Bent Saxo vts

[LewisT]

Anyone else hate mixing up two pack? well i do, but it was a necessity before the last few bits get welded in.

Painted o/s inner wing, front thingys, inner arch extension thingys, ends of the front cross member underside, and the undersides of the gearbox/engine mounts.

Then reattached the engine mount(part of). Will paint at later date didn't bother since it would burn off when welding.

 

[LewisT]

Stuck on the last few pieces, a surprise hole, slight modification of the inner wing and bumper bracket mounts, then a coat of epoxy.

Towing eye whether it stays on if used is another question

Slightly modified the ns inner wing so the bumper bracket would fit a bit better, previously had a peak in there.

The bumper brackets are riveted to the body with closed rivets from factory, most people stick them back on with pop rivets think this looks poo so drilled them for m6 bolts.

While cleaning up the ns strut found a few pinholes near a factory hole, like for like repair.

Slapped the gearbox mount top upper part and a wiring harness bracket (modified) back on, the bracket attached to the inside of the leg now its on the outside.

Pretty much went over everything with epoxy again bits had soot/charring that wouldn't wipe off.

 

[LewisT]

Also picked up a cheap upgrade for the brakes from a 207 from 247mm to 266mm mostly a direct fit, caliper carrier needed a small bump ground off.

 

[LewisT]

Modified the brakes for the other side took some pictures to show what needs done easy five minute job.

Rearranged all the junk in the garage in preparation of putting the engine back in, ran out of time today will get it in as the next job.

 

[LewisT]

Most people usually lift the car over the engine and gearbox then lift the engine up in to place, but it can be done from the top if your careful, forgot to put the power steering pipes over the top of the gearbox when i put it in so going to have to drop the gearbox mount again on the plus side no loud pings or bangs when the engine mounts were loaded up

 

[minimutly]

Why not paint it before fitting the lump?

 

[LewisT]

Why not paint it before fitting the lump?

Engine bay is getting left in epoxy primer.

 

[LewisT]

Been buying tools and connectors from aliexpress to replace ones on the car that are broken or been changed for the wrong type.

First up bought a sn series ratcheting crimp tool with a selection of interchangeable jaws for doing open barrel crimps, a cheap set of connector depinning tools, pack of chinese copy delphi sicma connectors uncoded.

First broken connector

Don't think this is how your intended to do these, think your supposed to put the pins in to the assembled connector.

Crimped new contacts on cut the bare minimum of the existing wire.

Still waiting on some junior power timer connecters arriving, and still haven't identified what these connectors are called it connects to the abs loom which i have pulled off the car but might reinstate at a later date. Half the other plug is missing and don't see any brand names on them.

Ended up having to buy a second sn series crimping to do open barrel with water proof seals as they didn't sell those dies separately from the tool car doesn't look much different to the last pic but have stuck the driveshafts back in, connected the clutch and throttle cable , all mounts in place, some wiring routed and connected, new set of tie rod ends( tracking is miles out, don't think the rack was even centred previously) still a fair bit to go back on.

 

[LewisT]

More of a teaser today, been on another aliexpress buying spree, fir tree connector clips, fir tree cable ties, junior power timer connectors.

Oval fir tree connector clips, oval fir tree zip ties

Round hole connector clips took a gamble on these couldn't find what i wanted on ali but these were close and could be modified.

Junior power connectors they had a few types colours, replaced one on the car correct colour wrong coding needs modified.

Sight admission to make, when i put on the arch extensions a while back they might not been at the right heights had been using the slam panel to position them prior to welding and should never assumed it was straight, well one of them was ok but the other side was way out when i straightened the slam panel and needed drilled out and moved. Threw front end on again for a pic after fixing the debacle.

 

[LewisT]

Some of the original earth points in the engine bay behind the headlights had been lost during the first repair, slightly half assed job they should be m6 square weld on nuts there's one in this pic blue arrow i used m6 flange nuts and stuck them on the opposite side of the panel to where they should be just for ease of welding red arrow.

 

[LewisT]

Bought a new battery for it recently so i can start checking the electrical systems, normally when you turn the key to the second position the fuel pump primes, well mines doesn't and the gauge is just wagging its needle at me, was expecting a little bit of corrosion on the sender, think i need a new one

Also finished up some wiring repairs on the drives side, first i bought a horn with bracket from ebay so i knew where the horn was suppose to be, then set about extending the wiring and fitting a junior power timer connector to replace the spade connectors.

Extented the wiring with some open barrel connectors then heat shrunk touch of tape and some convoluted tubing.

The washer bottle had been swapped and had one from either a mk1 saxo or a 106 i'm not sure got the right one on order from ebay, two problems with it, single outlet pump, it clashes slightly with the horn assembly and to top that off it had a junior power timer connector, mk2 used a sicma connector the same as the indicator. set about replacing the connector wiring might be a touch too long.

 

[LewisT]

Got a intact fuse box, new fuel pump and the washer bottle from ebay.

Fitting the washer bottle it seamed something was amiss, the plastic hook that wasn't on the old bottle was hitting the inner wing and the arch liner wouldn't fit, did some detective work on youtube the mk2's had a small cut out in the inner wing.

Without any good measurements i went for eyeballing it, the result was satisfactory.

 

[LewisT]

Been working away at the electrical faults that the car had when i got it, airbag abs and the handbrake/brake warning light were permanently lit, airbag system i found had the wrong slip ring at the steering wheel so the airbag was disconnected because it had the wrong connector, abs and handbrake light took me a while to figure out they normally function independently of one another but if the the abs system fails it causes both lights to be illuminated, well probing the wire that goes from the dials to the abs ecu( which has been removed) it was sitting at 12v i decided to ground this wire and turn on the ignition well the abs light did go off never to come on again even after i ungrounded it and the brake warning light was still on, looking at the wiring diagram for the dials there's a diode fitted between the handbrake/ brake waring light and the oil pressure light makes me think will it be as simple as starting the engine ( which hasn't run in 6/7 year ) and the light will go off?

My working theory at this time for the abs light/brake warning light is the abs ecu grounds the wire coming from the dials to signal everything is ok but the dials stores the last working state that the abs was in, in my case the abs system wasn't operational and had been left disconnected.

 

[LewisT]

Things took a turn for the worst car was going back together was nearly finished, then the overheating incident happened turns out the old thermostat was choked full of himalayan salts(dried up coolant), head it currently at a workshop getting checked/skimmed. bought a new thermostat housing to cheer myself up.

Taking the inlet manifold off while the head is still in the car was the worst job i've ever done on a car.

 

[LewisT]

Saxo continues to try my patience, after rebuilding the engine it was running rough quickly noticed only manifold pipes 1+4 were getting hot, tested coil pack getting four sparks, strip intel manifold down again to access injectors only 1+4 firing, check continuity to ecu all good, points to dead injector driver in ecu order new ecu, new ecu has same problem test injectors 2+3 with direct feed one comes back to life other is totally dead, get new injector loud as fook but works, test old ecu all is working again. have spare remanufactured ecu luckily still within returns window fires it back to seller, seller not happy ebay refunds me.

So car now runs managed to bleed it successfully this time the coolant fan works and coolant circulating system fine, have started putting it back together.

Now need some advice on how best to tackle a new problem saxo has pp + epdm bumpers there's two mounts barely holding on to the bumper they were originally held on with some sort of plastic welding, was going to epoxy them on but there a note on the epoxy i have not suitable for polypropylene apparently it doesn't stick it it very well. Here's a picture of a mount what would you suggest.

Thanks for looking.

 

[Turbo]

The inner and outer bumper on my 306 were separating due to accident damage.
I bought one of the leister type plastic welder clones and managed to get them welded back together.

It was not pretty, I struggled to get a nice weld with it. But it was strong enough and well hidden.

Search the forum for plastic welding as there are other easier methods.

 

[LewisT]

Ordered a pack of pp+epdm rods of ebay and received a pack of pp rods drop shipped from china . Could have just bought them myself from aliexpress for a third of the price. Don't have a heat gun but i do have a Atten hot air rework station so had a go with that not exactly pretty but the brackets feel stuck on good and the paint on the opposite side didn't bubble off either.