast road cam and a slight skim to give me hopefully around 110+bhp with a 4-2-1 exhaust manifold and an S1 Rallye inlet. The engine will likely be rebuilt by Naismith's in Wimbledon, who are relatively local.
Standard, new Bilstein B4 dampers will be fitted with -30mm lowering springs and a reconditioned beam at the back. And, hopefully, I can get a gearbox built up with a Quaife LSD.
The idea is to have something around 850kg with a NA engine that revs to almost 8k rpm with a close ratio 'box but looks fairly standard.
Some other parts bought/ on their way:
- New radiator
- New zero miles odo for after full rebuild
- New, original/ OEM spark plugs (rare)
- New head gasket (rare)
- New Valeo clutch kit
- New radiator cap
- New thermostat
- New water pump
- New engine gasket/ seals set
- New timing belt kit
- New rocker cover gasket
Just waiting on a quote to get the chassis torn down and resprayed!
I have been fancying another little project for a while as the Clio V6 is in the garage over winter. I was looking for something small, light and revvy - The complete opposite of what manufacturers seem to be releasing.
I'd have loved to get back into a 205 GTi but with good ones appearing to start around £10k now, with reasonable mileage, I felt that there may be more 'value' in the 106.
Originally I was looking for a black S1 Rallye but good ones are few and far between and also appreciating rapidly. I didn't fancy a GTi as I don't like the S2 face lift and I wanted to stick with an 8v engine.
So, I am now the proud owner of a little, S1 blue XSi. It has the 1.4 iron block engine, which basically has the Rallye head and produces over 90bhp in standard trim.
The plan is to strip it down to its nuts and bolts, repaint it and build it back up with new components and a little fettling!
I paid £800 for the car with a blown HG and some ugly alloys. When it arrived (back of a loader) the rear box was hanging off so I picked up a standard one (just £20, new) to get it running, which will be swapped for a full stainless system as the build progresses.
The windscreen washers (I think the bonnet had been changed recently) were also missing as well as the bonnet stay clip, so I have been picking up parts and putting that back together.
It also needed a new battery terminal and battery, so that's now all sorted and it runs nicely... minus the headgasket!
I also ordered some new, steel wheels from Tyre Leader to give it the Rallye look - so they'll be painted white, shortly.
The engine will be torn down and rebuilt with a CatCams 4900602 fast road cam and a slight skim to give me hopefully around 110+bhp with a 4-2-1 exhaust manifold and an S1 Rallye inlet. The engine will likely be rebuilt by Naismith's in Wimbledon, who are relatively local.
Standard, new Bilstein B4 dampers will be fitted with -30mm lowering springs and a reconditioned beam at the back. And, hopefully, I can get a gearbox built up with a Quaife LSD.
The idea is to have something around 850kg with a NA engine that revs to almost 8k rpm with a close ratio 'box but looks fairly standard.
Some other parts bought/ on their way:
- New radiator
- New zero miles odo for after full rebuild
- New, original/ OEM spark plugs (rare)
- New head gasket (rare)
- New Valeo clutch kit
- New radiator cap
- New thermostat
- New water pump
- New engine gasket/ seals set
- New timing belt kit
- New rocker cover gasket
Just waiting on a quote to get the chassis torn down and resprayed!
Edited by dom9 on Wednesday 9th March 11:46
Thanks all - I didn't realise there would be so much interest! It's only recently I found out about the XSi existing and how 'special' it is (mine has the homologation plaque).
The interior isn't in terrible condition but I am considering the options on the front seats. I'm tempted to get some buckets trimmed using the original (or similar) material so they "blend".
Getting the body, engine and 'box sorted are first on the list though
Ultimately - It would be nice to have a set of say non-adjustable Ohlins on there but I think I need to sort the body and engine first and then see how I feel about the set up
The interior isn't in terrible condition but I am considering the options on the front seats. I'm tempted to get some buckets trimmed using the original (or similar) material so they "blend".
Getting the body, engine and 'box sorted are first on the list though
PaulJC84 said:
Looking forward to following this, did you consider using B6 or B8 dampers with the shorter springs?
Considered it but with this purely being a road car and the roads being rubbish etc etc - I think I'll start with the B4s as a full new set is only £110 - Will then see how I feel.Ultimately - It would be nice to have a set of say non-adjustable Ohlins on there but I think I need to sort the body and engine first and then see how I feel about the set up
Edited by dom9 on Wednesday 9th March 10:45
I love the blue of this one as it reminds me of my old, Miami 205 GTi.
It's also a non-sunroof, so best for stiffness... I do hate a sunroof!
The gears are like stirring porridge so I'll get the bushes sorted and a short shift kit in there, when the 'box gets rebuilt with the Quaife.
I suspect it will be ready in summer. I'm ordering parts as we speak, will get them fitted and then shift it to the bodyshop.
It will end up costing a fair bit (which I probably wouldn't get back in a sale) but it should still be cheaper than a 205 GTi and effectively back to zero miles.
Just got to select the right place to tear it down for me, spray it and put it back together!
It's also a non-sunroof, so best for stiffness... I do hate a sunroof!
The gears are like stirring porridge so I'll get the bushes sorted and a short shift kit in there, when the 'box gets rebuilt with the Quaife.
I suspect it will be ready in summer. I'm ordering parts as we speak, will get them fitted and then shift it to the bodyshop.
It will end up costing a fair bit (which I probably wouldn't get back in a sale) but it should still be cheaper than a 205 GTi and effectively back to zero miles.
Just got to select the right place to tear it down for me, spray it and put it back together!
Thanks guys - wasn't sure how much love there would be for a little Pug on here, when they haven't reached 205 GTi cult status!
I'm trying to keep the momentum up on the build and do something or buy something (no matter how small) each day so that it doesn't get forgotten, rotting away on the drive.
That's why I bought the standard exhaust box, for example, keeps the car 'mobile' and allowed me to get it started and running (without upsetting the neighbours) even though it will be swapped for a stainless system in the next few weeks (will do it after the engine is back from rebuild).
I am fairly sure I will be getting an S1 Rallye inlet manifold (waiting for another PHer to get back to me on that) but I am still not 100% clear on what needs to be swapped in terms of wires on the TPS and whether or not I need to drill the manifold for the ICV. I need to check and see what ICV I have on the XSi. Some seem to report a straight swap (as they had a stepper motor) and others seem to have more of a mission, ending up with high/ erratic idle.
There is a suggestion that the simplest way to get it running nicely is to actually have an adaptor plate made to take the XSi throttle body and use that on the S1 Rallye manifold, keeping the original TPS, ICV etc as-is.
The thing is; for my spec, I am not sure I need the Rallye inlet but it would be nice, all vapour blasted and sparkly!
I'm trying to keep the momentum up on the build and do something or buy something (no matter how small) each day so that it doesn't get forgotten, rotting away on the drive.
That's why I bought the standard exhaust box, for example, keeps the car 'mobile' and allowed me to get it started and running (without upsetting the neighbours) even though it will be swapped for a stainless system in the next few weeks (will do it after the engine is back from rebuild).
I am fairly sure I will be getting an S1 Rallye inlet manifold (waiting for another PHer to get back to me on that) but I am still not 100% clear on what needs to be swapped in terms of wires on the TPS and whether or not I need to drill the manifold for the ICV. I need to check and see what ICV I have on the XSi. Some seem to report a straight swap (as they had a stepper motor) and others seem to have more of a mission, ending up with high/ erratic idle.
There is a suggestion that the simplest way to get it running nicely is to actually have an adaptor plate made to take the XSi throttle body and use that on the S1 Rallye manifold, keeping the original TPS, ICV etc as-is.
The thing is; for my spec, I am not sure I need the Rallye inlet but it would be nice, all vapour blasted and sparkly!
The thing with a Rallye is that in order to keep the 'value' of the rebuild in the car, you'd need to make everything original OEM, which means no personalisation and difficult to obtain parts (in some cases) etc.
The 'beauty' of this project, to me, is that no one seems to care too much about XSis yet, so changing wheels, suspension, engine etc isn't seen as sacrilege.
I haven't got the space and tools to do it all myself, really, and being a contractor - it's probably cheaper to have someone build the engine and respray the car than me take the time off or lose momentum spreading the build over months.
I'll trial fit everything to the car before it goes to paint so i'll have got my hands as dirty as I need and will be able to maintain it myself from there but I want the engine warranted and a good finish to the paint.
Mrs9 text to say the head gasket is here!
The 'beauty' of this project, to me, is that no one seems to care too much about XSis yet, so changing wheels, suspension, engine etc isn't seen as sacrilege.
I haven't got the space and tools to do it all myself, really, and being a contractor - it's probably cheaper to have someone build the engine and respray the car than me take the time off or lose momentum spreading the build over months.
I'll trial fit everything to the car before it goes to paint so i'll have got my hands as dirty as I need and will be able to maintain it myself from there but I want the engine warranted and a good finish to the paint.
Mrs9 text to say the head gasket is here!
bulldong said:
This is going to be great! Good luck!
Thanks bulldong Kitchski said:
Also, the homologation plate you mentioned - I'm intrigued! Where's that? I didn't realise the XSi was homologated for anything. I'll have to go and see if I can see one on my old black XSi from years back 
Forgot this bit!It's on the slam panel, to the right, kind of above the bonnet latch...
Picking my old man up from the airport tonight but will try and grab a pic tomorrow.
I believe some have them (perhaps early cars) and others don't. I guess they needed more of the Rallye chassis to homologate the car than they had made Rallyes, at the start hence both had them?
Looks great si_xsi!
Found it on eBay, negotiated over Whatsapp and then got a delivery quote off Shiply!
Saw pics and video so knew it was solid and I was going to break it down and rebuild it anyway, so the rest was fairly unimportant.
Not sure if £800 was slightly over the odds for the 'project' without MOT etc but it's a non-sunny in a colour I wanted and they're rare as hens teeth, so I had to have it.
Guessing I'll be about (hopefully) £5k to £6k in when all is said and done but find another with fresh paint, fresh engine, fresh 'box, fresh suspension etc etc!
The V6 is insured for £10k more than it was last year so if I was to lose my job (oil and gas) - I'll keep this and move that on
Just got my first quote for tear down and build back up... Waiting on two others!
Found it on eBay, negotiated over Whatsapp and then got a delivery quote off Shiply!
Saw pics and video so knew it was solid and I was going to break it down and rebuild it anyway, so the rest was fairly unimportant.
Not sure if £800 was slightly over the odds for the 'project' without MOT etc but it's a non-sunny in a colour I wanted and they're rare as hens teeth, so I had to have it.
Guessing I'll be about (hopefully) £5k to £6k in when all is said and done but find another with fresh paint, fresh engine, fresh 'box, fresh suspension etc etc!
The V6 is insured for £10k more than it was last year so if I was to lose my job (oil and gas) - I'll keep this and move that on
Just got my first quote for tear down and build back up... Waiting on two others!
Edited by dom9 on Thursday 10th March 09:45
A lot of what has driven me this way is the fact that my old 205 GTis were so much fun. More so than my Porsche 996 built for track days.
I miss screaming, small capacity engines and carrying low inertia into every bend and turn. Perhaps the best drives I've ever had were in my <1 litre Seat Marbella (identical to the original, boxy Fiat Panda) around the Norfolk countryside, when I worked at Lotus Motorsport.
Foot to the floor everywhere and limits low enough to make it fun but not dangerous. Weighed absolutely nothing and although pretty gutless; seemed to love being revved and felt unburstable. I did 'burst' a clutch and a gearbox though... I'd love another for comedy!
I'm thinking that this car will inspire me to get out and drive for fun a bit more. My Clio V6 has just 950 miles on it and is a garage queen, if I am honest, so my daily is Bella's transport; the big, V8 BMW Touring. As lovely a noise as that makes (had a custom cat-back exhaust made) - it isn't much 'fun' round the lanes on my way to work!
The new clutch should be in Mrs9's hands any minute now...
I miss screaming, small capacity engines and carrying low inertia into every bend and turn. Perhaps the best drives I've ever had were in my <1 litre Seat Marbella (identical to the original, boxy Fiat Panda) around the Norfolk countryside, when I worked at Lotus Motorsport.
Foot to the floor everywhere and limits low enough to make it fun but not dangerous. Weighed absolutely nothing and although pretty gutless; seemed to love being revved and felt unburstable. I did 'burst' a clutch and a gearbox though... I'd love another for comedy!
I'm thinking that this car will inspire me to get out and drive for fun a bit more. My Clio V6 has just 950 miles on it and is a garage queen, if I am honest, so my daily is Bella's transport; the big, V8 BMW Touring. As lovely a noise as that makes (had a custom cat-back exhaust made) - it isn't much 'fun' round the lanes on my way to work!
The new clutch should be in Mrs9's hands any minute now...
CarlosV8 said:
Great choice of car, will be watchin good with interest. My wife had a 1.6 XSI that we bought cheap years ago because it needed some work. Needed plenty more work during her ownership but was always a joy to drive. My lasting memory is stripping the head down on the kitchen table to do the valve stem seals with the other half - weirdly I've never been allowed to do that with my cars!!
See, my missus would let me do that (valve stem seals are in that box of goodies) but I think it's better if I just do 'everything' at the same time and have someone rebuild the engine for me.hoppo4.2 said:
Epic little things back when I was 19 I had a gti and my best mate had a grey 1.4 xsi. We had so much fun respectfully following each other around the country roads.
There really wasn't too much in it up to about 50.
I guess the XSi is lighter and a little shorter geared with closer ratios, so there shouldn't be much in it. If I can lose a bit of weight and add 20bhp - it should be a proper little B-road blaster.There really wasn't too much in it up to about 50.
Just ordered 16x black wheel bolts for the new steel wheels
hoppo4.2 said:
If I remember correctly the xsi was quite a lot shorter geared. Seem to remember about 4.5k at 70mph. About 123mph off the limiter (down hill) ??
I've been tempted by some Quaife ratios recently (and maybe quick rack) but I think they're short enough already, for road work... It's the Quaife ATB I really want! That's integral to the end game, as far as I am concerned, but they're not cheap... Have my eye on a rebuilt box with one fitted but haven't heard from the seller, sadly
To be honest; I've only ever had plate diffs so I am kind of working on the assumption that the ATB is 'softer' or less aggressive and more set up for road driving.
However, it may have to wait unless I get track one down at a good price as I'd rather not be paying over a grand, all-in, with a gearbox refurb!
However, it may have to wait unless I get track one down at a good price as I'd rather not be paying over a grand, all-in, with a gearbox refurb!
Hi Ian - good to have you on board!
I'm looking forward to this; no PAS or ABS... proper old school!
One day this modification will probably look like sacrilege but I honestly can't wait to get it finished!
Intake manifold coming off tomorrow and injectors and ICV will be sent off for cleaning and a refresh ahead of the engine rebuild and S1 Rallye inlet (in the post this weekend) modifications!
I'm looking forward to this; no PAS or ABS... proper old school!
One day this modification will probably look like sacrilege but I honestly can't wait to get it finished!
Intake manifold coming off tomorrow and injectors and ICV will be sent off for cleaning and a refresh ahead of the engine rebuild and S1 Rallye inlet (in the post this weekend) modifications!
There is a blue 106 XSi on eBay at the moment!
It's a bit dented and rusty but it is a 1.6 (not sure that's better), which might be fun!
I pulled the throttle body off today to try and get to the ICV and then decided the whole inlet manifold would have to come off... So I put it all back together, walked back inside and watched Deadpool with my stinking hangover!
Cam on its way, S1 Rallye Inlet Manifold should be coming this weekend and a few, small bits (new ecu cover, new plastic cambelt cover, black wheel bolts) have arrived.
Oh, and a "106 XSi" logo boot mat!
A few of the sensor plugs in the engine bay looked a bit the worse for wear and there seemed to be the odd rogue wire so that could all do with tidying up.
Else, still progressing... albeit slowly today!
It's a bit dented and rusty but it is a 1.6 (not sure that's better), which might be fun!
I pulled the throttle body off today to try and get to the ICV and then decided the whole inlet manifold would have to come off... So I put it all back together, walked back inside and watched Deadpool with my stinking hangover!
Cam on its way, S1 Rallye Inlet Manifold should be coming this weekend and a few, small bits (new ecu cover, new plastic cambelt cover, black wheel bolts) have arrived.
Oh, and a "106 XSi" logo boot mat!
A few of the sensor plugs in the engine bay looked a bit the worse for wear and there seemed to be the odd rogue wire so that could all do with tidying up.
Else, still progressing... albeit slowly today!
The MA gearbox isn't the strongest, sadly
To me, my car has to have the Quaife ATB and I may drop a VTR 5th gear in, for motorway journies.
Interestingly, the XSi 'box is very rare but there always seem to be the (slighter shorter) S1 Rallye 'boxes available.
Perhaps I'll pick one of those up, drop in the Quaife and longer 5th and sell the XSi 'box.
To me, my car has to have the Quaife ATB and I may drop a VTR 5th gear in, for motorway journies.
Interestingly, the XSi 'box is very rare but there always seem to be the (slighter shorter) S1 Rallye 'boxes available.
Perhaps I'll pick one of those up, drop in the Quaife and longer 5th and sell the XSi 'box.
The rust worries me otherwise I'd have had it last time it was up for sale (recently). If the top is bad, what's the bottom like?
Having said that; boots etc are common so that may be able to deal with.
Hopefully get my S1 Rallye Inlet soon, then i'll design various little bits and bobs to get it running with the XSi management!
Also getting the rocker cover done in Honda VTEC crackle red, which should set the engine bay off!
Having said that; boots etc are common so that may be able to deal with.
Hopefully get my S1 Rallye Inlet soon, then i'll design various little bits and bobs to get it running with the XSi management!
Also getting the rocker cover done in Honda VTEC crackle red, which should set the engine bay off!
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