small french hatchback

  1. madkayaker

    madkayaker Pro sparkey Pro Welder

    Messages:
    13,695
    Cumbria
    It has been a good thread though with some nice looking engineering examples
     
  2. PhillipM

    PhillipM Member

    Messages:
    1,865
    Rotherham
    They've only gone because the bandwidth limit is reached, they come back when the account resets.
     
  3. davenport Member

    Messages:
    496
    england, cambs
    Aye... it resets every month and ive started a new account so it'll be fine in a few weeks...
     
  4. davenport Member

    Messages:
    496
    england, cambs
    Well... work is still busy and im still on 7 days a week 7till5.. cant complain really the money is handy...

    Havent been down the workshop for a few weeks but last time I was I started playing with the bumpsteer, I was using a small scissor jack as it gave nice controlled movement, but being so low I needed a block of wood to stand it in...

    thats not very "motorsport" is it?? A chunk of wood with soaked in engine oil!!!!

    there was only 1 thing to do, I waited till the storeman popped out for his mid-morning break and moved fast...

    I scampered out with a couple of laser cut plates 8countersunk bolts and some threaded spacers which just happened to be the height of the chunk of wood I was using.....


    [​IMG]

    a bit of countersinking on the plates and bingo..


    [​IMG]

    MASSIVELY ott and unnecessary but hey, it looks the part!


    Ebay bargain... 20mm hubcentric spacers for £6.50 these may be a bit too big but for that price I'll gladly machine them down..


    [​IMG]


    finally the TRI wheel studs arrived, 12.9 rated. rolled, silky smooth, threads and a nice domed end..

    cheaper than anywhere in the UK for equivalent spec


    [​IMG]


    thats about where im up to unfortunatly.. I reckon theres about another month of grabbing mental overtime then the job will be done, so I wont get my hands on anything till then....
     
    Last edited by a moderator: Aug 6, 2013
  5. davenport Member

    Messages:
    496
    england, cambs
    managed to do a bit yesterday as I`m now on holiday for 2 weeks so grabbed a few hours before we go to the isle of wight...
    the passenger side 307 shaft was chopped in half and the 2 bits put in there respective slots:

    [​IMG]


    levered the CV to full compression at full droop and marked the shaft, chopped it down and machined a slug to go inside to keep things inline while I tacked it up (the Satchell crew will put in a suitable amount of preload on the CV when the do the final joining:
    tacked up in place:

    [​IMG]


    whipped ooot and on the bench:

    [​IMG]


    things at this point were going well..... too well.....
    anyone whos built a car will know the feeling that accompanies the next few pics, I do mean built by the way, not just throwing s*it on from a catalogue, actually making stuff..
    sooo drivers side...


    the hollow section was cut and the intermediate shaft threaded into the box...
    instant issue!:

    [​IMG]


    the bearing just below the CV joint should be in the ally housing about 80mm below it...
    out it came and a tape measure thrown over it:

    [​IMG]


    I haven't got any 106 shafts for reference so called on the powers of FaceBook, luckily Mike Nash was oline and helpful, a massive thanks must go out to him:

    [​IMG]

    my immediate reaction was "mike needs a funky tablecloth like mine"

    followed by "hmmm his shaft is shorter than mine.."
    luckily my local pug breaker is only a mile away so popped to see him and explained the situation (by now he knows nothing with me is easy but is always mega helpful) a selection of shafts were layed out and it became clear that all 206 and 307 shafts on a MA boxed/TU engine car were longer than a 106 setup...


    "you got any carriers lying around"


    a stumble around the engines found 1 that had fallen over suitably and the carrier was took orf:

    [​IMG]


    this should get the intermediate shaft in place but leaves the drivers side shaft (between the CVs) short, very short.....
    it was at this point I had that, ooooooh ****** feeling and remembered that the Satchell boys shifted Deans engine over 20mm......

    which would help the mega short shaft issue.. but also means I need to move the friggin engine, and REDO the shaft I`d just shortened..


    AAARRRGGGGHHHHHhhhhhhhh cockin poxy bloody stupid modified cars!!!!!


    so, speed dial #1, a quick chat with Dave @ satchells and hey presto! 1 of these will be waiting for me when I get home..

    [​IMG]


    which will fit up like so and shift the engine into the better position ..

    [​IMG]


    I'll just have to modify the gearbox mount but that should be easy enough....
     
  6. davenport Member

    Messages:
    496
    england, cambs
    well...


    back off holiday and back onto it....


    unwrapped the mount to find the generousity of the satchel boys knows no bounds:

    [​IMG]


    first up was to machine a conical spacer for the mount, Dave had kindly sent a drawing of what I needed so it was over to the BOX-O-BILLET for a rummage:

    [​IMG]


    ta-daaaarrrrrggghhhhhh:

    [​IMG]


    from then on it was a case of disconnecting- gear linkage, exhaust, top hose hang the engine from the crane, rip off all the mounts, drill the shell, fit new satchel mount, modify the gearbox mount, modify the lower torque link, refit stuff.....

    a couple of snags,

    the big ass ally mount that bolts to the block seems to be different on mine from newer versions as it fouls of the new intermediate shaft carrier AND the holes don't line up:


    [​IMG]


    but, like the proverbial something or other, the show must go on.. and after many, MANY more profanities, we had it all in:

    [​IMG]



    the only tiny bit of luck I had was that with the MA box being so small I don't need to mod the chassis rail at all, its close, but will be ok...
     
  7. Cris B

    Cris B Every day welding is a school day

    Messages:
    450
    Location:
    Sefton
    Nice... So what are you doing about the mount? Do you need a different alloy one. Just so happens I might have what you need :)
     
  8. clen666 Member

    Messages:
    48
    Co. Durham, UK
    Fantastic work mate, should be quite a weapon when finished.

    Do you have a link for 'TRI' where you bought the wheel studs please?
     
  9. Cris B

    Cris B Every day welding is a school day

    Messages:
    450
    Location:
    Sefton
  10. clen666 Member

    Messages:
    48
    Co. Durham, UK
    Awesome, thanks Cris :)
     
  11. davenport Member

    Messages:
    496
    england, cambs
    alright folks, hows things?????


    been a bit quiet so my apologies for that.. this parenthood lark/work/project juggling aint easy!!!


    anyhooooooo...


    the engine is now fully shifted over 20mm and I could get busy mocking up the 307 shafts to suit the 106 track width:

    [​IMG]


    in doing this I got sidelined with ANOTHER mini project, the engine project my dads involved with seemed to be getting closer and closer to my front bumper and upon catching my hip on something sharp and pointy I declared enough was enough (actually I declared it to be a f**king pain in the f**king **** and if it went away the workshop would run better) so a few lunch breaks at work had this knocked up:

    [​IMG]

    [​IMG]


    I could now move the thing outta my way when needed!!!!


    with the engine shifted over luckily everything still operated like it should my custom gear linkage just needed some rod ends wound out, the gearbox still cleared the chassis.. unfortunately the centre scuttle panel bracket thingy was now fouling my trumpet, off with the bodies, out with the dremel, off with the bracket:

    [​IMG]

    happy days:*

    I then started shaping the tubes that will form the turret to lower wishbone pickup bracing, you can just about see them tacked in place on the pic:

    [​IMG]


    finally the pushrod rear suspension!!!

    dunno if any of you watched the clip above but its a new setup designed by my friends over @ Satchell Engineering

    *non techy bods skip this bit*

    the standard 106 (and many other pug) rear suspension is an odd setup in as much the wheel travel to damper stroke ratio is only 3:1 (wheel moves 3mm damper moves 1mm) this results in dampers having to be MEGA stiff and trying to control the wheel with minimal stroke.. its a big compromise...

    a few people end up turreting the rear which stands the damper upright and you get a lovely 1:1 ratio, wicked!! but, if the cars going to be used in competition a lot of classes deem this mod illegal, this setup gets around the issue by retaining all the factory pickups and skinny std torsion bars and use this kit as a "helper" spring and damper unit...

    *tech drivel over*

    so the Satchell crew were kind enough to ask if i fancied doing a bit of guinea pig work on these new kits and try the fit to make sure the jigs/proceedures all make it a simple bolt on conversion and have been sending me a few pics of things progressing:

    [​IMG]

    [​IMG]

    [​IMG]


    all I needed to do then was select a damper/coilover setup.. they used a GAZ monotube on there trial car, but... I know a few people.. 1 person in particular works for Penske, if you haven`t heard of them, have a look under the bodywork of a few current F1 cars/nascars..

    knowing this meant 1 thing, they would be bastard expensive, and yes, when he quoted some prices, they were indeed at the bastard! end of the scale... even the single adjustables... but he had a plan!!

    after a few days I got another message saying h`ed been rummaging among the old test units and 2nds bins (faded anodising/scratchs) and found 80% of the bits I`d need for some single adjustable units (these can be upgraded to double or triple adjustable) and I could have a finished set for about half the new cost...

    [​IMG]

    [​IMG]

    as you can see there a bit grubby but tbh, the insides are mint and there a very VERY good damper.........

    and that's about it.. just waiting on Devons finest to send me some bits and I can crak on a bit more.. maybe even get it back on its wheels!!
     
  12. Tupers

    Tupers Member

    Messages:
    671
    Devon - England
    That's a very interesting suspension set-up. I recon there's probably just enough room under the back of a Mini for a similar system.

    Nice deal on those dampers as well,never hurts to save a bit of cash on builds this size.
     
  13. j_mcvic Member

    Messages:
    21
    Edinburgh
    Fantastic read! Loving the engineering and practicality in this thread! I see you have a ph1 172, are you on CS.net?
     
  14. davenport Member

    Messages:
    496
    england, cambs
    Aye I go on there now and again... dont use it much though usually just to check a few build threads of interest.... I think my username is Frenchthing on there...

    my 172 doesnt get much attention, I bought it already modified so I can just enjoy it as a fun family car now...
     
  15. davenport Member

    Messages:
    496
    england, cambs
    evening all......

    apologies for no being very active on here (I do have regular looks thru though)

    so, the car....

    with a west country delivery imminent, I decided to get the rear beam stripped off


    the 22mm bars were already removed and sent to there new owner so it was fairly straightforward.. I did however have a horrible feeling the stub pins would give me yet another expense, the disc beam went onto the car 11 years ago (ok ok I know its been off the road for 6) and in that time I`ve NEVER checked them.....

    but luck was in!!

    [​IMG]

    [​IMG]


    theres an obvious surface difference where the bearings run but everything measures up correct with a micrometer and theres no imperfections in the surface so I think I`ll get away with just new bearings in the trailing arms...


    my std 18mm torsion bars have been stripped down and temporarily sprayed in red-oxide (these came up quite well):



    [​IMG]


    managed to press/wrestle out the old polyRACE bushes:

    [​IMG]


    and that was about it.. just needed some bits to throw under here:

    [​IMG]

    then this turned up




    [​IMG]


    [​IMG]


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    [​IMG]





    for now, lets just say im happy its on its wheels.. but it needs lowering BADLY!!




    [​IMG]


    [​IMG]


    scene points YO!



    [​IMG]


    despite being on all four wheels I was still waiting on a few bits then the other day Santa came early..



    [​IMG]



    my Penskes arrived from Ed, (who also works for SPA so while he was busy I got him to sort some carbon mirrors out for me..

    mains/helpers/joiners for the rear and some helpers/joiners to go on the front..

    I`ve also had a LONG conversation with Ed and his boss at Penske regarding setup advice (seeings as they`ve done just about every competitive BTCC car in the past 15 years i thought they might have a bit of FWD experience..

    been given a few pointers and some parts are gonna require mods when it gets stripped down for painting but I`m confident it`ll all be worth it in the long run..


    cheers

    Stu
     
  16. davenport Member

    Messages:
    496
    england, cambs
    decided to say "balls" to work today and popped down the workshop..

    after a few hours I had this:

    [​IMG]

    [​IMG]

    [​IMG]

    [​IMG]

    that moves like this!!:

    [Youtube]


    STILL not happy with the rear ride height so next trip to the shop will sort that, set the droop, fit springs, rework exhaust hangers + backbox and declare the **** end, finished!!

    oh, and on a :D:D note, work have just installed a powder coater which should become very useful once the cars stripped down for final welding + paint!!
     
  17. davenport Member

    Messages:
    496
    england, cambs
    a friend of mine was popping over today to borrow the shell spit, so while I waited for him, I set about dropping the back end a bit more and a few little jobs that I had been avoiding..

    #1 getting its **** down...


    [​IMG]

    [​IMG]

    personally I think I`d prefer a bit lower..... but anyhow....



    #2 rear view mirror:


    [​IMG]

    [​IMG]

    this wasn`t as easy as I`d hoped and just as much of a **** as I`d feared.. the cage bar sits against the shell so using the clamps supplied with the curved mirror was gonna be a PITA, however with the trusty dremel, a hacksaw blade several files and LOTS of foul language relieved a bit of shell and it was done.. WIIIiiiiiiiiiiiiiiiDDE field of vision !! I can see out of the passenger 3/4 window right round the back and even my own receeding hairline and the fear in my eyes...




    #3 door mirrors:


    [​IMG]

    [​IMG]

    so happy with these!! (even though they are carbon) I always thought these diddy mirrors looked a bit lost on saloon cars, even small ones so these bigger beauties fit the bill perfectly for me, they even have 100cm2 or something so there legal too, WIN!!


    with the rattlebox having donated its rear calipers to the clio I needed to address the issue..

    sourced a set of Mathais for a good price, nothing seized or bust, a good start point!

    [​IMG]

    [​IMG]


    these were promptly took to bits, the holes bunged up and blasted:

    [​IMG]

    [​IMG]

    things were looking good, but the bolts that hold the carrier to the all body were pretty shot so I decided to get some new`uns..

    a bit of investimagating determined M12 x 1.5 - 27mm long..

    the local fastener place only had std or mega fine pitch so ebay!, ebay always has what ya need don`t it??

    and indeed they did!!

    [​IMG]

    and at that price, they could **Language** keep `em.. I`ll make me own...

    so, into the stores at work and found some long 12.9 sockets:

    [​IMG]

    they were then attacked with the thin disc:

    [​IMG]

    put in the lathe and chewed a new thread on them:

    [​IMG]

    ran a tap thru the ally bodies to clean out any left over threadlock/blast debris:

    [​IMG]

    the carriers have been treated to a BZP (bright zinc plated) which luckily has come back a bit dull so they look nice and subtle:

    [​IMG]


    new sliders/seals/pad retaining clips have been ordered from BOSCH in zee germanland, knowing there ruthless efficiency they will be here early next week and I can cross these off "the list"...


    cheers
    Stu
     
  18. davenport Member

    Messages:
    496
    england, cambs
    evening all..
    sorry for the prolonged silence.. as you`ve probably worked out from the lack of updates I`m pretty much a working machine of late.. I wont lie, its ****.. hardly see the yob, hardly see the missus and as hard as money comes in it pretty much immediately ***** off again.. however..
    end of March/start of April we managed to get away for a weeks holiday (despite the clio doing its best attempt to ruin it by spitting its diff out the casing) so, 1 brand new 308 hire car was hired and we went off to Cornwall...
    I`ve got a few friends down there.. Trace has a few friends down there.. I REALLY didn`t like the thought of taking yob abroad and even if I did I aint got a passport..
    so then.. progress!!!
    the turret tops have been modified (again) to accept the new billet topmounts, the reasons being I no longer need camber adjustment as that's done on the strut/hub connection of the satchell front end and I also liked the idea of being able to swap springs quicker and easier by bringing them thru the top..
    so.. a bit of welding.. a bit of holesawing.. a bit of drilling and hey presto!!
    [​IMG]
    which allows me to do this
    [​IMG]
    all I needed then was the billet!! they weren't finished before we went away so my efforts were directed to the dampers - the Bilsteins are LOOOOooong ol things and have a lot of droop this causes a few issues the joints on the suspension end up having to go thru a LOT of articulation and driveshaft lengths change quite a bit not to mention the handling issues it also introduces..
    so, I popped over to see "the man... the myth... the... ENIGMA!!" that's is Colin:
    [​IMG]
    not only him but also Dean/Dave and as luck had it Sandy.. while chatting away Dave kindly did this:
    [​IMG]
    and rethreaded the end.. HERO!
    I spend a a few more days doing stuff like this:
    [​IMG]
    then came home.. (gotta say the NEW 308`s are pretty cool, the touchscreen dash is funky, they`re comfy and despite being gutless it did a 1000+ miles at over 55mpg)
    *cough*
    I then bought a 307 family car
    *cough*
    got an email to say the topmounts were finished:
    [​IMG]
    [​IMG]
    [​IMG]
    new bearings pressed in:
    [​IMG]

    a MASSIVE thanks must go to Andy @ Kaitech for these, I didn`t request it but he even mirror polished them bless him..

    and that's about where I`m up to.. the front end can be rebuilt and driveshaft lengths reset AGAIN!!! for the new reduced droop and hopefully finished this time...
    much love, and again a big thanks to Col/Dave Vanstone @ Satchell HQ and Andy @ Kaitech precision...
    stu
     
  19. davenport Member

    Messages:
    496
    england, cambs
    Hello all....

    a few little step forwards saturday...

    Dash panel was collected from the harness manufacturer that was supposed to be sorting it all out...

    12 months and F**K all to show, so added to the 16 months wasted at "expert #1" makes over 2 years of lies/false promises/bullsh@t...

    Anyhow. . Reinstated this:

    [​IMG]

    also after a quick chat with the potential 'new' harness maker the relay boxes are getting relocated but I'm still faffing with a bracket on that...

    Shortened inserts are back in the struts.. 2nd turret top has been cut/welded/drilled/smoothed/primed and the suspension refitted:

    [​IMG]

    a few people asked if there was actually any bonnet clearance with these..

    Heres some proof...



    Loadsa room!!!

    Also got myself a Vband assembly for the rear section.. still undecided on tailpipe though..

    My head says keep it simple.. straight.. clean

    [​IMG]

    My heart says downswept (like Espens white 205 (shiny racing for those with LONG memories!!))

    My testies however say this!

    [​IMG]


    Only kiddin... well... maybe for comedy value....
     
  20. davenport Member

    Messages:
    496
    england, cambs
    needed to mount the relays up near the centre console to aid the wiring so took the opportunity to make an OTT bracket...

    started off with a simple 3 sided tray:

    [​IMG]


    attacked it with a thin disc/holesaw/file.. stitched some M6 nuts on the back and hit it with some temporary black aerosol:

    [​IMG]

    [​IMG]


    which fits all up like so:

    [​IMG]


    and mounts up here:

    [​IMG]

    [​IMG]


    got a new cat to fit on the 307 saturday so will hopefully get the shafts length corrected and fired back down to cornwall.... again.... lmao...
     
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