[car_overhaul] Reshell, Restore And Rebuild

[pugpete1108 62 1 Cars]

might look into a head skim

 

how do i measure the head height?

Edited November 24, 2012 by pugpete1108

[cybernck 402 1 Cars]

Roughly like this, just using more accurate verniers .

[welshpug 1,661]

That's exactly it

[pugpete1108 62 1 Cars]

Is there a set tolerance for this?

 

And I don't have a precision set of verniers.

[welshpug 1,661]

http://petrila.net/peugeot/Service/406d8/info/gb/b1db2ck3.htm

 

standard = 137mm +/- 0.05mm

 

minimum = 136.8mm +/- 0.05mm

 

 

Which means don't listen to any "specialists" that say 0.3mm skim is fine...

 

Gasket data here too.

 

http://petrila.net/peugeot/Service/406d8/info/gb/b1db2dk3.htm

 

Don't want this do you...

 

 

[dcc 855]

if you have a thicker gasket wouldnt that make the 0.3mm skim ok?

[pugpete1108 62 1 Cars]

Ouch

[johniban 59 1 Cars]

that colour is pretty nice! i like it!

well done for spraying the whole car in your garage, im going to attempt to do mine in my garage, little worried it will look naff tho

[Anthony 1,003]

The paintjob looks very good in the pictures for a first attempt done in a garage!

 

Which means don't listen to any "specialists" that say 0.3mm skim is fine...

 

Gasket data here too.

 

http://petrila.net/peugeot/Service/406d8/info/gb/b1db2dk3.htm

 

Don't want this do you...

That is quite misleading IMO.

 

A 0.3mm skim alone is NOT going to result in that and an otherwise standard head that has had 0.3mm skimmed off it with standard cams correctly timed in will be fine. There will be plenty of heads out there that have been skimmed by that and more with owners blissfully unaware.

 

If you're running non-standard cams or you're running the standard cams with the timing advanced though, then that 0.3mm skim could well be an issue. Mind you, it's often an issue on an unskimmed head as well.

 

Manufacturers claimed "minimum" heights are often very conservative, and take into account an awful lot of factors that may or may not be applicable in individual cases. 8v's are a very good example of this, as are Mi16's to a lesser degree - I've seen the later skimmed so much that the skim has cut into the valve seat inserts, and yet still appeared to function quite happily on a otherwise standard bottom end and management!

 

Clearly makes sense to measure it accurately though so you know what you're dealing with and potential implications on ability to run cams or have further skims in the future.

[welshpug 1,661]

The valve seats are quite close to the surface of the head on these later ones.

[pugpete1108 62 1 Cars]

that colour is pretty nice! i like it!

well done for spraying the whole car in your garage, im going to attempt to do mine in my garage, little worried it will look naff tho

The paintjob looks very good in the pictures for a first attempt done in a garage!

 

many thanks im pretty pleased how it turned out given it was done in a single garage and my first attempt. we will see if its last the test of time though.

 

its all in the prep, and i spent alot of time prepping it trust me.

 

small update.

 

got the other half of the engine in the kitchen much to the wifes amusment (she had to help me bring it in too )

 

 

sumps off to have the temp sensor hole drilled then its back on clean and paint.

 

looks like a nearly new water pump too along with recent belt, tensioners and crank seal (timing side)

 

also thought this sticker to be a bit strange?(very clean and new looking) given the car showed 147k ? i always thought the engine was strong so im thinking it may have been changed out at some point? is there anyway of tracking the barcode/number?

 

 

may have to search for engine numbers and hope is still have some paperwork for the car about to check.

Edited December 2, 2012 by pugpete1108

[welshpug 1,661]

my engine has one of those too, most of the bits on it were stamped 95 iirc and it was in general pretty clean as well.

[pugpete1108 62 1 Cars]

i think i have seen a 95 on it somewhere come to think of it?

 

its a 2001 car but as ive said supposedly has 147k on it

 

also need the hockey stick seals doing, right after i sold off the last spares from when i bought 10 pairs last time

 

so expect a for sale for some seals in the near future.

[pugpete1108 62 1 Cars]

right so i havent updated this thread in a while (lots of other threads beeen started though)

 

after putting the engine in with the xu7 bottom end and the xu10j4rs head on it after only a hour of so running time i noticed oil back in the header tank and knowing the bottom end was good it all pointed to the top end.

 

Now i could have had a pressure test done but at £90 a pop i didnt want to risk wasting it if it came back cracked so i opted to use the xu7 head that came from my cab along with the matching bottom end.

 

whilst removing the head i managed to snap a headbolt in the block, i tried to drill it which resulted in a snapped drill but in the block too so the block was scrapped.

 

 

i sourced another much lower milage one from a swiss 306 cab which was reading 149000 kilometers (92000 miles ish) and was in really good condition, fitted new hockey seals and both crank seals and the xu10j4rs sump which is ready to be mated up to the xu7 head soon enough.

[pugpete1108 62 1 Cars]

with the bottom end sorted i set about the top end.

 

i stripped both the xu10j4rs head and xu7 head to compare the port sizes and found a massive difference.

 

 

so set about opening up the xu7 port to somewhere near the xu10 ones (how good this proves to be only time will tell). I also had the head skimmed which only needed 6 tho off so happy there.

 

here you can see the ports opened up.

 

 

 

ive sources new head bolts and more importantly cleaned the threads for them (which was my downfall on the other head) sourced a new good quality h/g, bought some assembly paste and new stem seals which should be here this week.

 

in between this i have fitted the 306 trailing arms with disks which now means i dont need spacers on the rear for the nimrods, it was amazing ho easy the beam came apart given i rebuilt it near on two years ago. i gave it a good greasing when it went back together.

[pugpete1108 62 1 Cars]

along with all this i managed to get some cosmetic bit done.

 

sprayed both my strut brace which was stripped some time ago and my quarter badges.

 

the badges got some decals i bought some time ago, and im sure most people wont like the '8' but i really done care

 

 

as and afterthought i cut out and fitted one of the pts sticker i got from baz and i think it looks rather good on the strut brace??

 

 

hopefully i should have the engine back in and running in the next couple of weeks then hopefully get an mot only two months later than i planned.

Edited April 1, 2013 by pugpete1108

[allye 530 3 Cars]

Any updates Pete?

[pugpete1108 62 1 Cars]

Yeah, been meaning to update this actually.

 

Engines in and running, small water leak on a pipe on the rear (just a jubilee clip) no oil in the water which is good.

 

Running real lumpy but nothing a few data logs won't fix. it feels really responsive and revvy and I have no tapping so just looking forward to giving it a blast.

 

I have turned my attention to some cosmetics and interior which is a nice change from the oily bits.

 

So picked up and fitted a new screen today ( in one piece) as I cracked the last one when fitting it also sound proofed both doors with dynamat stuff and sound proofing foam like under the carpet.

 

Fitted the front speakers so now have a stereo.

 

Fitted the quarter badges.

 

Basically it's all ready for the mot apart from the 205 section tyres are rubbing on the rear inner arches even with the 306 trailing arms. So I need 2 new 195 tyres.

 

Been flat out last week as you can see, but the end is in sight and it WILL see the hill at pugfest this year

 

Ill get some photos up tomorrow

 

Should also add I got two new handbrake cables and rear pads so I now have brakes.

 

And I managed to tear a beam mount when refitting the beam so have ordered 2 new ones which will be here this week.

 

I'm aiming for an mot end of the week fingers crossed

Edited April 27, 2013 by pugpete1108

[pugpete1108 62 1 Cars]

right, fitted the lst couple of bits today i.e front grill and numberplate alsong with some temporary spacers on the rear to stop the tyres fouling.

 

found out that ive crossthreaded the brake union on the rear calliper so thats buggered and i need a new one.

 

i gave it a couple of runs around the block while running a log and its getting better but still seems really flat under throttle so will need to investigate that further.

 

anyway heres a couple of pics in the sunshine.

 

 

 

 

 

[damien 22 1 Cars]

nice astra... and the 205 an't bad, looks great for a home done respray

[ALEX 98 1 Cars]

 

i was kinda hoping someone would ask that

 

it went like this:

 

primer whole badge

steel wheel silver whole badge

laquer whole badge

 

leave for laquer to fully dry (few days)

 

couple of coats of matte black all over, then before it fully goes off (couple of hours max) using a cotton bud soaked in thinner i removed the matte black from the tops of the letters.

 

then i left it for a few days then buffed up the silver bits.

 

the gti badge i just left in red oxide instead of the silver as i didnt have any red

 

twas a fair bit of hastle tbh but worth the effort for something a bit different.

 

 

Cool idea.

I used a little rubber roller used for flattening out wallpaper.

Sprayed silver paint on it and lightly rolled over the letters.

I had to clean the edges up with a knife to make the letter edges look sharp.

[pugpete1108 62 1 Cars]

Mini update,

 

Picked up a rear box at the weekend for the princely sum of £10 and today set about cutting and welding it to fit my system.

 

Not a bad job and its not too loud ( well not tried it on the motorway yet.

 

Waiting on a seat bracket and some more sound deadening for the rear then the end of the month for some tax and its time to hit the road.

 

 

[Darrens205GTI 10]

Very nice job Pete,

 

Looking forward to seeing it cruising round the area.

 

Cheers,

Darren

[pugpete1108 62 1 Cars]

Very nice job Pete,

 

Looking forward to seeing it cruising round the area.

 

Cheers,

Darren

cheers Darren, yours not on the road I take it? not seen a single 205 about for a long time.

 

can afford tax for mine this month so you may well see it about

 

been meaning to add some more pics anyway so last weekend I set about painting the bumpers body coloured. also painted the trim with some left over silver paint I had lying about (they were purple??)

 

 

now that is shiney:

 

 

and some serious beading, must be well waxed: