#1: Hey Jude: Sim's 2.0 HDi "Rust Away" Author: Sim, Location: West CountryPosted: Sun Jan 19, 2014 1:33 pm ---- Hello all!
first couple of pages are done on a minimal budget with links to cheap yet still reasonable ebay items
Changelog:
Still TODO:
fix PAS hose leak for good with "ear" hose clamps [update: even after sourcing the most correct Clic-R 86 165 clip, it still leaks. Probably a split in the housing. Oct '19]
good quality (not volume) audio system in every tone range, SilentCoat the bodywork shell
make her look as good as new all round
find shock absorbers (not coilovers) that would have adjustable damping and rebound (optional)
de-cat (will be a bold attempt to gut it without opening up, more like gynecologist job, interestingly because no-one tried that before). De-cat is needed to reduce the needless backpressure for a turbocharged engine, in prep for stage2 remap, or at least 125brake map [update: no longer relevant due to new MOT rules. May '19]
Done:
☑ 16" Nimrods (thanks Andrew!)
☑ straightened and de-rusted bent sill
☑ de-rusted under the aerial (interior, above roof lining)
☑ calipers and drums paint do
☑ 65mm stubby aerial, so boot opens without scuffing the spoiler (radio reception is now sh*te )
☑ top mount tower water damage do
☑ nippy 120brake remap @pro_steve's HDI-Tuning !
☑ new numberplates
☑ AUX cable for stock cassette radio, also killing the noisy tape motor
☑ front bumper do
☑ AVOs rear shocks on, she now sits tighter on the road \o/
☑ endless exhaust alignments
☑ rear rustproven & undersealed with Dinitrol kit
☑ ~45mil drop on pezhdi's fully adjustable AVO coilovers, thanks matey for selling those!
☑ Coilovers are for track really, such a hard ride, that I got rid of the front ARB (made no difference)
☑ recon and fit disks rear axle from a GTi 138 of similar year (to avoid ABS comms problems, thanks @pro_steve for the tip)
☑ proper wash habit with 3 buckets and lamb's wool mitt
☑ 206 SW refurb disc axle from IMAxle (no sway bars)
☑ After driving around knew optimal height, ditched AVO coilovers
☑ Fitted Eibach lowering springs (30mm) and original shocks, ARB had to go back in
☑ FK Automotive smoke rear lights
☑ New windshield with grey top-tint
Original post:
Finally found time to write what kept me busy last two years, and what's still in store for her.
The 2.0 HDi W-plate I got in March 2012 was cheap, mint, sports bumpers, only 64k on the clock, doing 40mpg no remap, low on insurance; who could ask for anything more?
There was a catch -- problems.. No wonder they sold her
She has been draining my pockets on suspension problems, top it up with two crashes on wet roads (yes, she's got the oomph and I haven't tamed the beast yet). I still managed to mod some bits (aiming for least money spent), so here it goes!
207's Monaco alloys with tyres from a friend at local garage (on a 206 looks like came off a truck :D)
The main problem was judder when braking, and when I finally found the cause and replaced the buckled wheel hub...
...crash! skidded into a Galaxy's ass..
Luckily, a friend quickly sourced needed bits from a phase 2:
Fun on the driveway:
I chose to stay with the old bumper with the horizontal grille: the hexagon ones look so out-of-place on a pug in my opinion -- read: front bumper strip has horizontal grille too ;P
Still lots and lots of bits waiting to be touched up/aligned/painted:
Got the silver bits quick-sprayed green...
...but ran into another unfortunate smack (again wet roads and myself an ole mucker driver, yet later found out that was a classic crash-for-cash trap using two cars -- always keep your distance fellows!! And only a fool breaks 2 second rule ):
Put myself to refurb as much as I could. PlastiDip spray the bumper before/afters:
I figured you can spray PlastiDip even on top of old layers of it (just sand off a little bit the scratches and the peels), and the new layer will cover it all up.
Headlight replaced and front bumper strip cable-tied:
The painter friend ran out of paint, so couple of layers of tuscany green are missing, as well as the clear coat - leaving those for next time
Couldn't wait to meet some of 206info fellows at FCS'13, and that also meant the car has to look pristine.
Bought 50 profile tyres, and decided to spend a weekend spraying remaining layers myself, with cans from Halfords. Lessons learned:
DO IT ONLY IF YOU HAVE:
I was "proud" only of the worst disaster - the tolerable under-bumper grille paint-do and the front bumper strip replacement from ebay matched KRU colour code just fine (not in the photo):
FCS was only 3 days away, so I decided to chip all in and the whole front respray got done by a professional (yes, he did it in less than 3 days, for £300, got myself waay out of pocket )
Months later the car became quite roadworthy, so next investment was £20 spoiler bargain. Though something was rattling inside it, and once I drilled it a bit open and spent half-hour jerking the bugger, a tooth-sized filler chip came out:
PlastiDipped (good stuff, as 4 months passed - not even one chip after daily trips on M4!)
I went for bumper looks (black plastic) as that's my chosen theme -- standard pug with budget kinks:
The spoiler chipped a couple of times at the beginning, I dabbed some tiger seal carefully, and it's now unnoticeable.
So here's how Jude looks currently (October 2013)
Cheers mates, rate it or slate it Last edited by Sim on Mon Jan 06, 2020 2:11 pm; edited 38 times in total
#2: Re: Sim's project budget Author: frenchfrog40, Location: MaidstonePosted: Sun Jan 19, 2014 1:43 pm ---- coming along nicely (may want to stop crashing it though) i remember seeing this at FCS. My car got abandoned in the 206info stand for the day as i spent all my time in the euro paddock with my mate and his saxo... this year im determined to stay with my car
#3: Re: Sim's project budget Author: Sim, Location: West CountryPosted: Sun Jan 19, 2014 1:52 pm ---- Cheers man, going crash-free now by keeping foot off the accelerator I remember your car as well good job! hope to boost mine for FCS'14
#4: Re: Sim's Project Budget Author: frenchfrog40, Location: MaidstonePosted: Sun Jan 19, 2014 2:17 pm ---- mines changed alot since last years. iv just updated pics in the garage section actually. sooooo much to do before FCS this year though!
#5: Re: Sim's Project Budget Author: hush1275, Location: newburyPosted: Sun Jan 19, 2014 2:53 pm ---- Looking good sim! Look forward to seeing it at FCS! I think we've all been busy with the pugs by the sounds of it haha
#6: Re: Sim's Project Budget Author: Sim, Location: West CountryPosted: Sun Jan 19, 2014 3:17 pm ---- Heya hush! Just seen your marmite vinyl wrapped, going great mate (finally :D), shame about the most precious GT bumpers bumped :/ keep us posted and looking forward to FCS!
#7: Re: Sim's Project Budget Author: hush1275, Location: newburyPosted: Mon Jan 20, 2014 2:01 am ---- Lol that wouldn't be my car bud, I've just painted and repaired it all. I have a massive amount of pictures etc to put into a build thread when I get the time ha.
#8: Re: Sim's Project Budget Author: Timon2210, Location: PalestinePosted: Mon Jan 20, 2014 11:24 am ---- Well that car looks great,but it seems that you drive a bit fast on the roads..lol,but the paint done by a prof. made the car looks great again,but since you got the plasti dip in black,I saw that the plastic roof rails need some of it
#9: Re: Sim's Project Budget Author: Andrew, Location: Black Country Ay IPosted: Mon Jan 20, 2014 12:10 pm ---- Hey Sim, I recognised this car as I started to read further on! Hope to see you at FCS 2014
#10: Re: Sim's Project Budget Author: Sim, Location: West CountryPosted: Mon Jan 20, 2014 12:39 pm ---- Thanks for the Plasti-tip Timon Awe car Andrew, hopes to see you around
I would love to tow this baby home for spares (subframe and nimrods would fly in first), but this labour I didn't plan so soon, short on money and space at the moment to SORN it in the garage (but probably could prep something up..)
What could you fellows advise?.. BTW I could ask a mate to tow a SORNed car down on M5 (with metal bar probably, better no ropes hehe..) - is that legal?
Unsure if this car is taxed/MOTd/SORNed yet (waiting for answer from deebee), but if it's all roadworthy could take out insurance for one day..
Are there 2.0s being broken frequently you reckon? I might want to wait for a phase two multiplexed one..
#11: Re: Sim's Project Budget Author: Mada, Location: Manchester/ AberdeenPosted: Mon Jan 20, 2014 1:27 pm ---- on ebay there will always be one getting broken, but ill say that price is very good
#12: Re: Sim's Project Budget Author: DSWR, Location: SolihullPosted: Mon Jan 20, 2014 5:28 pm ---- top effort on the crash repair:) paint work looks spot on!
#13: Re: Sim's Project Budget Author: astra_aurelis, Location: NorwichPosted: Thu Jan 23, 2014 6:36 pm ---- I love the colour!! Looks great
#14: Re: Sim's Project Budget Author: Sim, Location: West CountryPosted: Wed Apr 30, 2014 7:37 pm ---- And they arrived!
Who spotted that something's wrong gets a pint
So, afterwards they sent me the missing odd one, now I got a spare
Hello babes!
And this is how old cheap ones used to get knackered :
It's driving mint now, no more pulling to the side!!! Last edited by Sim on Mon Jan 06, 2020 2:15 pm; edited 1 time in total
#15: Re: Sim's Project Budget Author: Sim, Location: West CountryPosted: Mon Sep 22, 2014 7:42 pm ---- Hey a colour-coded mate just found and contacted me about what to do on his car, time to update the thread:))
Doing the car up just before FCS was pleasantly hectic, staying up late, getting up early, also: never paint car parts-by-part, or it will not blend in! In progress of swapping a painted door to see it won't match colour;) Good it happened a week before FCS!
Also took Timon's advice and PlastiDipped roof rails a bit with blending gradually half-way. Also rear spoiler needed another layer to refurb:
Even FCS Saturday in the morning the car wasn't yet ready as I wanted, but with help of Andrew and Adam we finally set off, t'was an awesome day, thanks everybud!!
Here are some after-wash pix. Those are crystals oli_aspinall, everything else I keep phase 1. Why? Just because I can ('t afford otherwise ) :
And some natural bits, loving the green On a roadtrip across Dorset:
Last edited by Sim on Mon Jan 06, 2020 2:17 pm; edited 2 times in total
#16: Re: Jude: Sim's "Rust Away" (aka Project Budget) Author: Sim, Location: West CountryPosted: Wed May 06, 2015 10:11 am ---- Alright! Time to put this thread back together. Some catching up:
November 2014:
Finally swapped 207 15" Monacos with Andrew's 16" gunmetal grey Nimrods
Plan to refurb and repaint them same silver colour as Monacos
January 2015:
MOT is sneaking up, time to aling the headlights as youtube instructed:
Fit some nearly new pads I salvaged years ago
Had an unfortunate buckled wheel hub back then, which kept on warping nearside brake disks. It cost me a couple of pads'n'disks replacements until I found the root problem. Had a gut feeling to keep these pads, and voila!
Made sure to copper grease metal2metal touching parts, and never heard a squeek from them! (previous pairs squealed like a pig..)
Had just a day to replace pads before the MOT re-check! Working in cold...
...asks for retreat to the garage with a heater. What purpose are such tiny garages built for? To fit a Mini?
April 2015:
Project "Rust Away" in motion (yes, you can read it in two ways ), some before/afters:
Was mainly testing Dinitrol underseal kit, will need to attend more corners in the boot where an ex owner drilled through for their sub
Jacking sill repair (warning: never let your friends jack up your pug. Some of them simply may not know where jackpoints are, some of them who prefer another car maker, might do it on purpose to falsely show how fragile your car is and make you jump ships ):
Applying Dinitrol undersealer kit on the jacking sill was a risky thought, but even after careful jacking up on rubber hockey puck, the scratched marks heal themselves - the power of Dinitrol!
Lots of work ahead:
This one poses most worries, will attend it with pressure washer ASAP to see how bad it really is:
Cured a patch underneath, we'll see how it behaves once exposed to the elements (UPDATE: months later some rust did come back through, will need more thorough treatment):
One blanking cap was a dud, so I dabbed it into a blob of tiger seal, it will do for now
If it s(h)its it fits The yellow foil was from an easter egg that I dabbed tiger seal on. Got glued so I stuck with it (will try not to cross border where they inspect under your car with an angled mirror :D)
So little time to FCS yet so many things to iron out; can't wait! Last edited by Sim on Tue Mar 20, 2018 7:59 pm; edited 4 times in total
#17: Re: Sim's "Rust Away" (aka Project Budget) Author: PezHdi, Location: ShrewsburyPosted: Wed May 06, 2015 6:07 pm ---- If leave the wheels that colour mate they set of that paint off lovely just needs lowering a little
#18: Re: Sim's "Rust Away" (aka Project Budget) Author: Sim, Location: West CountryPosted: Thu May 07, 2015 8:17 am ----
PezHdi wrote:
If leave the wheels that colour mate they set of that paint off lovely just needs lowering a little
Yo bro, good to hear from you! Yes she needs lowering, but I want to get it right rather than get it done
I know it's far from MattyP's lush'lloys but I do miss the shiny Monacos: to my mind they went along with headlights and side indicator (see my avatar pic). I won't tint/change them headlights, as the goal is to keep it OEM clean.
After some photo editing, rate it or slate it
Last edited by Sim on Wed Jun 22, 2016 10:10 pm; edited 1 time in total
#19: Re: Sim's "Rust Away" (aka Project Budget) Author: Sim, Location: West CountryPosted: Mon May 11, 2015 8:53 am ---- Came up with completely new idea about alloys. Will see how it pans out.
Thought about pressed plates, but all of them have that ugly coachline, whereas this project is going for the clean looks.
The old ones've become somewhat opposite of clean...
Last edited by Sim on Sat Mar 17, 2018 3:13 pm; edited 1 time in total
#20: Re: Jude: Sim's "Rust Away" (aka Project Budget) Author: Sim, Location: West CountryPosted: Wed May 20, 2015 7:34 am ---- Stage 1 is in!! Boy she's nippy now Also looking forward when MPG results jump in
Billions of thanks @pro_steve !!
#21: Re: Jude: Sim's "Rust Away" (aka Project Budget) Author: Sim, Location: West CountryPosted: Thu May 28, 2015 1:47 pm ---- Gutted that will have to give FCS a miss this year, but all that work on the car pays off nevertheless to soothe the soul and comfort
Wired a permanent iPod/MP3 adapter from an old stock cassette player over bank holiday, read howto here:
PlastiDipped the wiper cover trim and gave a good polish+wax:
Can't wait for conclusive MPG results coming in in couple of weeks after stage 1 remap, she already feels less thirsty! If I can resist the boost fever that is Last edited by Sim on Sat Mar 17, 2018 3:36 pm; edited 1 time in total
#22: Re: Jude: Sim's 2.0 HDi "Rust Away" (aka Project Budget) Author: Sim, Location: West CountryPosted: Sun Jun 21, 2015 5:44 pm ---- News are in: +3.5 MPG after stage1 remap \o/ !!
Had an awe Saturday meetup with pezhdi and Andrew, here's the story
Wirebrush drill bit, flappy sandpaper drill bit, less elbow grease
Cheapest (500ml for ~£8) black paint Hammerite type turned out to be grey but I like it!
Old aerial base was seized up everywhere, sourced new one and a stubby - fleabay might sell you both for ~£17 (or ring up pug dealer)
Now reception is crap will go for A-pillar aerial; so this will stop scrubbing the spoiler and only for looks if you can't be asked to smoothen out the two holes
Running water eaten off paint and more over the years around top mount tower:
Got liking of spraying Dinitrol combo everywhere:
Finished with Tiger Seal and Dinitrol Underseal, will also clear coat for dust not to stick.
Road illegal haha
Double-sided tape with slant for water run-off and extra thick on the top ends as boot has a slant -- holds to date
Happy with that
Won't replace front numberplate just yet, first have to deal with bumper having reacted with old paint (bad prep) and bubbled out under fogs
Bumper do
PlastiDip off
Primed (450ml £15) - decided on the day, used what's around. Using black primer is better (and cheaper)
Sanded
1st coat (400ml £6.74 satin black paint from B&Qs if you paint last minute, otherwise order from ebay cheap ones)
4th coat
Happy with that (used up 1.5 cans), could do with more sanding after each paint layer, but was in a hurry (last coat at 1am before meeting pezhdi and Andrew :DD), looks rough around the edges (literally too) but will try to polish see what happens
Peace out! Next up - pugfest and lowering
Damp adjustable at the rear as well!!! Was in 7th heaven when found that out gotta love tinkering! Last edited by Sim on Tue Mar 20, 2018 7:13 pm; edited 2 times in total
#23: Re: Jude: Sim's 2.0 HDi "Rust Away" (aka Project Budget) Author: Sim, Location: West CountryPosted: Mon Jul 06, 2015 4:56 am ---- Short update, applied underseal and fitted pezhdi's rear AVOs shocks - amazing how she sits now! More experiments with damping to follow, will report here
Whole week wasted (but what an experience!) in trying to knock out dead-seized torsions bars, short story in the talk forum, will follow-up long story here later on.
Project "rear lowering":
Was well happy when torsion bar torx bits just pop-twisted and didn't null the star at all!
But that was just a beginning of nightmare on Elm road. Got slide hammer, mounted as much mass on it as possible, bars were still stiff:
Tried to leverage out - nada:
Try to torch it out - nothing:
If you try this at home, at least cover brake lines with soaking wet towel
Mate calls me a hoarder, because I keep all sorts crap in the garage.. Well back at you mate! This random 307 tank aluminium lightning shield has come finally handy!
Nope, not even skin of teeth it moved (also watch out for brakelines better next time!)
Last resort of extraction bracket and 10.2 strength bolts - they gave up either (even when I was sledgehammering from another end, after torching for 5minutes. BTW did I mention that this flipping torsion bar thing was soaking in plus gas for the whole week and didn't make its hole weak!?):
The verdict speaks for itself, gave up on this granny axle; a recon on is in in plans now (one good thing - at least will be able to do conversion to disk brakes as well):
July 2015
"Rust away" in action.
Sequence:
User pressure washer to get dirt and loose rust off
Wait to dry, then use steam cleaner to get more rust off
Use wire brush to wipe out yet still dangling loose ruse (don't brush too hard or you'll just press it into the metal)
Sand it, i used flappy sandpaper wheel drill bits, wear face mask
Air blow rust dust out (no need to make everything wet again, especially on exposed bare metal)
Put Dinitrol rust converter, all remaining rust in crevices turns then black inert iron
Spray cavity wax everywhere (it has more of that convertor, and stick everywhere)
Finish with undersealant - that one never cures hard and will keep painting your face everytime you're under the car, but worth it, as it's self-curing from the chip damage
Not super happy with initial rust removal, many places I could have done with extra elbow grease, and did a bit hastily as pugfest was climbing on my nose:
(See "before" photos in previous post)
But I leave for Dinitrol RC900 to finish the job:
Undersealed with cavity wax and black spray, some runs, but this can be adjusted, as it never cures to hard anyway
Shiny Pez's AVOs
Happy for now, let's see if/when rust comes back through
After feeling how awesome stiffer shocks are at the back, can't wait to fit AVO coillies at the front too. Gutting commenced:
How to take the shock out from the strut without popping ball joint
(DISCLAIMER: NOT THE SAFEST WAY OF DOING THINGS!)
This might involve removal of front wing for better access for securing the process with spring clamps, so better do that when you have other things lined up for your car too.
Especially polybushes make it much harder to lever the wishbone out, so I try to avoid splitting balljoints as much as possible, also the following method is done with only one pair of hands:
Do the usual (undo droplink, then pinch bolt, pry it with screwdriver, spray some WD in rinse repeat etc like in this HOW-TO)
Then jack the springs up by using a bar of proper length (my breaker bar was too long, so I raised by brake disk first with another jack)
Secure breaker bar with with rubber pads and raise as high as it goes (look for it not to slide out, and use crease in the spring bottom mount plate):
Once spring is really compressed, you'll find a gap to push spring compressor clamp through, for extra security (you won't need to screw the top of it which is inaccessible anyway, just mildly fasten by turning the threaded pole):
The lower arm should now be parallel to the ground. Then keep hammering the strut (metal block behind brake disk). I used a long bar from the top and hammered its end, so I don't have to stand in front of wheel arch in case breaker bar pops flying out (hence the unsafe approach, a proper vertical hydraulic jack would be better, still not perfect)
The weight of strut, hub, caliper, and disk will help you and youll see them sliding down with each hammering (if you WDed it all properly). I think my ones never been prodded, so 15yearold shocks looking well and sliding down like through butter!
Eventually it will all pop out (even when you think there's still some hammering left!), it should pivot its way to the front of the car
The top mount bearings will tilt out of their rubber sockets, but no damage whatsoever
If something has not been secured well, this final popping might end up with breaker bar shooting across the yard, so use at your own risk or get a vertical hydraulic jack! Use always a spring clamp as in the photo!
If your breaker bar was too long for the job like mine (however that saved a jack of going too high and hitting CV gaiter during the process), jack by brake disk again to liberate the breakerbar
Once pressure is gone, you'll then undo the top mounts and free the shocks+springs.
Surprisingly amazingly the 15yo strut bearings are still intact! And move about smoothly-ish (especially after extra WD, even if they got some rust in during this whole prying game). It's just that they are seized into the top plate, so I picked new bearings today from pug's ~£19 each way worth it
After hosing down:
Now onto rust-treating the turret, and many other do-ups this weekend!
#25: Re: Jude: Sim's 2.0 HDi "Rust Away" (aka Project Budget) Author: David1156, Location: East LondonPosted: Sat Jul 25, 2015 5:03 am ---- Looking good so far! How long did the rust removal take you? Nimrods suit the car much better and the colour is much better than the standard silver. Have you got any cosmetic changes planned?
If I have time and want to do as proper as possible, it takes couple of hours to prep and remove rust for e.g. a wheel arch. Spraying itself is very quick, but would result in crap if not prepped well/masked beforehand, just like painting
Still pondering over nimrods colour, I like either colour lol, BTW looking at our forum's top banner of green pugs:
Cosmetics not planned atm this will be more of a sleeper and OEM clean; yet after having first professional valetting service I bought genuine lamb's wool mit and grit guards for washing buckets haha, so cosmetically it shall always shine
But will respray the rear spoiler either colour code or satin black just like I did to the front bumper, because PlastiDip attracts all sorts of fluff and doesn't come off without a tape
Big update coming soon Last edited by Sim on Thu Oct 22, 2015 8:55 am; edited 1 time in total
#27: Re: Jude: Sim's 2.0 HDi "Rust Away" (aka Project Budget) Author: Addaz, Location: SuffolkPosted: Sun Jul 26, 2015 5:33 am ---- Absolutely awesome to see another w reg looking so clean and looked after!
I timed, the dirtiest part to de-rust the front wheelarch with sandpaper drillbit took me an hour, but the whole prep and post spraying earns at least an hour each, so 3-4 hours for a wheel arch.
I'm fussy, picky, and novice, so for me I think with tea breaks it was 5-6 hours (things like taking all tools away and closing garage door and shielding body work from the rust dust havoc that starts. Last edited by Sim on Wed Jul 29, 2015 7:49 am; edited 1 time in total
Absolutely awesome to see another w reg looking so clean and looked after!
Cheers Addaz!
I see Lucy is also W! How is she coming back together?
We name them pugs after girls names from Beatles songs Had one Lucy too, then Penny, and all started with Michelle (N-plate 306) because she's French
Been working on the car daily now, like nuts and not only, will post pics when catch up with breath
#30: Re: Jude: Sim's 2.0 HDi "Rust Away" (aka Project Budget) Author: Sim, Location: West CountryPosted: Wed Oct 21, 2015 6:18 pm ---- Update in need indeed!
July 2015
Paid a detailer for pugfest:
Since shocks were out, was time to rust away under the arches (they'd take 6-8 hours for a scrupulous do and this given amount of rust)
Appalling view:
Sanded:
Rust converted:
Cavity waxed:
Undersealed:
Same for another side:
Rust likes this bit under headlight surround, treat it well:
Too much cavity wax caused runs (not mine):
Used leaf blower to ripple the runs instead:
Dinitrol underseal spray smoothened it all nicely thereafter, also now with Pez's coilies fitted:
Just before the moment of truth
Happy with the result
Since the front was taken apart, took a chance in attempting to sort out PAS pipes (who cares if it rains, when garden umbrella fits the towbar like a fiddle )
Ran out of time to replace the bent headlight surrounds, so put the old headlights back, meaning I had to again cable-tie the driver's side one, but looks like I'm getting better at this, should ask for a bumper sticker from Shadowstalke "Certified cable-tie specialist" Also very happy with aligning the bonnet and wings even more flush than before (considering car's accidental past ):
Followed tips online about proper carwashing, got £1 buckets from B&Q, gritguard and natural lamb's wool mitt to avoid more swirls on a dark coloured car like this:
Here's how she looked washed waxed
Dropped at the front by some ~45mm and then straight off to Lee at FCM Wheel Alignment, best specialist in Bristol:
August 2015
Visited Andrew en route my usual travels
Looks minter and minter mate Can't wait till you turbo her altogether!
Mate brought a flag he kept at home collecting dust from his former workplace (where it was actually binned!!), a real deal to have the 2000s Peugeot lion logo! Will be great to stretch out at the farm workshop we're currently just building up
September 2015
Who said that a 206 can't fit a mean Audi? Saving a fellow after some bad driving by sourcing spares from scrappy..
My latest purchase, didn't think twice, and couldn't be happier! But that's a whole new page if not a book, will start a separate build thread for this thrilling GTi 180, the name suggests itself to be "Blue Jay Way"
Further plans for Jude will be to replace rear axle into drums and lower it, as current torsion bars wouldn't budge at all. Also sealing PAS low-pressure hose would be nice, so I stop driving with a rug strapped around the leak-point I think I'll ultimately need ear hose clamps, just what it was there originally.
But since she has valid MOT, tax, and insurance, I'll be working on the Blue Jay instead, which has none of the above, and needs few things sorted before becoming ship shape again, yet that's a new story stay tuned! Last edited by Sim on Tue Mar 20, 2018 9:21 pm; edited 2 times in total
#31: Re: Hey Jude: Sim's 2.0 HDi "Rust Away" Author: Sim, Location: West CountryPosted: Sun Nov 29, 2015 10:48 am ---- Why hello there!
#32: Re: Hey Jude: Sim's 2.0 HDi "Rust Away" Author: Addaz, Location: SuffolkPosted: Sun Nov 29, 2015 2:56 pm ---- 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
#33: Re: Hey Jude: Sim's 2.0 HDi "Rust Away" Author: Sim, Location: West CountryPosted: Tue Dec 01, 2015 3:14 pm ---- 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)
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!
#34: Re: Hey Jude: Sim's 2.0 HDi "Rust Away" Author: Shadowstalke, Location: GloucestershirePosted: Wed Feb 17, 2016 5:23 pm ---- ^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
#35: Re: Hey Jude: Sim's 2.0 HDi "Rust Away" Author: Sim, Location: West CountryPosted: Wed Feb 17, 2016 6:20 pm ---- 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)
#36: Re: Hey Jude: Sim's 2.0 HDi "Rust Away" Author: Shadowstalke, Location: GloucestershirePosted: Fri Feb 19, 2016 6:00 pm ---- 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!
Three happy-new-years later Jude's back and is badder than ever
#38: Re: Hey Jude: Sim's 2.0 HDi "Rust Away" Author: PezHdi, Location: ShrewsburyPosted: Tue Jan 02, 2018 7:53 am ----
#39: Re: Hey Jude: Sim's 2.0 HDi "Rust Away" Author: Edward, Location: In the garagePosted: Tue Jan 02, 2018 7:15 pm ---- Looks like a good little project. Car is looking good.
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
#41: Re: Hey Jude: Sim's 2.0 HDi "Rust Away" Author: Sim, Location: West CountryPosted: Tue May 01, 2018 11:14 am ----
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)
#42: Re: Hey Jude: Sim's 2.0 HDi "Rust Away" Author: Sim, Location: West CountryPosted: Fri May 11, 2018 7:21 pm ---- 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
#43: Re: Hey Jude: Sim's 2.0 HDi "Rust Away" Author: VorTechS, Location: Gloucestershire, UKPosted: Mon May 14, 2018 6:43 am ---- 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!
#44: Re: Hey Jude: Sim's 2.0 HDi "Rust Away" Author: Sim, Location: West CountryPosted: Mon May 14, 2018 11:13 am ---- 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
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!
#46: Re: Hey Jude: Sim's 2.0 HDi "Rust Away" Author: Sim, Location: West CountryPosted: Sat Jul 14, 2018 9:34 pm ---- Back in April the AVO coilovers had to go, and original shocks back in. The rear axle arrived pre-lowered by 40mm, so Eibach's closest sensible option was 30mm drop at the front:
After ditching coilovers, the ride became nice and comfy, and down to earth It however started begging to put back the ARB, what I did in time for the Pugfest hillclimb.
Following the one-change-at-a-time approach on this daily driver, shocks will also need an upgrade, read on.
Pugfest on approach demanded a tidyup in the detailing department; have to say lemon scented IronX doesn't take your breath away, this sadly meant I couldn't annoy the spectators with the smell of pure rotten eggs! But it does leave a smooth finish and barely needs a claybar after such decontamination!
VorTechS taught how to properly wax-on-wax-off (that karate kid!), so I haven't got round to using the polish itself yet. Poorboy's Paste Wax had actually concealed most of them ugly swirls!
Midchem Speciality's snow foam does the job well, and is cheap as chips when buying 25litres
Last-day-before-Pugfest decided to replace the 2-month-old top mount bearing as it started rattling, only to find out it was the shock that's making the noise when steering the wheels (very misleading!) It will be time for a new pair later this summer, I'm thinking AVOs or Spaxs, as I can't find evidence that Bilstein make damp/rebound-adjustable shock absorbers for the 206.
Last minute sanding and respray of the spoiler that I'd PlastiDipped 5 years ago, and the scuffs had become very unsightly. This time I've used grey primer and satin black rattle cans just like for the front bumper moulding years ago
Finally fitted FK automotive smoked non-LED lights that I bought years ago from a member on here for next to nothing (one of them was cracked). Then ordered another set brand new from Germany (at a nice discount), which arrived in a damaged parcel last year, never bothered/had time to follow that up, because only one of them got smashed in transit and, luckily, the other side one! So one from each lot, went nicely in
And that's how they rolled out to the Pugfest!
#47: Re: Hey Jude: Sim's 2.0 HDi "Rust Away" Author: Sim, Location: West CountryPosted: Mon Jan 06, 2020 2:18 pm ---- In autumn 2019 pulled Jude out of misery by washing away autumn leaves (of 2018), and started inspecting where the dreaded engine knock is coming from. Would this be the demise of the HDi?
And as always, rummaging through the forums I found gazza's reply about red dust prevalent near the crank pulley (aka harmonic balancer).
Sump had a good deposit of such dust, yet not only near the pulley: the insides of each of the front alloys were covered in such dust, which was clearly from the brakes.
The knock was heard from the drive belt side of the engine when on ground, but actually was louder near the flywheel when listening with the car up in the air (suppose it resonates throughout the crankshaft)...
Inconclusive yet I went ahead and replaced the balancer nevertheless (Corteco brand £57 from fleabay)
And whaddayaknow the knock was gone! So an indirect thanks to gazza82 for the pointer
This meant the pug coult still become a winter banger of 2019! Yet all of a sudden I was overwhelmed by an irresistible urge to de-wiper the front
(more on this later)
Discovered a nasty rip of the inner CV joint boot (near the clip), that had already made some mess while my mate was driving it back in 2018.
Out with the old, in with the new (GSP brand; Qdrive ones from ECP/GSF have given me grief, and there's nothing else left to try but GSP -- still no issues at the time of writing Jan '20)
The olde one being put away for a rebuild in the unforeseeable future.
Another worry that the car developed was a big pulsing from the brakes during hard braking. This time it was felt also at the slow speeds (for "medical history", see first post), so I didn't suspect the hubs, just discs warped.
Fans of the clean looks should certainly take interest in coated discs, as they still haven't developed any rust to-date! Hope these Bendices won't bend
(another good thing: they arrive not soaked in any oils:)
De-wipering the front was just in prep for a windshield replacement (in case you were wondering), because someway somehow the screen had cracked (from inside!?) overnight, while my mate had the car... Why nothing goes wrong when I drive (well, other things do)
Decided to go with a grey top-tint to match the overall spirit of the car
Treated immediately with the Gtechniq kit, will see how that fares
Was happy to find a spare set of wheels kicking about that I hadn't binned, they are the legendary 207's Monacos. Sourced also a shiny replacement one in addition
It was refurbed and I worried about the colour match as it looked truly sparkly, but as soon as it gotten covered with dust, looked just like the old ones
You'll notice why I bought a spare by closely looking at one of the old ones:
Shoed with Nexen Winguards, had zero issues, still waiting for that snow though
(please excuse the choice of alloys, the gunmetal Gray nimrods (from Andrew!) are housing the summer tyres)
Ever so chuffed to say it everytime: Jude is back, and is again badder than ever!
#48: Re: Hey Jude: Sim's 2.0 HDi "Rust Away" Author: gazza82, Location: South BucksPosted: Mon Jan 06, 2020 3:47 pm ---- Glad I could be an indirect help ...
It was very obvious when I'd taken the crank pulley/damper off ...
#49: Re: Hey Jude: Sim's 2.0 HDi "Rust Away" Author: Sim, Location: West CountryPosted: Mon Jul 27, 2020 12:57 pm ---- That fine dust had really manifested itself before I fixed it again this time on the 1.4 HDi that had that distinct knock
Back to this project, it hasn't skipped a beat as a winter beater, and then as this lockdown beater, that I rewarded the car with paint decontamination and claybar treatment last week:
As well as fitted the ancient birthday present Garmin HUD that I now use for speedo (thanks Garmin for killing its app, so the only way I can still use it is by using my olden Nexus 4 and hope it won't pack up anytime soon).
#50: Re: Hey Jude: Sim's 2.0 HDi "Rust Away" Author: ekjdm14, Location: CheshirePosted: Mon Jul 27, 2020 6:38 pm ---- Surprising how scary-sounding that balancer pulley can be isn't it! The 1.4HDi parts car we had also had a bad pulley, I'd have sworn blind it'd run a bearing if it wasn't for the fact that the noise stopped if I took the aux. belt off!
#51: Re: Hey Jude: Sim's 2.0 HDi "Rust Away" Author: VorTechS, Location: Gloucestershire, UKPosted: Wed Jul 29, 2020 7:28 am ---- She's looking good! Will have to have a post-lockdown meetup, now that we are finally allowed out of the house!
She's looking good! Will have to have a post-lockdown meetup, now that we are finally allowed out of the house!
A meet is defo in order, but first -- off to Cornwall!
Notice bigger aerial, "kindly donated" by the resting 180, and the pre-mux radio finally packed up, so ripped out a muxed one from the 1.4 HDi (has own screen, so works!), even threw in Connects2 AUX bit from the CC that works too!..
"When all cars come together"
#53: Re: Hey Jude: Sim's 2.0 HDi "Rust Away" Author: Edward, Location: In the garagePosted: Sat Apr 03, 2021 6:41 pm ---- Just noticed your replacement driveshaft. Was it not a lot thinner than the original shaft? I got one once but decided to fit a genuine Peugeot shaft which matched the original.
#54: Re: Hey Jude: Sim's 2.0 HDi "Rust Away" Author: Sim, Location: West CountryPosted: Fri Apr 09, 2021 10:48 am ---- Well spotted, but the 2nd joint looks more massive, most likely compensating for the weight difference. I wonder what gave first, gearbox or driveshaft with such a thin axle:)
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