[car_restoration] Sorrento Gti16v Full Rebuild

[welshpug 1,622]

e v e r y t h i n g ! !

 

New engine bay "attention" stickers too!

 

 

oooooh! where from??

[Paintguy 0]

Mmmm....

 

Shiny

[kikiturbo 0]

oooooh! where from??

 

 

part nr. 130388 from your friendly Peugeot dealer, IIRC...

[cybernck 400 1 Cars]

success!

 

i'm proud to say i'll be one of the very few members of this forum that will get to see and "feel" the car when it get's finished, hehe .

[de Noir 0]

Cheers people, glad you like her.

 

I'm not 100% satisfied with paintjob, as painters have forgotten to paint inner wheelarches in body colur.

This is I believe DIY stuff, will order some paint in spray can and finish it myself. Everything else is fine.

 

Opportunity is taken to replace wing nuts, speed bolts and door pins with new parts.

Wings are new, so is the windshield and windshield rubber seal. Unfortunately, new tailgate window seal wouldn't fit on the glass (at least glass people told me so), so they reglued the glass and refitted the old seal. I still don't get how is this possible to happen, but will worry about it later.

 

So, this is it I guess, half way thorugh. Now comes the glamorous part of putting her back together.

 

Plan is to dismantle McPhersons, front frame and 309 GTI16V rear beam, weld, sandblast, paint and refurbish. At the same time I will clean, inspect and sort remaining 205 parts and 309 leftovers, prepairing everything for assembly.

All broken, dirty and rusty parts are banished from this car.

In a paralell universe mate already started working on 309 GTI16V gearbox, braking it into pieces.

 

Body specialist who did the preparation and respray reckoned it will take about 500 workhours to put her back together.

We'll see.

 

 

 

For stickers part numbers, check out here

Edited January 3, 2007 by MH_

[DamirGTI 323]

nice ...

[de Noir 0]

Been swallowed by my regular job, so she had to wait for a while.

Started to tinker around with suspension, steering, fueling, misc piping, heatshields etc...

 

SUSPENSION + STEERING

Edited January 3, 2008 by MH_

[de Noir 0]

Bad news from suspension department...

I had high hopes for rear 309 GTI16V arrangement, but the beam tube is dead. So are both shafts, one end of ARB and ARB brackets. Trailing arms and TBs are okay.

 

Checked part numbers and searched some 309 beam topics here... Seems like 16v tube is different from regular/GTI tube. Sourcing new 16v tube is out of question, used ones hard or impossible to find.

I'm interested if someone actually compared these two and what are the differences, as I have never seen an regular/309GTI beam tube. AFAIK 16v rear negative camber comes from trailing arms, so this is not a tube dependant. The only unusual detail on my 16v beam are shaft bearing oiling/greasing points (don't know the right expression in english but you get the idea).

 

 

I have kind of rear beam situation right now...

 

Most obvious and also my first choice is to get regular 309 tube, two second hand shafts + ARB brackets, bearings + fittings from new.

There's 205GTI rear beam sitting in my garage waiting to be broken apart for shafts, with risk of finding similar mess inside. That would be 2nd choice, but still have to get a 309 beam.

Or should I stick with 205 beam with 309 ARB and TBs? As they're 50mm longer, is this a straight fit? I believe not, correct me if I'm wrong. This would leave me with standard 205 beam. As I have already purchased new 309 front trailing arms, having ultra wide front + 309 16v ARB with standard 205 GTI rear beam setup is a bit questionable IMHO.

Edited December 19, 2007 by MH_

[Rik 0]

You wont be able to fit the 205 beam with the 309 ARB / TB's.

 

ASFAIK the 309 beam is the same as any other...

 

There shouldnt be a big problem with running 309 front arms and a standard 205 rear, FWD cars are meant to be set-up with a wider front track.

Though doing this may change the characteristics a little so i would try and search for people who have done this...

 

But i cant see why you just dont buy a 2nd hand 309 beam tube, why do you think the 16v isdifferent?

 

Rik

[de Noir 0]

I am going to buy second hand 309 beam tube if I could find one worth it.

 

Me thinks 16v beam tube is different from lesser 309 models because Peugeot spare parts bible tells me so.

Different part numbers. They may differ in detail, just wanted to know what detail it is.

Edited February 22, 2007 by MH_

[Edp 67 3 Cars]

I've got 309 front arms and driveshafts with a 205 rear beam and it handles on rails.

[de Noir 0]

Rear beam situation solved, another 309GTI beam purchased (3rd one!), bearing set on order.

Still haven't decided whether to use:

- standard 309 beam tube castings + 16v ARB torsion bars, or

- full 16v setup

 

One 16v casting is a bit damaged on bearing holding position, unfortunatly not repairable.

I ordered bearing set and will try to press in new outer bearing and see how it behaves, and then make the final decision on rear beam setup.

 

In the meantime, I sorted the wheels. Washing, yet more washing, balancing, sandblasting, priming, painting and lacquering..

 

SPEEDLINES PHOTO STORY

Edited January 3, 2008 by MH_

[chrisj21 2]

those wheels are drop dead paint details please!!!!!!

[de Noir 0]

Thanks! This is one of many original Peugeot silvers.

It appears a bit darker on the picture than it really is.

 

Color name: Quicksilver

Color code: MOVH

 

...as already mentioned above!

 

Please note that finish like this is easy to achieve when you do some effort (read: spend money) on quality preparation.

Wheels were sandblasted and primed, 2 coats of paint + clear laquer on outer surfaces.

Regular paintshop job, nothing fancy. 0,5 liter of paint should be enough for 4 wheels.

Edited April 2, 2007 by MH_

[chrisj21 2]

Thanks! This is one of many original Peugeot silvers.

It appears a bit darker on the picture than it really is.

 

Color name: Quicksilver

Color code: MOVH

 

...as already mentioned above!

 

Please note that finish like this is easy to achieve when you do some effort (read: spend money) on quality preparation.

Wheels were sandblasted and primed, 2 coats of paint + clear laquer on outer surfaces.

Regular paintshop job, nothing fancy. 0,5 liter of paint should be enough for 4 wheels.

 

Excellent thanks for the info and great job on the car!

[GTI6BOY 29]

very nice

[TeCh2pe 0]

Very nice indeed! Liked the color combination. Keep up the good work! MH_

Edited May 7, 2007 by TeCh2pe

[de Noir 0]

Because of rear beam issues, project stalled a bit. Also, a newborn in family prolonged it even further.

Now, modest update after a while...

 

As stated before, 309 16v beam proved itself beyond reparation. Needed new beam tube.

Decided to buy another 309 beam, which was also dead.

Bought the third one, from a 309GT, which was fine.

 

Both 16v and GT beam were broken apart, and hybrid 309 beam was assembled, using:

- GT beam tube

- 16v cast beam brackets

- 16v trailing arms and hubs

- 16v ARB and TBs

 

Then I took all suspension parts, beams, frames etc. to sandblasters and opted for 2-component epoxy primer with black matte finish. This turned to complete disaster as sandblasters' airbrush skill and equipment proved themselves very

 

Everything was done again... Sandblasted and powdercoated to black matte finish.

Suspension parts look superb now.

Next step is to press in all bearings, hubs + shafts and to assemble the beam using new seals, cups, bolts and everything.

 

So far bringing dead 309GTI16v rear beam back into life was the most expensive and time consuming job on the project.

Edited December 19, 2007 by MH_

[de Noir 0]

I'm having fun with brakes at the moment..

Edited December 19, 2007 by MH_

[matty_gti 20]

Lookin' sweet , hats off to you.

 

Matt

[mickie 3]

this ever get finished?

[de Noir 0]

I hope it does...

[cybernck 400 1 Cars]

bear with him guys - he's got another little time consuming project that's alive... literally .

[de Noir 0]

Hello! It is I, Leclerc!?

 

In short, my poor sorrento project couldn't stand against family and career moves.. But:

 

- I've added some already seen pics to project gallery

- Will rearrange this topic a bit to focus on gallery (no more Photobucket, pisture links will die in few days)

- Will expand current picture line-up

- And most important, publish some new stuff

 

Fair amount of work has been done, mainly gathering and sorting components & assemblies.

More of everything soon! Cheers!

 

Edited September 5, 2008 by MH_

[de Noir 0]

Update!

 

As said, moved everything to gallery and added some new stuff.

Published stuff is most about prepping components for assembly which should start soon...

Yes, no single bolt is installed on a car.

 

It seemed suitable to prepare everything and then have fun with clean assembly. Of course, this is almost impossible to achieve in real world. I managed to get pretty close, although lost great amount of time on some stuff. Rear beam and brakes, for example. More details in later discussion, if any.

 

Hope album order is clear and fine by you. I will remove Photobucket hosted pictures today.

Components stories are left open, will be finished and pictures posted paralell to work carried out in real world.

 

Thanks.

Edited December 18, 2007 by MH_