Project_5AXO - Reliving my youth!
Discussion
Crikey, I genuinely never thought I'd ever start a thread in the readers car section of PH. However, here I am and here's the start of the story.
To gain some perspective we need to jump in the time machine and look back to my late teens where, after crashing my 1st car after 2 days of driving, a 1.4 Ford Escort, I pick up my first Citroen Saxo. It was a 1.1 with the MK2 conversion and VTR body kit in Poseidon Blue. It was great car that I did a few period relevant modifications too. As a young lad it got me around and really sparked my interest in cars. Apologies for the shocking picture, it's all I have of it.
As you see it was very low and had a false 2nd tail pipe. I kept it clean and it did the job for a good couple of years before my insurance calmed down a bit!
It also gave me the french car bug and I couldn't stop. So with that one sold onto a guy at work for his daughter to use as a first car, I purchased my 2nd Saxo, this time an 8v VTR. Bought standard and modified over the years.
At this point I was attending all the car shows and involved with the SSC (SaxoSportsClub). Modifying cars consisted of bodykits, big wheels and sound systems. There were still only a few 'fast cars' around. Mine was no different, it was on 17's and had an immense JL Audio sound system which used the entire boot. The amps were in false floors in the foot wells, graphic equalisers the lot. It was amazing and I loved it. I was still living with mum and dad at the time and remember coming home with one of the JL Audio W6's 12" and putting it on the kitchen top. Mum asked "How much was that?"...I replied "only £70"...."HOW MUCH!!!!?" she shouted! Little did she know they were actually ~£400 and I had two of them, plus a JL monoblock amp that cost me £1k! Thankfully she knows now and we laugh about it!
I kept that for about 3 years before going with the power trend. Still wanting a Saxo, I kept looking for a VTS before this little gem popped up for sale.
It was Mk2 VTS which was running the GMC Rotrex Supercharger kit, 4 pot brakes and a good exhaust system. It was bloody fantastic and I loved it. The spec list was good but I could see potential for better. It ran about 190bhp. I swapped out the engine management for a KMS standalone, turned up the boost a little (smaller pulley) and it made 228bhp at the fly. I was made up and ran it for about a year. Sadly, it had a quick visit to a ditch when attempting to avoid colliding with a van that pulled out on me. Little did I realise but one of the pistons had seized in the left caliper and the braking under full load meant it send me sideways very quickly.
I purchased the car back from the insurance as I wanted to keep all the parts that weren't damaged. By this time I was pretty handy on the spanners, I work for JLR (still do) and built prototype engines daily. I decided to buy another shell, do a swap and go for a full track build. Hence Saxo no4
The spec this time was far superior. Forged pistons, roll cage, aqaumist intercooler spray, flocked dash, Cobra seats. Quite simply it was epic. It made 252bhp and was a real weapon. A trip to the Nurburgring didn't phase it, several UK track days and it was brilliant. It was featured on the cover of PFC and made a small feature in Fast Car mag. I was happy. It was used as a second car until I started using it less and less and decided to move it on. Sadly I regret that decision every day.
I sold the Saxo and bought a Clio 172 which I put Jenvey ITB's on.
I sold the Clio and bought an Evo 5
I sold the Evo5 and bought a Focus RS Mk1
At this point madness descended and I traded in the Focus for a 325i Msport tourer. I started cycling a lot more and it rarely got used. I sold it on and ever since then I've had a succession cheap run abouts, Nissan Primera, Toyota Corolla and finally a Toyota Avensis (which I still have). Additionally I passed my bike license and loved the 2 wheel thrills, currently riding a BMW S1000XR, adore it.
With the trip down memory lane complete it brings us to present day lock down. Now I've been pining after a C63 for a years. I've so nearly pulled the pin on many an occasion. What's stopped me is my limited mileage. I don't drive a huge amount (cycling to work etc) and the thought of spending 25k on a car in one go scares me! Then a thought occurred, by far and away the best and most enjoyable experience of my automotive history was the red Saxo, I built it myself and some friends. Why not do that again but just better.
Thus started a search for a MK1 Saxo. I prefer the earlier shape. I've had a Ebay watch in place for almost 3 years for Mk1. In all that time I've seen 2 come up for sale, 1 was so rotten it wasn't worth the money they were asking.The search stopped shortly after, they just don't exist. I contacted a load of people from SSC days and quickly found none for sale and those that had them weren't willing to part ways. So I settled for a Mk2. Now the challenge is finding a non rotten one.
Sadly this was challenging, until an old contact of mine put me in touch with a guy who had one but it wasn't listed for sale. I dropped the guy a note and quickly arranged a COVID safe visit. Finally, after 12 years away I'd picked up another VTS!
It has 10 previous owners and 110k miles. Crucially, it was rot free. These cars tend to go in a few key places. Under the ECU, Under the fuse box, sills, jacking points and boot floor. Happily the ECU had been cut and repaired only the fuse box place needed attention. That was all. I was astonished to see the rest in excellent shape.
Spec list was a good starting point too. Much of which would get replaced but some things would be kept.
Safety devices roll cage
Satchell gear shifter
MSD coil pack upgrade
Bucket seats
Aftermarket exhaust
Aftermarket manifold
Brembo 4 pots
Braided lines
Gaz coilovers
I got the car home and put it in it's resting place for the next year while my plans are put into action.
So what are those plans....well that's subject to my second post...stay tuned!
To gain some perspective we need to jump in the time machine and look back to my late teens where, after crashing my 1st car after 2 days of driving, a 1.4 Ford Escort, I pick up my first Citroen Saxo. It was a 1.1 with the MK2 conversion and VTR body kit in Poseidon Blue. It was great car that I did a few period relevant modifications too. As a young lad it got me around and really sparked my interest in cars. Apologies for the shocking picture, it's all I have of it.
As you see it was very low and had a false 2nd tail pipe. I kept it clean and it did the job for a good couple of years before my insurance calmed down a bit!
It also gave me the french car bug and I couldn't stop. So with that one sold onto a guy at work for his daughter to use as a first car, I purchased my 2nd Saxo, this time an 8v VTR. Bought standard and modified over the years.
At this point I was attending all the car shows and involved with the SSC (SaxoSportsClub). Modifying cars consisted of bodykits, big wheels and sound systems. There were still only a few 'fast cars' around. Mine was no different, it was on 17's and had an immense JL Audio sound system which used the entire boot. The amps were in false floors in the foot wells, graphic equalisers the lot. It was amazing and I loved it. I was still living with mum and dad at the time and remember coming home with one of the JL Audio W6's 12" and putting it on the kitchen top. Mum asked "How much was that?"...I replied "only £70"...."HOW MUCH!!!!?" she shouted! Little did she know they were actually ~£400 and I had two of them, plus a JL monoblock amp that cost me £1k! Thankfully she knows now and we laugh about it!
I kept that for about 3 years before going with the power trend. Still wanting a Saxo, I kept looking for a VTS before this little gem popped up for sale.
It was Mk2 VTS which was running the GMC Rotrex Supercharger kit, 4 pot brakes and a good exhaust system. It was bloody fantastic and I loved it. The spec list was good but I could see potential for better. It ran about 190bhp. I swapped out the engine management for a KMS standalone, turned up the boost a little (smaller pulley) and it made 228bhp at the fly. I was made up and ran it for about a year. Sadly, it had a quick visit to a ditch when attempting to avoid colliding with a van that pulled out on me. Little did I realise but one of the pistons had seized in the left caliper and the braking under full load meant it send me sideways very quickly.
I purchased the car back from the insurance as I wanted to keep all the parts that weren't damaged. By this time I was pretty handy on the spanners, I work for JLR (still do) and built prototype engines daily. I decided to buy another shell, do a swap and go for a full track build. Hence Saxo no4
The spec this time was far superior. Forged pistons, roll cage, aqaumist intercooler spray, flocked dash, Cobra seats. Quite simply it was epic. It made 252bhp and was a real weapon. A trip to the Nurburgring didn't phase it, several UK track days and it was brilliant. It was featured on the cover of PFC and made a small feature in Fast Car mag. I was happy. It was used as a second car until I started using it less and less and decided to move it on. Sadly I regret that decision every day.
I sold the Saxo and bought a Clio 172 which I put Jenvey ITB's on.
I sold the Clio and bought an Evo 5
I sold the Evo5 and bought a Focus RS Mk1
At this point madness descended and I traded in the Focus for a 325i Msport tourer. I started cycling a lot more and it rarely got used. I sold it on and ever since then I've had a succession cheap run abouts, Nissan Primera, Toyota Corolla and finally a Toyota Avensis (which I still have). Additionally I passed my bike license and loved the 2 wheel thrills, currently riding a BMW S1000XR, adore it.
With the trip down memory lane complete it brings us to present day lock down. Now I've been pining after a C63 for a years. I've so nearly pulled the pin on many an occasion. What's stopped me is my limited mileage. I don't drive a huge amount (cycling to work etc) and the thought of spending 25k on a car in one go scares me! Then a thought occurred, by far and away the best and most enjoyable experience of my automotive history was the red Saxo, I built it myself and some friends. Why not do that again but just better.
Thus started a search for a MK1 Saxo. I prefer the earlier shape. I've had a Ebay watch in place for almost 3 years for Mk1. In all that time I've seen 2 come up for sale, 1 was so rotten it wasn't worth the money they were asking.The search stopped shortly after, they just don't exist. I contacted a load of people from SSC days and quickly found none for sale and those that had them weren't willing to part ways. So I settled for a Mk2. Now the challenge is finding a non rotten one.
Sadly this was challenging, until an old contact of mine put me in touch with a guy who had one but it wasn't listed for sale. I dropped the guy a note and quickly arranged a COVID safe visit. Finally, after 12 years away I'd picked up another VTS!
It has 10 previous owners and 110k miles. Crucially, it was rot free. These cars tend to go in a few key places. Under the ECU, Under the fuse box, sills, jacking points and boot floor. Happily the ECU had been cut and repaired only the fuse box place needed attention. That was all. I was astonished to see the rest in excellent shape.
Spec list was a good starting point too. Much of which would get replaced but some things would be kept.
Safety devices roll cage
Satchell gear shifter
MSD coil pack upgrade
Bucket seats
Aftermarket exhaust
Aftermarket manifold
Brembo 4 pots
Braided lines
Gaz coilovers
I got the car home and put it in it's resting place for the next year while my plans are put into action.
So what are those plans....well that's subject to my second post...stay tuned!
What are plans for the car?
Firstly, I want it to be a continuation of the red one I had years ago but far superior in every way. That was was essentially a combination of parts thrown together and hope for the best. It turned out OK but I know now that I can do it far better and to a higher standard.
It will be a boosted build. Not sure if that'l be S/C to Turbo just yet. Full under body restoration, full interior refresh. New bearings/bushes/seals/gaskets in every place possible. Paint and powdercoat everything I can. Nothing will be un-touched. That's the plan at least.
Additionally, I'll be putting myself out there on Youtube. That stuff doesn't come natural to me but after watching many build videos over the years I feel like it's a fun thing to do. Project Binky and Alex Crosse have inspired me no end. A good friend once told me 'stop watching others do it, do it yourself'. I'm running with that mantra and going with the flow.
You can catch the episodes I've done already below, hopefully my embedded videos will work
More episodes will follow and i'll put them in here for you to see.
Thus far progress has gone well.
I've erected the murder tent to keep me and the car dry.
Rear brakes have been refurbed
fuel tank has been removed and cleaned
Rear beam is out and off for refurb
Prep for underseal is underway
A few pics to entice you in:
![](https://thumbsnap.com/sc/6aRSJKcj.jpg[/img]</a> <a href="https://thumbsnap.com/U8aYAC2J" Target="_blank" rel="nofollow">[img]https://thumbsnap.com/sc/U8aYAC2J.jpg)
Still loads to do. It's early days.
Thanks for looking
Firstly, I want it to be a continuation of the red one I had years ago but far superior in every way. That was was essentially a combination of parts thrown together and hope for the best. It turned out OK but I know now that I can do it far better and to a higher standard.
It will be a boosted build. Not sure if that'l be S/C to Turbo just yet. Full under body restoration, full interior refresh. New bearings/bushes/seals/gaskets in every place possible. Paint and powdercoat everything I can. Nothing will be un-touched. That's the plan at least.
Additionally, I'll be putting myself out there on Youtube. That stuff doesn't come natural to me but after watching many build videos over the years I feel like it's a fun thing to do. Project Binky and Alex Crosse have inspired me no end. A good friend once told me 'stop watching others do it, do it yourself'. I'm running with that mantra and going with the flow.
You can catch the episodes I've done already below, hopefully my embedded videos will work
More episodes will follow and i'll put them in here for you to see.
Thus far progress has gone well.
I've erected the murder tent to keep me and the car dry.
Rear brakes have been refurbed
fuel tank has been removed and cleaned
Rear beam is out and off for refurb
Prep for underseal is underway
A few pics to entice you in:
Still loads to do. It's early days.
Thanks for looking
I'm always prepared to eat my words when i'm wrong and this is no different. Earlier I stated I'd found a solid car with very little rust. However, upon stripping back the arches I've noticed the outer skin is being pushed outwards. Essentially, water and debris has gotten between the two and corrosion has begun. Luckily I don't think this has been going for many year as the areas that require repair are small
Area of concern;
a few minutes with a 1mm cutting disc got the rot out:
While I was there I took the old underseal off ready for renewal;
This highlighted area number two which was hidden under very thick layers of underseal;
Two areas there, an area of double skin like the first patch and then a hole in the corner.
No way around it other than to cut it out;
Thankfully not a huge patch required. Pleased with my efforts given I've never done a rust repair job before. Welder is on the way so I can patch it up next week with some luck.
Underseal has also been purchased but i'll leave that for another post.
Area of concern;
a few minutes with a 1mm cutting disc got the rot out:
While I was there I took the old underseal off ready for renewal;
This highlighted area number two which was hidden under very thick layers of underseal;
Two areas there, an area of double skin like the first patch and then a hole in the corner.
No way around it other than to cut it out;
Thankfully not a huge patch required. Pleased with my efforts given I've never done a rust repair job before. Welder is on the way so I can patch it up next week with some luck.
Underseal has also been purchased but i'll leave that for another post.
Jcwjosh said:
Awesome reliving your youth thread so far..
Lookforward to seeing your progress
I should be joining you soon once i pick up my lockdown 'toy', again reliving my youth is the theme and i cannot wait..
I had a mk2 furio in the light blue colour same as yours, it was great fun. Out of interest what was that colour called ?
The silvery/blue was Icelandic grey. An absolute arse to colour match! Never again!Lookforward to seeing your progress
I should be joining you soon once i pick up my lockdown 'toy', again reliving my youth is the theme and i cannot wait..
I had a mk2 furio in the light blue colour same as yours, it was great fun. Out of interest what was that colour called ?
If I'd had it my way I'd go for a red one again (Citroen Venetian Red)
AlmostUseful said:
I wanted to love this thread, I really did. It just misses the mark though.
Back in 2001 my first car was loaned to me by my parents (they bought it for my sister, she went to uni, I was given use of it etc, the usual) and it was a 1.1i in red, 1998 R plate, key code immobilises (9681 for the record, my sisters birthday obviously) and 3 stud wheels (were they all?)
I loved it, bloody loved it.
I think I’d have a VTR now as I always wanted one, but it has to be a mk1. I don’t know what it is about the facelift that never fitted with me but those rectangle headlights and straight front bonnet lines are the front end of a perfect car in my eyes. The mk2 just isn’t right.
So I’ll leave you here, I’m joyous that you’ve found your car, I’m envious of all the Saxo’s you’ve loved and lost (damn, supercharged!!) and I’m going to wallow in self pity when driving my diesel E class that I’ve still never really had a small and fast hot hatch. Since I graduated uni my work commute has always been about 20k miles per year so I’ve always had diesels (aside from the I6 Cherokee and V6 RX300) in comfy cruisers.
God speed, enjoy that car, and well done for bringing it back to full health! I love it.
Totally agree, Mk1 is a much better looking front end. I really wanted one. As I said, finding one is impossible. I found one that was a total basket case and would've needed extensive welding work. Some had already been done which was bloomin awful! Back in 2001 my first car was loaned to me by my parents (they bought it for my sister, she went to uni, I was given use of it etc, the usual) and it was a 1.1i in red, 1998 R plate, key code immobilises (9681 for the record, my sisters birthday obviously) and 3 stud wheels (were they all?)
I loved it, bloody loved it.
I think I’d have a VTR now as I always wanted one, but it has to be a mk1. I don’t know what it is about the facelift that never fitted with me but those rectangle headlights and straight front bonnet lines are the front end of a perfect car in my eyes. The mk2 just isn’t right.
So I’ll leave you here, I’m joyous that you’ve found your car, I’m envious of all the Saxo’s you’ve loved and lost (damn, supercharged!!) and I’m going to wallow in self pity when driving my diesel E class that I’ve still never really had a small and fast hot hatch. Since I graduated uni my work commute has always been about 20k miles per year so I’ve always had diesels (aside from the I6 Cherokee and V6 RX300) in comfy cruisers.
God speed, enjoy that car, and well done for bringing it back to full health! I love it.
Mk2 was the next best thing and although it doesn't look quite so special it's the same car underneath! Substance over style!
Hopefully you keep looking back here despite the vomit inducing front end.
alexcrosse said:
Found that zinc plate episode fantastic, good Dad cameo too. Not found any other good walkthroughs through the whole process, so really enjoyed it. I liked the spray bottle to really stop the cross contamination, and the tank heaters.
I too have a plating obsessed dad, but on the smaller side of things for his own restorations. You guys knew it already, but if you blast things you'll get the matt finish. It's hard to beat a wire wheel on a bench grinder for cleaning up bolts, usually quicker than blasting too. I started doing it before getting mine plated by the company I use, their tumbler seems to only be 80% successful.
Also, there is a way of calculating the exact amps you need. Your kit supplier should be able to give you a mA/cm2 number. You then calculate the surface area of the parts your putting in. Might help you get an even more consistent process than you've already got.
Enjoying all the updates! keep it up
Thanks Alex, we tweaked the process somewhat for later parts but for us the best process was to bead blast any muck off, then hit it with a wire wheel to bring up the surface to something acceptable. I too have a plating obsessed dad, but on the smaller side of things for his own restorations. You guys knew it already, but if you blast things you'll get the matt finish. It's hard to beat a wire wheel on a bench grinder for cleaning up bolts, usually quicker than blasting too. I started doing it before getting mine plated by the company I use, their tumbler seems to only be 80% successful.
Also, there is a way of calculating the exact amps you need. Your kit supplier should be able to give you a mA/cm2 number. You then calculate the surface area of the parts your putting in. Might help you get an even more consistent process than you've already got.
Enjoying all the updates! keep it up
Agree on the mA/Cm2 number. My dad was furiously doing the maths (In imperial) to work out amps per square inch. Bolt threads really add a lot of surface area. I think we got to an acceptable point and had some great results. I think our success rate was higher than 80%, only the odd part didn't plate.
Happy with the results though.
Quags said:
Excellent project good luck with it.
I had a Supercharged VTR back in the day, was a rep for SSC in the south east and had a small feature in Max Power for my sins...
Mine is the green one:
I think I remember your green S/C one. Always looked dead understated.I had a Supercharged VTR back in the day, was a rep for SSC in the south east and had a small feature in Max Power for my sins...
Mine is the green one:
Glad people are enjoying the flash back to their own past!
Little teaser update and following on from episode 7
1. Underseal has now been applied, here's proof of me mixing it
2. My Axle turned up too. Fully rebuilt by AxlesByStef. It looks incredible and will look great against the fresh underseal coat ive applied
Episode 8 should see a few things go back on the car!
1. Underseal has now been applied, here's proof of me mixing it
2. My Axle turned up too. Fully rebuilt by AxlesByStef. It looks incredible and will look great against the fresh underseal coat ive applied
Episode 8 should see a few things go back on the car!
It's been a strange few weeks here on Project 5AXO, half term has meant some time off work with the sprogs. The car gets put to one side for the time being but I have stolen the hour or two on the car. A couple of minor things we're accomplished...
I got rid of the nasty maxpower style metal fuel filler cap and replaced it with an original black one:
With the unfortunate events with the rear axle being damaged during shipping (powder coat damage), I've had news from Stef that it's been redone and is due back to me any day now:
For anyone wanting an axle refurbed then head over onto Stef's Facebook page, he does all sorts and despite the issues with mine I would highly recommend him:
https://www.facebook.com/axlesbystef
I'll get that refitted as soon as it's back. It will also enable a load of other jobs associated with the rear axle being in place, brakes, suspension, fuel tank etc
Talking of which, more parcels arrived:
Lastly, because the rear axle has really held me up, I really didn't want to start stripping more off the car. I simply don't have the mental capacity nor the storage space to deal with more coming off the car. So I did the only logical thing...take more off the car! Albeit only a minor job. Roll cage out:
There is the front section also, just not pictured. Taking this out was an absolute arse. The cage was painted/powder coated and then assembled meaning the tubes were unbelievably tight. I needed hammers to tap it out, this lead to the unfortunate events of a minor accident and 2lb nylon lump hammer hitting me in the face after ricocheting off the cage. I'm not one to make a fuss over small injuries however this clearly needed professional attention. Saturday night, Easter weekend in A&E for 10 stitches in my top lip. Thankfully no lasting damage. I wont post a picture, but it wasn't pretty.
You'll see the damage in Episode 10.
With the roll cage out the car I could get to sorting the interior out. I wanted to take the nasty paint off that someone had applied before, it was flaking off in places and only applied to the floor and a few inches up. This is a grueling job but perfect while I wait for the rear axle to arrive:
The above is only half complete but took about 4 hours. I'll use black raptor bedliner inside too. It's hard wearing and will look very tidy.
That's all for now. I'm working on Episode 10 and should hope to deliver that in the next 7-10 days.
Thanks for looking
I got rid of the nasty maxpower style metal fuel filler cap and replaced it with an original black one:
With the unfortunate events with the rear axle being damaged during shipping (powder coat damage), I've had news from Stef that it's been redone and is due back to me any day now:
For anyone wanting an axle refurbed then head over onto Stef's Facebook page, he does all sorts and despite the issues with mine I would highly recommend him:
https://www.facebook.com/axlesbystef
I'll get that refitted as soon as it's back. It will also enable a load of other jobs associated with the rear axle being in place, brakes, suspension, fuel tank etc
Talking of which, more parcels arrived:
Lastly, because the rear axle has really held me up, I really didn't want to start stripping more off the car. I simply don't have the mental capacity nor the storage space to deal with more coming off the car. So I did the only logical thing...take more off the car! Albeit only a minor job. Roll cage out:
There is the front section also, just not pictured. Taking this out was an absolute arse. The cage was painted/powder coated and then assembled meaning the tubes were unbelievably tight. I needed hammers to tap it out, this lead to the unfortunate events of a minor accident and 2lb nylon lump hammer hitting me in the face after ricocheting off the cage. I'm not one to make a fuss over small injuries however this clearly needed professional attention. Saturday night, Easter weekend in A&E for 10 stitches in my top lip. Thankfully no lasting damage. I wont post a picture, but it wasn't pretty.
You'll see the damage in Episode 10.
With the roll cage out the car I could get to sorting the interior out. I wanted to take the nasty paint off that someone had applied before, it was flaking off in places and only applied to the floor and a few inches up. This is a grueling job but perfect while I wait for the rear axle to arrive:
The above is only half complete but took about 4 hours. I'll use black raptor bedliner inside too. It's hard wearing and will look very tidy.
That's all for now. I'm working on Episode 10 and should hope to deliver that in the next 7-10 days.
Thanks for looking
Edited by Evo Sean on Tuesday 13th April 08:32
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