[Rally_Prep] 306 2.1 S16 Tarmac Rally Car

[jorg 11]

I know its not a 205 but as the engine I have just bought used to live in one, I thought I had better start a project thread. After a long four year battle trying to build my own 205 rally car (I should of got one ready built ) I decided to strip the 205, sell bits no longer needed and buy this.

 

 

It was originally built to be a track car and no expense had been spared by the previous owner. The cage had been fitted by Phillip (Rippthrough) and had Colin Satchell solid engine mounts fitted. The plan was simple, replace and fit the bits required to get it through log-booking and get out on the stages. Unfortunately that did not happen and 14 months later it is still sat in the garage on axle stands.

 

a few pictures before work began:

 

 

 

 

 

 

The bucket seats and harnesses were out of date so they were sold. I already had a brand new pair of Ricco Racing harnesses from the 205 so after a quick phone call to Motordrive a pair of bucket seats arrived:

 

 

and drivers side was fitted after having to buy a new pair of side mounts:

 

 

Next I moved onto sorting out my suspension. I decided started with the rear beam and as Andy (jord294) is local, I ask him to build it for me. Some negative camber on the back was in order so I sent a pair of trailing arms off to Martin (CRF450) at Bridgecraft Engineering to work his magic. A cheap 30mm arb was up for grabs on the GTi6 forum so I snapped that up and placed an order with Anthony for some 23.5mm torsion bars. A few weeks later everything had arrived and as I already had a set of solid rear mounts I took a trip up to Andy's to drop everything off. Once the parts had arrived back from powdercoating it only took Andy a few hours to put it all together. The following weekend I took the car up there to get it fitted.

 

 

 

 

 

 

I ended up with AVO mono-tube fronts and two-ways on the back as I was trying to stick to a budget, looking back now I could have spent a bit more but was happy with what I had. The after-sale service from AVO seems highly rated so if I do have any problems I should be able to get them sorted pretty quickly.

 

 

 

well I was happy with the rears until something else popped up for sale the AVO two-way rears were sold on to buy these:

 

 

After waiting ages for a decent set of 4 pots to come up for sale I bit the bullet and got a pair of AP Racing CP6562 6 pot calipers

 

 

they are of a solid one piece alloy construction, fitted with titanium pistons with ceramic caps to stop heat transfer into the fluid. Next up to buy was a pair of Carbone Lorraine RC6 pads, as these calipers run a smaller size pad they had to be ordered in. Here is a picture of the caliper and pads on the kitchen scales:

 

 

Choosing what size rotor I was going to use would be a difficult decision. As I have 2 sets of Pro Race 2's, 1 set of Pro Race 1.2's and 3 Pro Race 1's all in 15" size and direct fit (ET15) I wanted to make sure all the alloys fitted over with no problems. I was very tempted to go with 310mm but the TD 1.2's really are p**s poor for clearance compared to the TD 1's and 2's. After much thought I went with a pair of 300x28mm rotors from Hi-Spec. I just need to get some bells and brackets made for them now.

 

 

more to follow.....

[jorg 11]

Inspired by what Pete (Mad Scientist) was doing with his rally car build I started to look at the engine side. I had already picked up some Peter Taylor stage 1 and 2 cams, kentcam vernier pulleys and some pocketed pistons for a S16 build but as luck would have it a ready made engine appeared for sale on the forum. Once I worked everything out it made more sense to sell the bits I had gathered for my own engine build to fund this ready built one. So last month I took a trip to Nottingham to pick up the 2.1 S16 engine from Lewis (Doof) By the time I had finished selling parts I had covered the engine, a set of alloys and a brand new 106 electric power steering pump!

 

I have no engine pictures for some reason so you can have a picture of the power steering pump instead

 

 

When Sandy Brown mapped the engine it made 180bhp+ at the wheels on a GTi-6 Inlet manifold so I will be hoping for around 200bhp+ once I have fitted some throttle bodies

 

 

I have already sent off a inlet manifold to Mr Satchell and he hopes to have it ready shortly along with some trumpets. Of course once I started going down this route there was other parts I would need to sort out to get the full benefit of the setup, mainly replacing the crap exhaust manifold which was fitted to the S16 As luck would have it Stuwee on the GTi6 forum had just put his jenveys up for sale on the forum, knowing that his car had a 4-2-1 maniflow exhaust manifold fitted I pm'd him to see if it was available. A few days later it arrived not too bad for £100 delivered!

 

 

So thats where I am upto at the moment. I only plan on doing one event this year due to work and thats in September so that gives me 5/6 months to pull my finger out and get her finished.

 

Spec I am hoping for when completed:

Engine:

2.1 S16 engine
45mm jenvey throttle bodies running 8 injectors
Colin Satchell inlet manifold and trumpets

DTA S40 Pro with professional loom

Colin Satchell Solid Engine Mounts
4-2-1 maniflow exhaust manifold
Rich_W Fuel Swirl Pot
Bosch 044 external fuel pump
refurbed VTS Gearbox with TranX Diff

Brakes:

AP Racing CP6562 6 pot brake calipers with CL RC6 pads
300mm x 28mm rotors

15" Team Dynamic alloys
AP Racing Bias Valve

Suspension:

Seam Welded Subframe

Rich_W Roller Bearing Wishbone Bushes
Xsara VTS Phase 1 steering rack
AVO mono-tube front coilovers
Russian Guy adjustable top mounts
PhillipM lower strut brace with sump guard mounting points
Rear beam built by Andy (jord294)
Bridgecraft Engineering Negative Camber Trailing Arms
FOX rear dampers
30mm rear ARB
23.5mm torsion bars
Solid rear beam mounts

Edited March 15, 2013 by jorg

[Zacky-94 7 2 Cars]

Looks nice mate well done!

[MiniGibbo 142]

Weather its a 205 or not still Peugeot and still a decent build... I look forward to the updates

[Alan_M 66 1 Cars]

Inspired by what Pete (Mad Scientist) was doing with his rally car build I started to look at the engine side. I had already picked up some Peter Taylor stage 1 and 2 cams, kentcam vernier pulleys and some pocketed pistons for a S16 build but as luck would have it a ready made engine appeared for sale on the forum. Once I worked everything out it made more sense to sell the bits I had gathered for my own engine build to fund this ready built one. So last month I took a trip to Nottingham to pick up the 2.1 S16 engine from Lewis (Doof) By the time I had finished selling parts I had covered the engine, a set of alloys and a brand new 106 electric power steering pump!

 

I have no engine pictures for some reason so you can have a picture of the power steering pump instead

 

 

What's the grey thing with the pump?

[welshpug 1,657]

heavy duty sealed relay.

[Mad Scientist 106]

Nice work so far. I'd love to know what you think of those rear shocks. I need an upgrade soon.

 

That cage looks like a work of art too.

 

I've always thought a 306 would be my next project. Good handling, and big enough to get the seats nice and low/ far back with a comprehensive cage. Trouble is, I've got a mk1 escort shaped itch that needs scratching next!

[johniban 59 1 Cars]

nice welding on that cage! looking good, can i ask how do they go about getting negative camber on them axles?

[jorg 11]

Cheers for positive feedback guys

 

Mr Satchell has finished the inlet and trumpets so hopefully they will arrive this week. The current engine is being removed next sunday (fingers crossed for some decent weather) and I hope to have the 2.1 dropped in over the bank holiday weekend.

 

nice welding on that cage! looking good, can i ask how do they go about getting negative camber on them axles?

 

Have a look in the group buy section John at the Bridgecraft Engineering thread started by allanallen.

[Doof 11]

interesting stuff. Looks like it's going to be an animal. Not sure I'm looking forward to hearing the engine on bodies, I'll regret never having done it myself!

[jorg 11]

Some goodies from Colin Satchell arrived during the week

 

 

that meant of course I would have to pull my finger out, get down the garage and remove the old engine. I had planned on doing it last weekend but the crappy weather put a stop to that. The sun was shining this morning so I had no excuses, one hour later I had the engine out and the subframe dropped.

 

[jorg 11]

After working the last 10 days in a row I finally had a day off to do some work on the car, I got down to the garage to find some scummy bastards had dumped the contents of a house right in front of the doors

I phoned the council to report it and did my best to move everything to one side so I could gain access, I wish I never bothered! When I removed the engine a few weeks ago I had a few issues with the solid engine arm and the alloy mount. One problem was that they didn't seem to sit flush together and the other problems was I could not get the bolt out of the alloy mount and get them separated.



My attempts today to get them apart didn't go too well the mount was then stuck in the cradle and had to get a chisel and hammer on it to get it out



So now I need to get a new alloy mount made up, plans to get the engine fitted by the end of the month are now looking pretty slim

Edited April 12, 2013 by jorg

[welshpug 1,657]

can you not bung a standard one on there for now?

[Tom Fenton 1,542]

That alloy mount looks easy to repair to me. Is it just a solid block with a pair of studs in?

[jorg 11]

That alloy mount looks easy to repair to me. Is it just a solid block with a pair of studs in?

 

I am now hoping to get it repaired It looks like the bolt has bent inside the spacer due to the arm not sitting flush, it isn't actually threaded so in theory should just fall out. Someone on the GTi-6 forum has offered to sort it for me if I can't.

 

Once the bolt is removed, a few seconds with an angle grinder will sort out the clearance issues with the arm.

Edited April 12, 2013 by jorg

[jorg 11]

well I tried and failed to get the bolt removed from the alloy spacer so I have taken up someone's kind offer on the GTi6 forum to sort it out for me. I may have found a short term replacement in the form of the solid rear engine mount I got off Phillip the other week.



I tried it on the spare arm I have and it fits perfect, the only issue is its 7mm smaller than the original but that should be a massive problem.





and my sump guard turned up too so I am having a much better day than yesterday!

[jorg 11]

the alloy spacer arrived back safe and sound, have to say a big thanks to Jim Davey on the GTi6 forum for sorting it out so quickly. I popped it in the post late saturday morning and it was back with me on tuesday (well sort of, missed the post and had to wait 48 hours to pick it up )



tomorrow I will be making the adjustments required so it sits flush with the engine arm and hopefully avoid the same problem happening again. As both arms were looking a bit manky I decided to rub down the one I was going to use and give it a lick of paint.



Today I wanted to fit the solid gearbox mount I picked up from Andre (306 Rxs) this meant I had to cut away part of the lip on the nearside inner wing, not an easy task in a garage with no electricity. I charged the batteries for the cordless angle grinder I have and made my way down to the car. Well the wanky batteries lasted less then 5 minutes but I did manage to cut the sides and bend the lip back using a hammer. I need to go back down with a dremel and sort it out properly.



I need to enlarge the holes on it slighty and try and get some new bolts, does anyone know what size bolts are used to secure the gearbox mount tray? I get the feeling they will be a weird size

Also arriving this week was my new injectors for the throttle bodies, I had planned on getting two used sets and send them off to be cleaned up but these brand new ones popped up at a good price so snapped them up.



just placed an order for some brake bits from Alex at Torques as I hope to fit my new brake lines over the weekend. also I have asked Stew at BBM to knock me up a lower fork bush for the 306 as no one lists an aftermarket/uprated one like they do for the 205.

[hcmini1989 16]

looking good mate.If the bolts for the tray are`nt a normal size shoot down to laten fasteners in ellesmere port they seem to keep alot of mad sizes in .

[jorg 11]

looking good mate.If the bolts for the tray are`nt a normal size shoot down to laten fasteners in ellesmere port they seem to keep alot of mad sizes in .

 

cheers Liam, turns out they are M8 bolts so got myself a thread cleaner and that has sorted it. I will certainly keep that place in E'port in mind though for the future!

 

After alot of talk of dodgy fuel injectors doing the rounds I have decided to send all 8 to the Mad Professor for testing. Would rather spend £40 now than waste a potential £400 at the mapping stage if injectors are not what they are supposed to be.

 

I have trimmed down the alloy spacer so the engine mount arm will sit flush, it took two attempts but I think it is finally done. I will look into getting a new one made up but for now it will do. (pic to follow)

 

I spent this morning attacking the offside strut top in preparation for the Russian Guy adjustable top mounts I have. It needs tidying up and some paint but I am quite pleased with the outcome.

 

 

 

I went back down this afternoon to do the nearside but the battery ran out before I could finish my fault for trying to cut off the bonnet stay bracket.

 

Edited May 3, 2013 by jorg

[custard-rallye 25]

Looks really good

[jorg 11]

Looks really good

 

Thanks

 

long time with no update and unfortunately not a lot of progress has been made, I should of been doing my local rally at the beginning on September but its my own fault for it not being finished

 

the engine and gearbox have been fitted with a 4-2-1 exhaust manifold:

 

 

The gearbox had to come back off as I had forgot that it was setup for a 205, didn't remember until I tried to put the gear rods back on Luckily I had the old gearbox to use for parts so last weekend I dropped the box, switched the arms and refitted it. While the gearbox was off I decided to swop back to the original solid gearbox mount that was on the car when I got it from rikky. I can't make my mind up on which one to use the original is winning at the moment as I can put a plate over it and use that area for the electric power steering pump.

 

this:

 

 

or the original: (stud was on order with Peugeot and has now been fitted)

 

 

I got in touch with Stew over a BBM to see if he did any solid bushes for the 306 lower fork, a few weeks later these arrived

 

 

and fitted into the housing:

 

 

Rich_w roller bearing wishbones and a PhillipM/Rippthrough lower strut brace fitted to subframe:

 

 

Picked up a TRS carbon fibre roof vent off eBay for £40 and set about making a nice hole in the roof of the car.:

 

 

and then last week I picked up another eBay bargain, a DTA S60 Pro with full loom It was from a Ford turbo setup so the loom has been stripped back to the basic wires and I have placed an order for some new connectors and wrapping.

 

 

Hoping to have the car rolling by Monday so I can start installing the fuel swirl pot and Bosch 044 pump under the boot floor. The big plan is to have the car out of the garage, mapped and MOT'd by mid October.

 

Geoff

[matt.f 16]

Nice car and a good thread.

What do you think of the Motordrive seats,comfy?

[jorg 11]

I am very impressed with the Motordrive seats to be honest. Mine are Budget Pro 4's which are the biggest seat they offer but the only colour available is black. For the money I don't think I could of found anything better (I paid no where near the screen price on the website)

[matt.f 16]

Nice one,might pop down as they are only down the road and will be needing two seats,belts and seat frames for my dads mg zr enduro build.

[Mac Crash 78 1 Cars]

Jorg,

 

Hi, I'm obviously missing something as it's clear you look like and sound like you know what your doing, but why would you want negative camber on the rear of the car?