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Forums › Tuning, Modification & Legal › Project Cars › Hey Jude: Sim's 2.0 HDi "Rust Away" |
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 Posted: Sun Nov 29, 2015 10:48 am |
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Joined: Jun 20, 2012
Posts: 1171
Trade Rating: +1
Location: West Country
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Why hello there!
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Posted: Sun Nov 29, 2015 2:56 pm |
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Joined: Feb 07, 2010
Posts: 7093
Trade Rating: +11
Location: Suffolk
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Literally this project is awesome, i have so much time for people who pride in clean cars!
I reckon your old girl is a keeper just like mine 
On a serious note mate, do you have me on facebook? If not i do offer torsion bar adjustment services if your intrested 
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| Team Impossible Possible
The only way of finding the limits of the possible is by going beyond them into the impossible - Arthur C. Clarke
Forged 1.6 Turbo
Click to see more
144Bhp @ 7PSi - 193.9Bhp @ 13psi
206 Gti Race Car
Click to see more
For all Race/Track Preparation, Feel Free to PM Me!
Whether its for a custom ratio gearbox or track-day alignment, I can help! | |
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Posted: Tue Dec 01, 2015 3:14 pm |
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Joined: Jun 20, 2012
Posts: 1171
Trade Rating: +1
Location: West Country
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Cheers for kind words Adam, I'm definitely keeping her! We've been through thick and thin, I'd never sell, and probably would break my heart for parts instead 
Because the next plans are as we see -- strip down that GTi 138 disk axle into bits, clean inside out (what solvent to use for torsion bar splines? I could just dip into something for weeks)
Then to use Piggy's electrolysis to remove rust from other parts and have a cuppa whilst doing it www.youtube.com/watch?v=9G976RDgEkM
I reckon Adam you noticed my sufferings with drum axle seized up torsions, but I'm not giving up on this axle will try to do it myself, and I'm not active on Facebook; it's better we organise some 206info meetup
But thanks for offer, I'll be picking your brainz surely!
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Posted: Wed Feb 17, 2016 5:23 pm |
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Joined: Jul 04, 2014
Posts: 151
Trade Rating: 0
Location: Gloucestershire
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^Then a big ass turbo and intercooler upgrade! 
I still need to finish my wheels - rain is hacking me off now! Good to see someone getting good progress! Is it slammed or just a mild drop? And is the disks all round braking power noticeable? Never driven a drummed 206...
I also need to finish the ipod conversion and get cracking on the catch tank, all whilst using as my daily (300 miles a week)! So another busy year might mean I spend almost as much time on my car as you do yours! :L
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| 1.6HDi. Pull like a train. Smokes like one too!
No Smoke, No Poke! | |
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Posted: Wed Feb 17, 2016 6:20 pm |
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Joined: Jun 20, 2012
Posts: 1171
Trade Rating: +1
Location: West Country
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Yo man! Happy New Year long time no see
I haven't touched the disk axle yet, it's resting at the unit, which has kept me busy until now, need a colossal project thread update
Indeed an intercooler is on the cards, but bigger turbo would be hard to get at, being a nice problem of a 2l engine
Hope your catch tank won't crack Just get a cheap daily runabout and put your quicksilver down as project Does it still smoke like a train yet yields an acceptable MPG?
Let's meet at the Unity once we'll've covered it up (still work to do though)
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Posted: Fri Feb 19, 2016 6:00 pm |
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Joined: Jul 04, 2014
Posts: 151
Trade Rating: 0
Location: Gloucestershire
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Happy New year bud yeah unit meet sounds good! You planning on being at FCS this year?
Yeah still creating smokescreens at 70 mpg
You could always twin charge? Reckon a supercharger would fit in there nicely!
Got my eye on a 208GTI...
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| 1.6HDi. Pull like a train. Smokes like one too!
No Smoke, No Poke! | |
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Posted: Mon Jan 01, 2018 8:14 pm |
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Joined: Jun 20, 2012
Posts: 1171
Trade Rating: +1
Location: West Country
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Posted: Tue Jan 02, 2018 7:53 am |
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Joined: Jul 20, 2012
Posts: 460
Trade Rating: +3
Location: Shrewsbury
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Posted: Tue Jan 02, 2018 7:15 pm |
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Joined: Feb 08, 2010
Posts: 7045
Trade Rating: +5
Location: In the garage
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Looks like a good little project. Car is looking good.
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| 2001 GTi 138, Bilstein Sprint dampers, H&R springs, 21mm Peugeot Sport torsion bars, 22mm rear ARB, Peugeot Sport Group A wishbones, 283mm discs, Goodridge stainless hoses, Maniflow 304 grade 4-2-1 2.5" manifold and system, 200 cell cat, Richard Longman head, 45mm Jenvey throttle bodies, 9.5mm TB spacers, 90mm air horns, Jenvey throttle linkage, Jenvey fuel rail, Aeromotive and Goodridge fuel fittings and braided hose, ITG sausage filter, Radtec custom radiator, Piper Ultimate Road cams, Piper vernier pulleys, Omex 600 ECU. Saxo electric PAS pump, Vibra Technics engine mounts. Samco coolant hoses, TTV steel flywheel, 4.76 final drive ratio, 307 CC 180 ratios. 2019 BMW 530i. 2017 Mercedes C300 convertible. | |
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Posted: Tue Mar 20, 2018 10:18 pm |
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Joined: Jun 20, 2012
Posts: 1171
Trade Rating: +1
Location: West Country
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Eh mate? is this to say "followin"
| Edward wrote: |
| Looks like a good little project. Car is looking good. |
Cheers Edward! In fact the car had been stood for 2 years, until mates decided to swap the axle and do the MOT for me as a present so I can be back in a Pug after winter holidays (enough was enough with Jags, missing 206 too much! and the garage finally allowed some actual work on cars)
As you remember the jolly old axle I sourced years ago, so that came on just before Christmas '17 (Jim looks like he's taking a dump here  )
And I didn't know what condition it's in, was questioning whether it had been lowered, or ARB and what not is about to collapse (just like it happened to VorTechS )
Together with all them bits that needed a refresh, including longer handbrake cables (it's nice to be choosing a GTi 138 model when shopping online for anything rear-axle-related, instead of entering HDi's regplate)
As many will know, when doing a drums->discs conversion important is to source an axle from around the same year, so ABS sensors match up. As I later found out, them sensors are even interexchangeable!
Servicing was the next most urgent work to carry out, you can see what time can do to a car being parked for couple of years (a spider made home in the airbox too):
Stay tuned for another update, where I'll write up why this had to happen
And no, the reason for getting a refurb axle was neither the GTi axle arms' bearings, stub pins, nor a VorTechS-style collapse
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Posted: Tue May 01, 2018 11:14 am |
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Joined: Jun 20, 2012
Posts: 1171
Trade Rating: +1
Location: West Country
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| Sim wrote: |
| Stay tuned for another update, where I'll write up why this had to happen |
We'll get back to our axle story later, because now I must say that this 18 year old has started aging.. But no matter, I've got lots of patience and spares lined up
There's one slight uphill that I like to put my foot down in 2nd after crossing the cattle grid, and just before taking Jude off road two years ago, I too remember enjoying a dollop of wheel spin there when wet...
Then it turned out to wheel spin also in dry conditions...
Then it turned out that wheels had never been spinning in the first place! But this wouldn't happen when driving anywhere else hmm
Back in the car on the 1st Jan 2018 and then driving around happily for two weeks, the clutch started so slip very badly all of a sudden. So I was faced with a Friday afternoon challenge to reach ECP
and the garage
Looks like someone liked to ride the clutch, maybe Clarkson or May owned this before!? Seeing how it works and wears down, I've now become extra conscious about not stomping on the pedal unnecessarily.
There was still plenty of friction material on the clutch, pointing at the diaphragm getting weak and not driving the pressure plate with enough force. It's good that it got tired earlier than the spring-to-thrust bearing failure happened!
Being cheerfully equipped with the new clutch, I've set out to see my missus the next day, only to find out that battery light started coming on at random.
Initially thought it was some wiring issue after disturbing the lot when replacing clutch, yet the light would come on more frequently with time and increasingly throughout the RPM range by nightfall.
Decided to wait for the next day, so that the headlights wouldn't drain the Duracell battery completely (yep, gave that one a go instead of Bosch/Varta for a laugh, so I can say I've got an sort-of electric car now )
Thanks to being a diesel, she happily took me another 100miles on battery alone while having quickly sourced this
and fitted
The fiddly signal cable (small wire) had to be routed the other way round from the right-hand-side instead, but otherwise pretty chuffed with this shiny refurbed alternator!
After the "incident", I've received a Top Gear-style "present of shame":
Which, I must admit, comes quite handy! (that being the charging ports)
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Posted: Fri May 11, 2018 7:21 pm |
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Joined: Jun 20, 2012
Posts: 1171
Trade Rating: +1
Location: West Country
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Back to our got-axled-up story; while enjoying the new clutch and alternator, a clanging noise started coming from the rear.
Been quite baffled for a while, forum search pointing to shocks, handbrake components, collapsing torsion bar splines, and what not.
Decided to give ImAxle specialists a try, a refurb arrived in good nick, but a word of warning all this hammeritesque coating is very thin, and grows an unsightly surface rust in weeks.
The oldie had an apparently snapped ARB within, so that explains the clanging. Left it for further inspection in unforeseeable future:
If you're careful, it's possible to rustle the axle down without disconnecting the brake lines:
Dropping the axle made it easier to inspect the rust-away situation.
Back in 2015 before the treatment (real bad):
Same 2015, after sanding (I didn't remove enough rust, was hard to get to!)
On the same 2015 week, rust inhibitor (didn't inhibit enough apparently:)
Coat of cavity wax and the undersealer (same 2015 obviously:)
2018, nearly 3 years and 7500 miles later (two years of being SORNed):
Lessons learned:
- don't use pressure washer to remove surface rust, as it will leave tiny droplets in hard-to-get places
- use steam cleaner instead
- ensure you remove all the rust you can, drop axle to gain easier access
- invest into sand blaster (would soda blaster be less messy, Edward?)
- if blasting is off the table, then a compromise would be this newish invention: Polycarbide Abrasive bit or disc, only bites the rust out and leaves the metal intact!
- consider several coats of rust inhibitor, cavity wax, and especially the final undersealant
Axles, axles everywhere!
Since it was the shiny one going up, I decided to toy around with the sandblaster. Picked the shoddiest-looking caliper brackets, and gave them a quick onceover:
Didn't go overboard, as that blastard thing just sprayed everywhere, even when you're wearing painters overalls
A spray of galv for protection:
Splash guards take the toll first if you drop your axle without too much care. My ones were also rusted beyond acceptable.
Picked up new splashguards from the stealer, they also got their share of galv spray, as they get scratched during transportation, that's where the rust starts to set in.
Now this part of the car starts to look more like from an Edwardian era, but alas this being my daily, had to go back on the road, meaning ran out of time to blast the brake calipers  Next time for sure!
The splash guards are still as shiny today after 3 months of abuse, and make the rear discs look bigger
Had one last niggle from the AVO rear shocks -- one of them was weirdly knocking.
All mechanical things being sound, meant I could start eliminating uncomfortable and noisy bits, meaning front AVO coilovers had to go too, with lowering springs replacing them (that's for my next post).
One of those AVOs up front has always been leaking fluid through the top damping adjuster since I've had this set. I wonder if AVO will want to look my way to investigate these imperfections
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Posted: Mon May 14, 2018 6:43 am |
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Joined: Feb 08, 2010
Posts: 2369
Trade Rating: +15
Location: Gloucestershire, UK
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Love the sandblasting Sim! How much were the splash guards from Pug? As you know from our recent work, mine are far from their best!
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Posted: Mon May 14, 2018 11:13 am |
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Joined: Jun 20, 2012
Posts: 1171
Trade Rating: +1
Location: West Country
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Sandblasting is fun but only if something like a cabinet is made. That abrasive dust gets everywhere!
Brake disc protector is £18.58 (I've used the wrong term there  ), I've got two more lined up for the 180 
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Posted: Mon May 14, 2018 11:51 am |
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Joined: Feb 08, 2010
Posts: 2369
Trade Rating: +15
Location: Gloucestershire, UK
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| Sim wrote: |
Sandblasting is fun but only if something like a cabinet is made. That abrasive dust gets everywhere!
Brake disc protector is £18.58 (I've used the wrong term there ), I've got two more lined up for the 180 |
Awesome, if I have enough money after the house move I think I'll invest in some!
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