Twincharged, Wide-arched Convertible Peugeot 405
Discussion
NotDave said:
Makes sense to me, as the whole frame would have strength, and line up to roof. Scuttle could be adapted to suit 
It's a good idea, but the whole frame wasn't available. I'll probably give it a good go with the bits I've got and the 405 windscreen frame and see if I can succeed with that. If not I'll hunt down an entire E46 windscreen frame.davetibbs said:
It's a good idea, but the whole frame wasn't available. I'll probably give it a good go with the bits I've got and the 405 windscreen frame and see if I can succeed with that. If not I'll hunt down an entire E46 windscreen frame.
BMW scrapyard, angle grinder. Off you go?Can't see there being much "demand" for that part, as most are gonna be crushed with the rest of the shell ain't they?
True enough. However, I forsee "difficulties" with getting the bottom curve of the E46 windscreen frame joined to the 405 bulkhead - it could actually be a lot more work than the way I've planned. Since I've already got the windscreen top I'll probably stick with the "strengthened 405 frame" plan for now, and if it doesn't work I can lob it off and try and use a full E46 frame.
A lot! As I understand it, it's not uncommon for factory convertibles to have an extra 200kgs of additional weight over the saloon/coupe model. I'll probably end up with quite a bit more than that. In fairness I haven't weighed the extra metal I've added as I've prioritised chassis strength over weight saving, with the idea that if it affects performance too drastically, my engine isn't powerful enough. I might take the completed car onto a weighbridge out of interest though.
Yes, the sills already have a lot of additional strengthening (essentially box section) both inside and outside the car. The door apertures will be strengthened at the hinge end with the same strengthening for the windscreen (to provide support for longer - and therefore heavier - doors), and at the latch end to restore rigidity to the (shortened) B pillars which will also double up as support for the roof. I'll try and get some drawings up at some point to highlight where all the strengthening has gone.
Yep, the list above isn't exhaustive. There's a front strut brace (just bolt-on though), and a welded cross-brace in the rear behind the seat. Plus I'm currently beefing up the front and rear chassis legs.
I'm considering an X-brace but not sure of the best way of approaching it at the moment.
I'm considering an X-brace but not sure of the best way of approaching it at the moment.
When I first skim read the OP, I thought we were about to see a Peugeot 406 coupe to cabrio conversion (which could look pretty damn good). Then I saw it was a 4-door 405.- now that is a LOT of work! Seem to remeber one of the Max Power type mags featured a 4 to 2 door conversion on a Pug 306 saloon a few years back...
Whitean3 said:
When I first skim read the OP, I thought we were about to see a Peugeot 406 coupe to cabrio conversion (which could look pretty damn good). Then I saw it was a 4-door 405.- now that is a LOT of work! Seem to remeber one of the Max Power type mags featured a 4 to 2 door conversion on a Pug 306 saloon a few years back...
I actually had a 406 coupe which I was tempted to do the conversion on, but couldn't bring myself to chop that beautiful body so chose the 405 instead. The irony is that it's now being broken for parts in my back garden 
Maybe I could do it in the future 
I remember the 2 door 306 saloon - it was an Ecosse job I think, I suspect they used the parts necessary (such as rear wings) from a 3 door hatch, but I have no such cheats available
Just a small update:
Making the mounting brackets for the airbags
Cleaning suspension turret mounting plates (still needs a polish)
Wishbones painted with all new bushes
Adapting Spax PSX Adjustable shocks to fit airbags:
First, cut off spring mounting cup
Then, strip paint
and weld on coilover conversion tube:
Once welds are tidied up and bottom mounts are finished, the shocks can be painted.
I also started stripping 406 Coupe Brembo calipers for seal replacement and painting:
And ordered some badge lettering on a whim
Making the mounting brackets for the airbags
Cleaning suspension turret mounting plates (still needs a polish)
Wishbones painted with all new bushes
Adapting Spax PSX Adjustable shocks to fit airbags:
First, cut off spring mounting cup
Then, strip paint
and weld on coilover conversion tube:
Once welds are tidied up and bottom mounts are finished, the shocks can be painted.
I also started stripping 406 Coupe Brembo calipers for seal replacement and painting:
And ordered some badge lettering on a whim
mwstewart said:
Interesting project. Did you weld those sleeves on with the damper assembly still inside?
Yes. I was in two minds whether to do so but didn't really fancy dismantling the shocks, which would have presumably required them to be regassed afterwards. As such we were very careful with the welding that it didn't get too hot, and I figure the fact that they still move afterwards means that they'll probably be fine Thought that this was due a small update:
Brake callipers prepped for paint
Painting the shocks
Brake callipers painted
...and lacquered.
Making the metal tube inside the airbag bigger so the shock (with newly-welded coilover sleeve) will fit inside it
Top mounting plate + bearing fitted to airbag
The complete strut
Fitted to car
New steering rack (though seemed to be fitted with incorrect track rods, but I recovered the situation by fitting 306 track rod ends rather than 405 ones).
Steering rack fitted
Brake callipers prepped for paint
Painting the shocks
Brake callipers painted
...and lacquered.
Making the metal tube inside the airbag bigger so the shock (with newly-welded coilover sleeve) will fit inside it
Top mounting plate + bearing fitted to airbag
The complete strut
Fitted to car
New steering rack (though seemed to be fitted with incorrect track rods, but I recovered the situation by fitting 306 track rod ends rather than 405 ones).
Steering rack fitted
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