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 had one of these (K930 CBF) back in around 1996 in red - loved that little car, watching this with interest. It looks like mine died sometime in 2008 with around 142k miles which isn't too bad I guess, it didn't make the next MOT so was probably written off.
Mind you - a "technician" at my local main Peugeot dealer managed to understeer mine into a kerb at speed while it was in a for a regular service - they tried to cover it up too (the little s
t) by putting the spare alloy on and the smashed one/split tyre back underneath.
If you're changing the rear exhaust box from OEM, make sure that it sits at the correct height - I had no end of trouble with a loud booming noise from an aftermarket (cheap!) box caused by exhaust gases exiting downwards behind the rear bumper. 3 replacement boxes later and every excuse under the sun from the garage about baffles quietening down after a while, I had a genuine Peugeot part put on which instantly fixed the noise.
Mind you - a "technician" at my local main Peugeot dealer managed to understeer mine into a kerb at speed while it was in a for a regular service - they tried to cover it up too (the little s
t) by putting the spare alloy on and the smashed one/split tyre back underneath.If you're changing the rear exhaust box from OEM, make sure that it sits at the correct height - I had no end of trouble with a loud booming noise from an aftermarket (cheap!) box caused by exhaust gases exiting downwards behind the rear bumper. 3 replacement boxes later and every excuse under the sun from the garage about baffles quietening down after a while, I had a genuine Peugeot part put on which instantly fixed the noise.
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!
I'll watch this one, it's right up my street!
Had a black 1400XSi some years back. Bought it for about £180 with known bottom end damage (exhaust manifold gasket had blown, which in turn had wrecked the head gasket as all the exhaust gases were being blasted at the edge of it. This caused it to leak oil big time, and the guy I got it off hadn't noticed until the red lamp of death came on, followed by a rattle.
I had similar ideas to you, only I got hold of a Saxo VTR block and turned it into a 1600 (known in AX circles as a VTi - VTR/GTi engine combo). Fitted a 1400 flywheel and the original 1400 gearbox. On went some white Speedline Turinis, and I stripped and painted the engine bay.
In the end I threw in the towel and swapped it with a guy from Blackburn (I was near Winchester at the time) for an MoT'd 106 diesel ph2. The XSi had been off the road for years, was covered in moss and grime (still), had wheel bearings that were hanging out and hadn't seen an MoT for about 4 years. He rocked up with trade plates (I know), jumped in with his mate and ragged it home! He text me later to ask if his mate's phone was still in the diesel 106, as he couldn't find it. Once I'd looked and failed to find it, I asked how he'd got on. "Yeah, got back fine!" he said. "Gets to a ton quick!"
I've got an AX GT at the moment which I want to do the same thing to, and had a ph1 Rallye a couple of years back. Great cars, lots of fun, and the XSi isn't too different to the Rallye either. I'd recommend getting a Rallye ph1 inlet manifold on that engine - it brings the noise
Had a black 1400XSi some years back. Bought it for about £180 with known bottom end damage (exhaust manifold gasket had blown, which in turn had wrecked the head gasket as all the exhaust gases were being blasted at the edge of it. This caused it to leak oil big time, and the guy I got it off hadn't noticed until the red lamp of death came on, followed by a rattle.
I had similar ideas to you, only I got hold of a Saxo VTR block and turned it into a 1600 (known in AX circles as a VTi - VTR/GTi engine combo). Fitted a 1400 flywheel and the original 1400 gearbox. On went some white Speedline Turinis, and I stripped and painted the engine bay.
In the end I threw in the towel and swapped it with a guy from Blackburn (I was near Winchester at the time) for an MoT'd 106 diesel ph2. The XSi had been off the road for years, was covered in moss and grime (still), had wheel bearings that were hanging out and hadn't seen an MoT for about 4 years. He rocked up with trade plates (I know), jumped in with his mate and ragged it home! He text me later to ask if his mate's phone was still in the diesel 106, as he couldn't find it. Once I'd looked and failed to find it, I asked how he'd got on. "Yeah, got back fine!" he said. "Gets to a ton quick!"
I've got an AX GT at the moment which I want to do the same thing to, and had a ph1 Rallye a couple of years back. Great cars, lots of fun, and the XSi isn't too different to the Rallye either. I'd recommend getting a Rallye ph1 inlet manifold on that engine - it brings the noise
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 S1 inlet just makes it sound better too. Gets quite 'cammy' at the top end.
This is all going to set you back a pretty penny though, especially if you're getting others to build the engine, strip & respray the shell etc. Full credit to you for going to all that effort, but I reckon I'd have hunted down the Rallye personally, as at least they're worth twice as much when you're finished.
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
This is all going to set you back a pretty penny though, especially if you're getting others to build the engine, strip & respray the shell etc. Full credit to you for going to all that effort, but I reckon I'd have hunted down the Rallye personally, as at least they're worth twice as much when you're finished.
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
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?
dom9 said:
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!
Good stuff, will watch with interest 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!
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