Yellow 205 Rallye
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Discussion

RallyeJackman

Original Poster:

34 posts

207 months

Sunday 28th June 2009
quotequote all
Hi all!

This is my first post on the Forum!

I have a 1992 Yellow 205 Rallye! It was completely standard when i bought it around 2 years ago!

Just a few pictures for now!





Will copy my project diary into here shortly, as it takes a while!


paul_gt4

26 posts

231 months

Sunday 28th June 2009
quotequote all
now that is awesome, health to enjoy

Kieran-rallye

7 posts

209 months

Sunday 28th June 2009
quotequote all
Im jealous...

paul26982

3,850 posts

247 months

Sunday 28th June 2009
quotequote all
like Mr Burns would say ' Excellent'

Pulse

10,922 posts

247 months

Sunday 28th June 2009
quotequote all

RallyeJackman

Original Poster:

34 posts

207 months

Sunday 28th June 2009
quotequote all
[color="#FF0000"][size=5][u]Chapter 1[/u][/size][/color]

All Started about 6 months ago when i got the car.

I bought it originally to make a profit but things didn't turn out that way.

When i bought the car the details were:

K reg [color="#FFFF00"]Yellow[/color] 205 Rallye.

83000 miles.

No Tax.
No Mot.
[color="#FFFF00"]No Interior[/color]









It sat in my garage for a long time wasting away.

Then i wrote my Quiksilver off within 48 hours of owning it. and everything changed.

Out the Rallye came. was time to get her MOT'd.

Went out and got a battery so that we could get her started and move her around.

Borrowed a drivers seat and seatbelt off a mate. and i was away

Then i just flinged her in for MOT to see what i had got myself in for.

Turns out. a bargain.

It failed. but nowhere near as badly as i expected!

Nearside CV boot - split
Brake discs pitted.
Offside caliper binding.

Freed my weekend up fixed the above and back in she went.

[color="#FFFF00"]PASSED[/color]

Excellent.

Swapped my insurance over, went and got tax. and she was alive and kicking.



Now just waiting for my cheque to come through the post so that i can get a few things sorted.

Currently have:

AX GT box and a new clutch waiting for go on.
Lowering springs to be fitted once Wolze gets over his fear of rain wink
Sparco Buckets and Luke harnesses to be fitted once my subframes are ordered and arrived.
Leaky sunroof to fix.


hope i didn't bore you to much.

Updates will be added as soon as they arrive.

[color="#FF0000"][u]Chapter 2[/u][/color]

So its been a while now!

done a small amount to the car in the last month!

Firstly i got the bucket seats fitted finally. and they look and feel great!

They seem more comfortable than previous seats ive had and sat in and hold very well!
really pleased with them at the price of £200!

I was going to have them fixed in, but then my dad offered to buy me subframes with sliding rails for christmas which seemed the more sensible option!

The harnesses are borrowed off a mate until i can decide on the ones i want!





RallyeJackman

Original Poster:

34 posts

207 months

Sunday 28th June 2009
quotequote all
[color="#FF0000"][u]Chapter 3[/u][/color]

So i haven't done alot with the car Recently as ive been waiting for my cheque to come through so i can give the Rallye the love it deserves.

First thing i set about doing was getting her lower to the ground.

Finally caught Wolze on a free day and let him do his magic.

I was ready for a hard days graft. but the Rallye had different ideas.

Much to all our amazement the torsion bars fell out!

Enough of the talking. Pictures say a thousand words!





I also ordered a new set of wheels as the black steelies were a temporary measure to get it through the MOT!

I was refurbing 2 S1 Steelies that i was donated but they are tucked away in the shed for now.

So i got a good friend of mine to order me a new set of the wider S2 steelies. and they finally arrived today!

heres the pictures!







Comments in my support thread would be much appreciated!

[url="http://www.sw-cc.com/forums/index.php?showtopic=79626"]Support thread[/url]

Small Update.

I've had the new wheels sat in my house for quite some time now waiting for my tyres to arrive. but after a cock up with mytyres which resulted in me recieving 2 tyres for free they arrived.

So popped them down to Fords today to Mr Mcdowell to have the tyres put on the rims!

They will be going on the car tomorrow weather permitting!

Tyres are Yokohama A539 in 195/45/14.

Here's a few pictures. my mum stole the good camera so these will have to do for now.





[u][color="#FF0000"]Chapter 3 Continued.[/color][/u]

So today was the day for the car to finally look a bit different!

Got woken up by RS Rob early this morning telling me to put the wheels on. Decided not to hang around and got right to it!

Also removed the aweful 205 Mudflaps that were on the car!

Ill let the pictures do the rest of the talking, but i can't say how pleased i am with them!











Also decided to shed some weight and lose the doorcards and a few other bits of plastic bits i didnt need from the bootlid:


RallyeJackman

Original Poster:

34 posts

207 months

Sunday 28th June 2009
quotequote all
So i've had a few new bit for the car recently. nothing special really.

Just some center caps for the steelies and a K&N Filter which screams its tits off to be fair.

I also dewipered her. i just need to find another grommit for the rear jet thingy lol.

Heres the pictures

Center Caps:




K&N:




Dewipered:





O and my new sticker!! from my track day on saturday!



And just 2 general pics after a quick wash today, due to the amount of dirt she picked up on track.




Car is acutally off the road at the moment thanks to this:



Timing belt tensioner packed in a threw the belt. Wolze is on the case to see what damange ive caused and see if we can get it fixed for Performance Car Action Day next week!

Also.

Done a little more strippage today, nothing special.

Just a few plastic trimming that werent needed and the roof lining.

Going to bring some stuff home from work that will hopefully remove the remaining glue!






New brakes went on today.

266mm calipers off a 306 S16 with brembo discs and some pads that i duno what they are lol.

Heres the old setup :N:



Braided hoses! i have got a full set but the fronts were all ready on when i decided to take pictures lol








How close they are under the steelies!




Also thinking of getting some of these badboys smile




And ive found a site that does brand new decal kits. will be getting a set of them also ! smile

Sooooooo the time has come to finally release the secret ive been hiding from people for some reason.

It all started when i went and done this:

Basically the timing bent tensioner failed doing unknown damage to the engine. Because i couldn’t be bothered with stripping it down i went and done something stupid.


Yes i picked up a little something from Snitterfield.

I never took pictures of it out of the car really. So for your information its a Citroen Saxo VTS engine wink
So off the car went to my friends unit to let the build begin!

Before:


During:

After:




And a few fun shots:



So now the engine was away from the engine bay:

Dai showing what he thinks of 8v power:


Rob and Wolze inspecting:

We starting pulling bits off the Rallye lump that we needed for the 16v conversion! Like the manifold that we later modified and the engine mounts etc etc.


So now the engine was out i had Group N engine mounts fitted to keep all that power stiffly in the engine bay.



Then we prepared the new heart to be dropped into her new home!

RallyeJackman

Original Poster:

34 posts

207 months

Sunday 28th June 2009
quotequote all
And then in she slotted!




Mmmmm 16v!


Next came the one of the most annoying parts of the whole conversion. My stupid manifold design.

Excuse the picture. but my manifold looks like this


So i went and bought a Sportex 4-2-1 and left Wolze get to work with the grinder.

Which left us with:


Then Dai got happy with the welder and started putting the 2 sections together.


Which produced this beauty !


Took a bit of fiddling but in the end she was a perfect fit!

Next was the part that caused us most grief i think lol. Wolze spent days and days doing the wiring and eventually crack it. Now i don’t know a great deal about this part as it was all done behind closed doors. I just saw it being put on and fiddled with!

So heres a few pictures!
My Rallye loom with about 5 sensors on it.

The 16v loom with a lovely 36 to be match up.

And a few of them being trial fitted on the car!


The man himself working away on a cold winters night 


Once the wiring was in i had to decide where i wanted to mount my ECU. now because ive mounted the battery in the boot, the battery seemed a good place to stick here. and she looks spot on if you ask me smile




Finally came the fuelling. I changed my mind on this part so many times it was insane.
I was going to run a battery box in the boot with a fuel pump that i acquired with a fuel filter with the lines running inside like this:

But the fuel pump kept blowing the lines off under the pressure all the time due to the ends not being good enough to tighten the lines down on.
So i bought a 205 GTi fuel tank for £20 and did a tank conversion so that i could run a in-tank fuel pump. Not only was it easier but looking back now it looks so much tidier as you don’t even know its there!

So we fitted the new tank and then we had to swap the fuel lines as the Rallye runs 8mm lines and the GTi run’s 10mm. So they are all secured underneath the car again now so from the outside you can’t even tell the car has had a conversion. 1.4 8v FTW anybody? wink


Thats basically the whole conversion cut short. As ive forgot alot of stuff along the long process lol.


Finally id like to say the Thank you’s.

AS Developments AKA Wolze. Thank you so damn much. Ive seen the stress and pain ive put you through with this conversion lol.
Thank you for taking on the job and doing it to your spot on standards.
But its not over yet my friend!

Also a massive thank you to Dai. As without him none of this would of happened as easily. Your use of the unit was much appreciated keeping us warm on the long cold nights!
And thank you to the few other people that were involved aswell!

And a few final shots because i reached the picture limit

And how she looked when she was put back togeather!





I do love Group N Stuff.





I do love parcels!









Been busy today, and stressed.

Finally got round to fitting half my suspension lol.

Had a battle with the rear shocks to get them off. they were an absolute pain in the arse.

Caused me calling help from 2 mates and my builder lol.

Eventually got them off. and they were ruined!



And put the new ones on! didnt get any comparisons sorry as i'd had enough and just wanted them on!




Then i got persuaded into losing some more weight.



GONE!




Next challenge is the fronts!

RallyeJackman

Original Poster:

34 posts

207 months

Sunday 28th June 2009
quotequote all
So its been a while since i update so i got something small for you.

While i was at Trax i was on the look out for a length of Silicone hose to push my raceland induction kit out further to allow me to fit the Scoop.

So i went through all the garages and eventually found this for £13



I haven't had chance to fit it yet as i've been ill and i've got to cut it down and move a few bits to let the scoop eventually fit.

Also i picked up some gauges. now i'm not normally big on gauges and fancy bits and pieces, but with this car being used on track if and when i can i need to know whats going on.

And with my Car being a 'Rallye' the tight french gits never gave me any gauges at all.

So when i seen these for 2 for £25 i though why the hell not.




Unfortuantly they didn't have all 3 with white faces so i had to opt for silver, but at the price i got them i can't complain to much.

I've got:

Oil Temp
Water Temp
Vaccum (was the only decent one left so i just grabbed it to get the deal)

Also fitted my nice new plates! couldn't use sticky pads for the front unfortunately.




Big thanks to RS Rob for them smile

Still waiting on my Exhaust to arrive:


Also still have my stickers to put on as i'm not to sure on a respray after some thought.

And finally some pictures for you from the weekend.





So today i had the mangaged to get a slot in Wolze very busy diary.

And headed for my mates unit that he lets us do a little work from.

Got the car up in the air and pulled the stuff out ready!


And got the stuff out ready to fit tongue out



then stripped the car down and pulled all the old parts off ready to be replaced!

Being replaced was:

Shocks with Group N Bilsteins
Springs from Spax to Eibach's
Top mounts to Group N Rubbers.

Not gona bore you to much so here's some pictures!

Difference between the shocks:




Difference in top mounts.

The ones on the right are origonals, which i could squash with my hands. the Group N's i couldn't get to budge!



Back togeather.


The difference is unbelievable. The car feels so planted compared to before. But thats probably because my old shocks were dead.

I compressed them and left them while we fitted the new ones. and they were still like these when they went in the bin.


Also fiddled about and had my Raceland scoop finally fitted.

Looks a bit strange with the long silicone hose. but its changed the noise and i love it lol!



More to come soon wink


Feel free to comment [url="http://www.sw-cc.com/forums/index.php?showtopic=79626&st=60&start=60"]Support Thread![/url]

Just a quick update of how the car now sits on the bilsteins after the springs have settled a bit.

It's a little higher than i'd like, BUT it handles amazing so it will do tongue out





Sorry the pictures are terrible. my phone was being censorede.
I did just try polishing it, but i got bored and walked away after doing the bonnet lol.

Cheers mate.

The way it handles makes the height worth it!

Today.

I've gone from this.



To this.



It's not quite finished and i need to do the surrounding areas. but i am slowly killing off the rust.

[url="http://www.sw-cc.com/forums/index.php?showtopic=79626&st=60&gopid=731256&#entry731256"]Comments Here![/url]

So its been a while since update this thread and a few bits have happened!

Firstly after 2 and a half months of waiting my OMP Exhaust arrived!





Had to shoot up to Prospeed in Cardiff to have it fitted as it need a bit of welding!




Quick Video

[url="http://s99.photobucket.com/albums/l314/MrJackman/?action=view&current=MOV02980.flv"][/url]

Also had a friend come down and give it a quick polishing!






A new mount after i snapped mine. that i need to get grinded and then fit smile



And my TI Motorsport Polybushes for my Track Control Arms. I'm guna buy new arms to put them in rather than replacing the old bushes ! I'll also have new ball joints then!



Also got a Lambda sensor that needs to be fitted at some point!

And finally my latest purchase!

For Christmas i bought myself these beauts!





Catcam 708's.

Won't be fitted till after i have the MOT sorted and i'm booking myself in for a new ECU and mapping for around Feb/April time smile

Well yesterday i gave the arms to Wolze to sort out, rather than me fannying about with burning then!

Didnt take him long to bring them back to me either!

Thank you once again Mr Wolze!

See some pictures of them at different stages smile

Before:


The Tool:



Out:




In:



Complete!:


Well its all done!

Was a bit of a bugger getting them to fit, they were alot tighter going in lol!

Pictures do the talking!

Off.



Going on.



On.




Thank you for reading smile

Well its time for a short update!

On January 29th at 16:52 the car Flew MOT! with only a few small niggles that the tester picked up! ( Thank you Wolze )

Been enjoying driving the car again, but as normal problems strike.

The day after having the car back, i managed to snap my Manifold.



I've never been 100% happy with the manifold on the car so i bit the bullet and have decided to bin it.

Got straight online and ordered a Raceland 4-2-1 Manifold.



But its not a straight fit so i'm taking the car to Xzorts in Pyle on Friday! Had a nice chat with the bloke and he seemed a top guy so im happy for the car to go there!

I've also dropped my AX GT gearbox off to the rebuilder to have my Diff replaced after i shattered it last year just before French Car Show!

The cars coming off the road for 2 weeks on the weekend due to insurance reason's! so she will be back bigger and better hopefully!

Peace out.

Hello All!

Another update for you!

Had my car back from a company called Xzorst in Pyle yesterday who have been modifying my raceland manifold for me!

Gotta be said i am very pleased with it so far, its looks spot on to me! just need to take the car for a test drive to check everything!

While it was down there i had them move the Lambda sensor hole ( as shown in the pictures!) and put a flexy section in to give it a bit of movement!

I havent got pictures of it off the car so i did the best i could of it on!








Thank you for listening!

It has arrived!





Should be going for Powdercoating this week! Hoping to have it in for Performance Car Action Day!

Just trial fitted the cage because i was bored and wanted to check it went in alright lol!

Looks spot on and fits fine, bit tight!

It should go off to be Powdercoated this week sometime!









Had a very busy weekend with the car this weekend!

Blew my gearbox at the start of the week. Typical, as i had Llandow on Saturday!

Thanks to Wolze, Paul_Collins and a few other hands we managed to get the car there!

I was very happy with how the car performed out there, really held up well against the Mi and GTi-6 engine cars!

Heres a few pictures i found!





And my pure slicks gave up on my last lap!


Then today there was a new Rolling Road open locally, so i popped down with the car as it was £20 for 3 runs!

It was really busy down there but we got it on by the end of the day!

On the Rollers:


Uploading a video now!


Graph:



[u][color="Black"]Power: 155.7 bhp @ Fly, 129.4 bhp @ Wheels![/color][/u]

Very happy with this, as the manifold has cracked slightly and to my shock the car is under fuelling!

Just a small update really.

Gave the car a bit of a spring clean today as i had a half day in work. Plus the car is on stand at Castle Combe for Performance Car Action Day tomorrow so though i'd make a bit of a effort.

Gave the arches a bit of a clean. Something i've never done before lol!

Before:



After:



Whole car after a wash and polish:


I've also had new brakes fitted recently. Being Godspeed Grooved Discs and Ferado DS2500. Absolutely awesome! Great improvement over the brembo disc and standard pads i had before!



And Mummy bought be a present today lol. Hopefully get much use out of it!



So this weekend was fun.

Firstly me and Paul_Collins picked up 4 XSi gearbox's !



Then my friend dropped my cage back off to me after being Powdercoated! Only cost me £50 and i'm really pleased!

Had it finished in Gloss Black! Hoping to get it in this time very soon!




Ordered new stickers for it aswell!



Also, 1 of the XSi gearboxs was for myself.

Its got a Quaife Diff hidden inside!

It's now on the car, but my clutch cable snapped so havent had chance to drive it yet!

Hopefully get it sorted tomorrow!

Update!

First off, the car will be going to Sandy Brown to be mapped next Friday. I'm sure some people have heard of him. He is well respected on the Rallye Register!

Secondly i decided i'd give my Raceland scoop a make over. The fact it has 106 on it has always been a bit stupid!

Before:


And heres how its going so far:






Hairspray

6,225 posts

236 months

Monday 29th June 2009
quotequote all
That looks lovely smile I strangely love the colour!

-Neil-

150 posts

212 months

Monday 29th June 2009
quotequote all
Looks great, must be a real hoot to drive down some lanes smokin

Neil.

Ecurie Ecosse

4,812 posts

247 months

Monday 29th June 2009
quotequote all
Wow, great work! I've always loved the Rallyes.

HereBeMonsters

14,180 posts

211 months

Monday 29th June 2009
quotequote all
  • spaff

Evangelion

8,593 posts

207 months

Monday 29th June 2009
quotequote all
Agree with Hairspray, yellow is so much better than the boring white ones.

And you'll never lose it in a car park.

pitbull turbo

663 posts

210 months

Monday 29th June 2009
quotequote all
lovely car mate.
makes me really want to get off my butt and sort my car out.
looks ace.

Marf

22,907 posts

270 months

Monday 29th June 2009
quotequote all
Awesome build mate, bet thats an utter riot to drive thumbup

John.

185 posts

222 months

Monday 29th June 2009
quotequote all
Thats fantastic! Your of sax-p right?

lewis87

361 posts

232 months

Monday 29th June 2009
quotequote all
Awesome looking little car thumbup

matc

4,736 posts

236 months

Monday 29th June 2009
quotequote all
Lovely car, and great thread. Thanks for sharing....looking forward to seeing any more updates. thumbup