Peugeot 106 Engine bay repairs... and maybe more!

  1. Alan Easton

    Alan Easton Member

    Messages:
    27
    Location:
    Warrington, Cheshire, England
    Hi all,

    Thought i'd put a thread up to show what i've done so far and see if I can get any ideas etc for future work and improvements I could make.

    Firstly, My name is Alan and i'm a french car addict!

    I've owned a few Citroen Saxos over the last 10-12 years.

    Most of these cars have needed some form of welding and a friend of mine has always helped me out and kept the cars on the road or track.

    Long story short... I ended up having to scrap my last Saxo as the rust had taken out much of the structure around the roll cage mounts and sills etc. At the time, I didn't have the time or inclination to weld it all myself and I didn't want to ask my mate to spend weeks worth of evening driving an hour to mine to fix it for me so off to the scrap man it went after it was stripped for parts.

    A few weeks later I was contacted by another friend who had a Peugeot 106 GTi complete with welded in roll cage, cammed engine and a gearbox with an LSD fitted and the short ratios i'd been after for a while. It was a little rough round the edges but was pretty much exactly what I wanted for a high level track car or starting point for a race car.

    I'll add a few pictures of my previous cars and one or two of the 106 somewhere in this post. feel free to ask questions or laugh. These are a bit old now and while i'd love a clio, megane or top of my list an E46 330 for smashing round the track, these cars are dirt cheap to repair at the minute and after the practice I have had, I feel confident that I can now tackle most welding jobs on these cars.
     
    • FCStrack4.JPG
    • 13925761_10210321204325916_5239832854643844585_o.jpg
    • 8K9U4788.JPG
    • 8K9U4666.JPG
    • FB_IMG_1470174329698.jpg
    • IMAG1180.jpg
    • IMAG0096.jpg
    • IMAG1183.jpg
    • IMAG0119 (2).jpg
    • IMAG0120 (2).jpg
    Nick DV, barking mat and Kayos like this.
  2. Kayos

    Kayos Member

    Messages:
    5,561
    Location:
    Yorkshire
    I had a VTR when they were still "current"

    I also bought a crashed 106 Rallye with a turbo conversion

    I will let you guess the rest....
     
    Nick DV, tom2207 and Alan Easton like this.
  3. grim_d

    grim_d Unlikeable idiot.

    Messages:
    2,748
    Location:
    Scotland - Ayrshire
    I'm a jap car man but I always liked the vts and 106 GTi, back during a time when it was as simple as putting a pokey engine in a light chassis.

    Couldn't drive then though with my size 14 feet, would press two pedals at once.
     
  4. Alan Easton

    Alan Easton Member

    Messages:
    27
    Location:
    Warrington, Cheshire, England
    So that's a brief history of where i'm up to now.

    Now, with the 106 coming along, I wanted to up my game and go from track day "make do and mend" mentality to full race car "Make it right" attitude.

    After I managed to get out for my first ever race in torrential rain at Oulton Park back in October 2019, I ended up hitting a barrier coming over the top of Clay hill and into Druids. Nothing serious but enough to warrant pulling the engine out and giving the engine bay some tlc.

    Engine was pulled and sent to a friend to do a full strip, check and rebuild with some improvements and the rest of the stuff was stripped out and examinations completed. Main issues were two large areas of rust that needed to be cut out and repair panels welded in. I found a few smaller patches that I could have sorted as well but due to time and a few other issues, I decided to treat and leave for now... Then lockdown hit us!

    Perfect time to get myself a welder rather than pay a pro to do it and acquire a new skill.

    What i'll do here is link to a few videos I did to document my experiences - A) it'll give you all something to laugh at, B) Sometimes people want to see as well as read and C)I'm going to have to watch them through again to remember what the process was so I can do the next post from starting the welder purchase right through to where I am now.

    Hope your all intrigued now ;P

    Here's the link to my YouTube videos: https://www.youtube.com/playlist?list=PLglH0tZRDVl4837h_uMvWiH31O-BQQK5c

    And here are a couple more Pictures of the 106 and the issues I was facing.
     
    • 73472525_2734596733245854_7876081881756729344_o.jpg
    • IMG-20191026-WA0004.jpg
    • IMG_20200301_172527.jpg
    • IMG_20191230_150131.jpg
    • IMG_20191230_150135.jpg
    • IMG_20200410_172601.jpg
    • IMG_20200412_164832.jpg
    • IMG_20200504_204136.jpg
    Nick DV and Kayos like this.
  5. minimutly Member

    Messages:
    1,100
    Location:
    Pembrokeshire Wales
    You then crashed it again? This time going a lot quicker?
     
    Kayos and Alan Easton like this.
  6. Kayos

    Kayos Member

    Messages:
    5,561
    Location:
    Yorkshire
    The VTR turbo was stolen, probably to order as they broke into the house and took the keys. Didn't touch anything elseb
     
  7. Alan Easton

    Alan Easton Member

    Messages:
    27
    Location:
    Warrington, Cheshire, England
    Kayos likes this.
  8. Alan Easton

    Alan Easton Member

    Messages:
    27
    Location:
    Warrington, Cheshire, England

    That is one big issue with them! Everything is crammed in!
     
  9. Alan Easton

    Alan Easton Member

    Messages:
    27
    Location:
    Warrington, Cheshire, England
    Ahh, not what I thought then. That sucks having it stolen but as you said, probably to order back then.
     
    Kayos likes this.
  10. bricol Member

    Messages:
    1,073
    N.Yorks, UK
    I have an 1100cc XT of 91 vintage - on 145 tyres, its pretty perfect for the power - you can sling it in, lift off to tighten the line, apply corrective lock if needed and generally have a right old time. I have an integrale, a Caterham, and a RWD V8 with close to 400bhp, and I still enjoy chucking the Pug around.

    It only needed similar repaired to the front inner wings relatively recently - maybe 4 or 5 years ago. I bought it ove r20 yrs ago from a breakers as it had been rear-ended, which also pulled the front mounts of the seats out of the floor - the only bit of the car I have never been too impressed with.
     
    Alan Easton likes this.
  11. Nick DV

    Nick DV Member

    Messages:
    306
    Location:
    Southampton
    You crashed it again ................................! :laughing::laughing::laughing:
     
    Alan Easton likes this.
  12. Alan Easton

    Alan Easton Member

    Messages:
    27
    Location:
    Warrington, Cheshire, England
    They are cracking little cars lol. Had very similar experiences in the Saxo VTR's I had prior to the red VTS and now this 106. So much fun!
     
  13. Alan Easton

    Alan Easton Member

    Messages:
    27
    Location:
    Warrington, Cheshire, England
    SO... As I said, Bought a 106, Raced it, bent it, stripped it and started to look for a welder...

    I didn't have a big budget due to just buying our first house but could stretch a few hundred quid for something gassy and miggy. maybe too much research later and I settled on this MIG/ARC Gas/Gasless welder from a company called Rohr. The only review I could find on YouTube that was english was from a guy called Joshua De Lisle, a professional welder and metalwork atisty type. He seemed genuine and after watching his review, I felt confident that this was the one for me.

    Birthday money and piggy bank emptied, the amazon delivery guy turned up and waddled over with my new purchases.

    Here is an appropriate time to mention again that as a bit of a tech nerd, I have made some youtube videos of my own to document all of this and you can find the welding playlist here: https://www.youtube.com/playlist?list=PLglH0tZRDVl4837h_uMvWiH31O-BQQK5c

    With the Rohr MIG-200MI unboxed, and cobbled together I realised it had no gas pipework nor a regulator... Back to amazon and a disposable bottle reg was bought. When it arrived I noticed that some bodgery was required to get the tiny disposable pipework to fit to the 6mm id barb on the welder. With the aid of some wire, some rubber fuel line and a couple of jubilee clips I managed to get something resembling a temporary solution to work.

    With that all together and a bottle installed I managed to have a play and do some test welds on some scrap steel in the shed. Once I was happy that i could run a basic weld, I took the angle grinder to the car and set about removing as much rust as I could bare to do in one sitting.
     
    • IMG_20200504_105142.jpg
    • IMG_20200504_204158.jpg
    • IMG_20200504_204213.jpg
    • IMG_20200511_162829.jpg
  14. Alan Easton

    Alan Easton Member

    Messages:
    27
    Location:
    Warrington, Cheshire, England
    Once I had all the above done, I tried my hand at making a simple patch panel for the passenger side and ordered a repair panel from D W Engineering to cut to size and fit the drivers side. This is where my video series really kicks in... Here's the link to the playlist if you want to watch...

    https://www.youtube.com/playlist?list=PLglH0tZRDVl4837h_uMvWiH31O-BQQK5c

    The process was not as easy as I had planned and i certainly had a steep learning curve as I went through it all.

    I'll let the videos do the talking for now but i'll add some pictures for you here to see some of the steps, missteps, mistakes and final semi-success.

    I'm pretty happy with the finished product BUT... I do wish i'd have got some filler on the welds just to fill a little warp and some of the edges that I couldn't get perfectly flat.

    The engine bay is all painted and lacquered now so the next job is to take some weight out of the front valance and get that painted to match.
     
    • IMG_20200511_165324.jpg
    • IMG_20200512_161355.jpg
    • IMG_20200518_162803.jpg
    • IMG_20200521_183416.jpg
    • IMG_20200523_182519.jpg
    • IMG_20200523_182602.jpg
    • IMG_20200526_141314.jpg
    • IMG_20200526_143902.jpg
    • IMG_20200527_105521.jpg
  15. Alan Easton

    Alan Easton Member

    Messages:
    27
    Location:
    Warrington, Cheshire, England
    Here are a few more pictures...
     
    • IMG_20200514_184533.jpg
    • IMG_20200515_115441.jpg
    • IMG_20200515_144824.jpg
    • IMG_20200515_144850.jpg
    • IMG_20200520_120213.jpg
    • IMG_20200520_120225.jpg
    • IMG_20200520_120244.jpg
    • IMG_20200527_105615.jpg
    • IMG_20200528_115357.jpg
    • IMG_20200705_174243.jpg
    slim_boy_fat likes this.
  16. Alan Easton

    Alan Easton Member

    Messages:
    27
    Location:
    Warrington, Cheshire, England
    Front valance halfway though adding lightness... thought i'd best give it some primer before it gets rusty.
     
    • IMG_20200530_162230.jpg
    • IMG_20200530_162647.jpg
    • IMG_20200711_195203.jpg
  17. spencer 427 Member

    Messages:
    6,924
    Location:
    uk colchester
    I did a saxo years ago. Hand fab all my own panels . Will dig out some pictures if I can find them.
     
    slim_boy_fat and Alan Easton like this.
  18. Alan Easton

    Alan Easton Member

    Messages:
    27
    Location:
    Warrington, Cheshire, England
    Yeah that would be great. Always interested to see how others have patched these things back together.
     
Advertisements