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Cazzo

[rally_prep] 205 1600 8v Hill Sprint Rally

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Cazzo

.

 

Hi all,

 

 

Been poping in and out of the site for a while now as its the 1st place I head to on fact finding missions :ph34r:

 

 

I had a 1600 8v back in 95-97 and still remember the fun I had in it.

So when a mate wanted to start some sort of motorsport a Pug was top of the list.

 

We decided that Hills & Sprint would be a god place to start as we could both drive the car and costs would be a lot less than rallying.

 

 

The wee car below was bought in 05 as a 1900 8v and we gave it a bit of a tidy up and replaced all the suspension/brakes.

We ran the car for 3 years (06-08) and fixed things as they broke lol, this is the main reasion for the 09 rebuild.

 

 

The car as we got it

Ext-95.jpg

 

Ext-93.jpg

 

 

 

 

Then after the tidy up + new brakes susp

 

Ext-12.jpg

 

Ext-2.jpg

 

 

 

 

There is more pics in the link below of the tidy up and I will upload more pics from the 09 rebuild as

I go

 

http://s298.photobucket.com/albums/mm280/G.../Pug/?start=all

 

 

 

 

Over the 09 winter it's getting a rebuild and a 1600 8v droped in, due to changing class.

 

The spec below is as the car sits now, all this has been done over the last 2 years, only the engine and box have been done in the past few weeks.

 

Shell

 

Omp Cage

Plated Sunroof

Striped Interior

Battery In Boot

Plumbed In Extinguisher

Areoquip Fuel/Brake Lines Incar

Cobra Monaco Seats

Trs Belts

Battery Cut-Off

 

 

Suspension Brakes

 

Bilstein Struts

Eibach Springs

309 Bottom Arms

WMMS Rebuilt Rear Beam Solid Mounts

Upper Strut Brace

Lower Strut Brace

Tarox G88 Discs

Mintex 1144 Pads

 

 

 

Engine GearBox

 

Rebuilt Std 1600 8v

K&N

WMMS Down Pipe

WMMS Single Pipe System GP N

Rebuilt BE1

Quaife Diff 4.4 CWP

 

 

 

Wheels & Tyres

 

15" 1900 Rims Yoko A048's White

15" 1900 Rims Toyo R888's Bronze

14" 1600 Rims Road Tyres

14" Steel Rims Gravel Tyres

 

 

 

Thanks for looking more to upload as the winter 09 rebuild gets under way.

 

 

 

.

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Cazzo

.

 

 

Over the last few weeks I have got the engine and box back so started to pull the old 1900 out.

 

When the engine and box was out I striped the suspension, subframe and a few other bits off the car so I could paint the engine bay.

 

The bulkhead, inner wings and top of chassis legs were spray painted.

 

I also painted the back of the wings and up under the arches, these where just brush painted as it gives more protection.

 

 

Then I set about the wiring, the loom had been in a mess just a ball of wires !!

 

Pics below show how far I have got to date.

 

 

post-12754-1258830277_thumb.jpg

 

 

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post-12754-1258831643_thumb.jpg

 

 

 

 

 

 

 

More pics of the wiring up soon

 

 

 

 

.

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Cazzo

.

 

 

Some pics of the wiring loom and engine bay before the engine and box goes back in.

 

 

The loom was striped cleaned and new connections fitted.

 

 

All the bits in the bay were new or cleaned and painted.

 

 

02112009897.jpg

 

 

02112009898.jpg

 

 

02112009899.jpg

 

 

02112009900.jpg

 

 

.

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Cazzo

.

 

07112009906.jpg

 

 

07112009907.jpg

 

 

07112009908.jpg

 

 

07112009909.jpg

 

 

 

 

 

The main engine loom is done and ready to go in with the engine.

 

When the engine box suspension are in then I'll start on the body work and interior.

 

There is a new bonnet to be painted and then both sides need a few repairs so I will end up painting both sides of the car

 

 

 

.

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Baz

Nice project, keep the updates coming. :blink:

 

What's the class structuring for your events? As i guess being stripped out, caged and running sticky tyres put you into the upper Modified classes?

 

Our class breaks are also upto 1400, then 1400 to 2litre, so i guess as you're sticking to 1600 yours are still old money? As they should've stayed IMO!

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Galifrey

Looking like a nice tidy project. Shell looks to be in very good order!

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Cazzo
Nice project, keep the updates coming. :lol:

 

What's the class structuring for your events? As i guess being stripped out, caged and running sticky tyres put you into the upper Modified classes?

 

Our class breaks are also upto 1400, then 1400 to 2litre, so i guess as you're sticking to 1600 yours are still old money? As they should've stayed IMO!

 

 

 

We'll be running in Class 6 Roadgoing Production Cars up to 1700cc

 

Last few years we were in Class 7 Roadgoing Production Cars over 1700cc

 

The down side of running Class 7 was that we were in with Impreza's, V8 Rover, V6 Renault and other cars with big cc's 4wd Turbos etc.

 

As the 205 never came with a Mi16 we could not use that engine, Roadgoing Production Cars must run with the std block, head and box, no fiberglass panels or plastic windows, everything else is free.

 

I think next year the 4wd turbo cars are in a class of there own, but we had started on the 1600 engine for class 6 before I found out about the changes, as of yet nothing has been confirmed.

 

Class 6 is full of fwd hot hatches so the 205 should fit in well

 

 

 

.

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Cazzo

.

 

 

Not a big lot to update as I have been flat out at work.

 

 

Just spent a few hours on Saturday and cleaned all the engine bits that were not replaced,

 

After cleaning they got a coat of paint just to tidy them up ......... ( adds 0.5bhp ) :blush:

 

 

 

All the bits + Rebuilt Engine and Box

 

 

08122009912.jpg

 

 

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Not be long before they fill with oil again ;)

 

Just need to get the clutch back and then she's ready to go back together

 

.

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Cazzo

.

 

 

Got a fair wee bit done today

 

 

Clutch in, Box and Engine bolted together

 

 

Droped it into the bay and started connecting things up

 

 

 

12122009924.jpg

 

 

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Off work for 2 weeks over crimbo so should get this part finished

 

And then make a start on the bodywork

 

 

.

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madspikes

Looking good.

 

Like the rocker cover, very OE. :ph34r:

 

Mad.

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Cazzo

.

 

 

Just keeping it real brother,

 

I think the oil stains on the sump look better :)

 

 

ps I have another rocker cover and sump to go on it

 

.

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opticaltrigger

Looks real good.Very clean looking car.Be good to meet up and see it in the flesh at some of the new seasons hillclimbs.

Keep those updates coming.

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Cazzo

.

 

I have been waiting on a few bits from the local motorfactors so have not been doing much to the engine,

 

With the time I had on Sunday and Monday I thought I would redo the wheels

 

 

The face of the wheel is a bronze colour with a silver lip

 

 

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The back of the wheel is silver

 

 

 

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22122009943.jpg

 

 

 

 

22122009951.jpg

 

 

 

 

.

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SimonJ

Hi Colin,

 

Congrats on a lovely job, think I need to get the garage cleared out and get some work done! Seriously, really inspiring. Hope the engine worked OK for you, you haven't got it started up yet? Who did the rebuild for you or did you do it yourself?

Fairly grumpy at the moment about (well there's usually something) the lack of regs for next year. Potentially have to source back seats, a heater, glovebox and so on and not sure whether to get a steel or fibreglass bonnet to replace my knackered one.

 

Simon

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Cazzo

.

 

 

Cheers Simon,

 

 

That wee engine was spot on, I gave it to a fella in ards to do the work.

He cracked it open and said that all the main bits were in good nick !!

 

I hope to get it up and running over crimbo, and get a few runs at Nutts Corner for testing ........... myself not the car lol

 

There is still no news on the regs for next year, I had heard about full interior and a few other changes for the Roadgoing class 6 & 7,

but my wee car is staying the same untill I hear for sure about any changes,

 

I will just turn up for the 1st event (sprint) and let them tell me what class I'm in, then register for the hills in that class lol

 

Just thinking...... None of the Roadgoing cars from last year would fit in with the new regs, so everyone will have to make changes

or Class 6 & 7 would have no entrys, we would all be in Class 4 & 5 with the Rally men and that may not go down too well.

 

 

I must give Conor a bell and see what the plans are for next year, I'll let you know if I here anything.

 

 

 

Colin

 

 

 

.

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Cazzo

.

 

 

Not much of an update,

 

 

Some bits from Peugeot have arrived today, so I will have a few things to do this weekend,

 

Also have the steering rack to change over, a bit of pipe work and front suspension to refit,

 

 

 

 

 

 

07012010986.jpg

 

 

 

All the switches, sensors, few gaskets, thermostat, oil filler bottle and exhaust manifold fitting kit,

 

 

 

 

 

 

 

And took a gamble on the ignition module being a " Bosch " item, it says bosch but i'm not so sure,

 

 

07012010978.jpg

 

 

07012010980.jpg

 

 

I was hoping for the older style bigger blue type :unsure:

 

 

 

 

 

 

.

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Cazzo

.

 

 

After a bit of a break, I got out into the garage tonight and got a wee bit done,

 

Most bits are fitted to the engine and all wired up/plumbed in

 

Getting closer to starting her up,

 

Some random pics

 

 

 

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And the new wheels all sodablasted and ready for painting

 

 

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24012010995.jpg

 

 

24012010997.jpg

 

 

 

.

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cybernck

Really nice build, I'm loving the 8v setup :P.

 

Your new ignition amp should be fine (it's MTR01), providing you've got the 7-pin connector :).

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Cazzo
Really nice build, I'm loving the 8v setup :D.

 

Your new ignition amp should be fine (it's MTR01), providing you've got the 7-pin connector :).

 

 

Cheers,

 

Its slowly getting there,

 

I'm just trying to stay as close to standard as possible so I can run in the road class,

and hoping for reliability (lol)

 

Hills&Sprints are just a bit of crack at the weekend, somewhere to push it on a bit

without the boys in blue wanting a wee chat :rolleyes:

 

I have the 7-pin connector so the ignition amp fitted spot on, I was just worried as I here that some give a misfire under load,

Looks like I picked the right one :)

 

.

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EdCherry

Its normally the cheap, or second hand replacements people have trouble with. You'll be glad you went for a new bosch!

 

Looking nice, cant wait to see it in its finished glory

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Cazzo
Its normally the cheap, or second hand replacements people have trouble with. You'll be glad you went for a new bosch!

 

Looking nice, cant wait to see it in its finished glory

 

 

Cheers,

 

Cant wait to see it finished myself, there is still a bit of cosmetic bodywork to do when I have finished the engine work,

 

I got all the front suspension & brakes finished tonight, its been spannered up double checked ready for the wheels to go on,

 

I'm flat out with work for the next 2 days so it will be Saturday before I get near it again, fan belt coil lead check levels and start :P

 

 

Some more pics from tonight

 

 

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http://s298.photobucket.com/albums/mm280/G.../Pug/?start=all

 

^ More pics in here ^

 

 

 

 

Roll on Saturday B)

 

 

.

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TT205

Can you not run carbs over there?

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SimonJ

Induction is free. Just as well as I switched to carbs last year! Lot of uncertainty about the regs though due to the standardisation of regs across the UK for this year. I guess it will have affected some regional associations more than others and maybe some not at all.

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Cazzo

.

 

Yeah, as Simon says induction is free,

 

Tho I would only put Carbs or Tb's on if I was going to do a bit of rallying

 

The wee car doesnt get much use lol

 

 

How are you getting on with the hunt for rear seats Simon, I'm near tempted to shoehorn the saxo seats in :wacko:

 

.

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