Willsy's 309 GTi - Latest update 04/09/2018

  1. West Midlands Joined: Nov 2005 Nuneaton (West Mids) Posts: 13835 '64 Volvo V40 R’Design, '89 Ph1 309 GTi, ‘97 Mk1 S
    #1
    New project begins, saw this 309 GTi listed locally and just had to buy it, an hour later and the bloke had kindly delivered it to my house.

    Essentially it's bloody filthy and needs a fair bit of tlc but it is still original in form. I'm owner number 4 and it's on 90,000 miles

    Pics as it arrived

















    This'll be more of a challenge than the AX and the XSi
    1 user thanked this post:
  2. L-plater Joined: Nov 2013 lancashire/accrington Posts: 47 Icelandic Saxo VTR 2003 mk2
    #2
    will be keepin an eye on this always loved 309's. what you got planned?
  3. Newbie Joined: Sep 2013 Glos Posts: 26 Saxo VTR 03, Mango Saxo Furio (Breaking for parts)
    #3
    sick !
  4. West Midlands Joined: Nov 2005 Nuneaton (West Mids) Posts: 13835 '64 Volvo V40 R’Design, '89 Ph1 309 GTi, ‘97 Mk1 S
    #4
    Quote:
    Originally Posted by GrumGTI View Post
    will be keepin an eye on this always loved 309's. what you got planned?
    As with my previous 2 projects everything done will be with the intention to restore it to its former glory.
  5. Saxperience Post Whore Joined: Mar 2009 Uppingham, Rutland Posts: 9569 mk1 JP4'd VTR, '16 Fabia Monte Carlo
    #5
    god thats beautiful, id love to have the older 309 gti 3 door
  6. Saxperience Post Whore Joined: Apr 2011 Posts: 9100 Amazon green VTR 16v, Inferno RS clio 182
    #6
    A very rare car nowadays, looks like a little bit more work to get right but that's part of the fun! Good luck with it


    Sent from my iPhone using Tapatalk
  7. Established Member Joined: Dec 2010 Preston Posts: 2007 '05 Golf GT FSI
    #7
    Oh yes!! Now THAT is a project! I cannot wait to see the way this turns out Matt!
  8. Newbie Joined: Oct 2013 near Manchester Posts: 8 Ax gti, T reg saxo vtr from new...
    #8
    Ha ha, thats filthy! Plenty to keep you busy!
  9. Frequent Poster Joined: Jul 2009 Littlehampton, West Sussex Posts: 613 1997 Amazon Green VTS
    #9
    I love these always wanted one
  10. Saxperience Addict Joined: Feb 2009 Middlesbrough Posts: 10620
    #10
    Gonna keep a keen eye on this oneee
  11. Established Member Joined: Apr 2008 Dudley Posts: 1634 106 GTI
    #11
    Snow foam and some crudzilla will sort the outa body work out a treat :-)
  12. Saxperience Post Whore Joined: Oct 2005 Sydney Posts: 8525 Mango Westcoast
    #12
    What happened to the xsi?
  13. Banned Joined: Nov 2013 Posts: 411
    #13
    Awesome I must have you on facebook as I saw this come up last night, such a beast!
  14. Saxperience Forum Bum Joined: Apr 2007 Fareham Posts: 3029 Saxo VTR
    #14
    I take it Lea has seen this........

    Looks an awesome project. I'm still tempted to buy leas 309.
  15. Saxperience Post Whore Joined: Jul 2011 Newcastle upon Tyne Posts: 7779 Phase 2 VTS , E61 M5
    #15
    Subscribed, I love a good 309
  16. West Midlands Joined: Nov 2005 Nuneaton (West Mids) Posts: 13835 '64 Volvo V40 R’Design, '89 Ph1 309 GTi, ‘97 Mk1 S
    #16
    Quote:
    Originally Posted by jpsaxo View Post
    What happened to the xsi?
    XSi is for sale mate :-)

    Just got home from work so I'm off outside for an hour to play with the 309.
  17. West Midlands Joined: Nov 2005 Nuneaton (West Mids) Posts: 13835 '64 Volvo V40 R’Design, '89 Ph1 309 GTi, ‘97 Mk1 S
    #17
    Bit of time spent on the GTi this evening before it got dark. My only aim being to finish getting the carpet out as the drivers side of the carpet was literally swimming, I had feared the worst for floor pan condition however I think it's been lucky. I'm sure the sunroof is the culprit with the drainage all blocked with foliage

    Rear drivers side footwell


    Front drivers side footwell needs some welding doing, both subframe bolts were badly corroded which I feared rounding off, the inside one snapped away from the mount and the outside one will be removed and replaced


    The carpet is in a horrific state. It's not excessively worn though so I'll see if it'll clean up with the wet vac


    All in all nothing dramatic so far
  18. Saxperience Forum Bum Joined: Apr 2013 Jarrow Posts: 4022 2003 Icelandic Grey 16v VTR 1991 Daihatsu GTti
    #18
    My old man had one if these when I was a kid, would love one. Can't wait to see progress.
  19. Newbie Joined: Feb 2013 Castelo Branco/Portugal Posts: 1 Citroën Ax 1.4D Citroën Berlingo 2.0 HDi Toyot
    #19
    Now that´s a big project!

    Good luck!
  20. Saxperience Addict Joined: Jan 2008 west london Posts: 13810
    #20
    wow thats a cool project

    always love a willsy restoration
  21. Saxperience Post Whore Joined: Jul 2010 Morley, Leeds Posts: 8469 Civic ep3 type r powered by TDI NORTH
    #21
    Quote:
    Originally Posted by willsy View Post
    The carpet is in a horrific state. It's not excessively worn though so I'll see if it'll clean up with the wet vac
    Fuck that willsy. Drown the fucker in some daisy apc and give it a jet wash. Had to do the same with my civic had windows left open for 6 weeks, Took 4 goes with the jet wash to get all the moss off.
  22. Saxperience Post Whore Joined: Oct 2005 Sydney Posts: 8525 Mango Westcoast
    #22
    looks like youve got a big job on your hands to get this up to scratch Matt, try and get it to the same standard as Leas 309 minter
  23. Infrequent Poster Joined: Apr 2012 newcastle Posts: 206
    #23
    Subscribed, looks like it's going to be a good thread! Keep it up and what does engine bay look like? You got many problems mechanically?


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  24. West Midlands Joined: Nov 2005 Nuneaton (West Mids) Posts: 13835 '64 Volvo V40 R’Design, '89 Ph1 309 GTi, ‘97 Mk1 S
    #24
    Cheers guys, seems to be quite a lot of love for 309's so I'll be as regular as possible with updates.

    It'll grab some updated pics this afternoon now that it's had its first wash and include some engine bay pics.
    There's quite a lot to keep me busy, passenger door doesn't open at the mo so that'll be one of the first bits to fix.

    I'm hoping my XSi sells quick so that I can get this in the garage to crack on with. I'm intending to get an MOT on it fairly quickly but until my XSi sells funds are limited. Does anyone know of someone who may be interested in my XSi?
  25. Newbie Joined: Aug 2012 Irvine Ayrshire
    #25
    I had one of these for 12 years, and covered 1TLC, , 000 miles in it. Great handling car without any mods. Mine leaked water also - the drain holes for the sunroof rust then the rubber hoses fall off. The rubber seal for the front windscreen also leaked, this was only £40 for the local windscreen place to change - no bonded windscreens to worry about.

    Looks like a straight car , just needing some tlc
  26. Newbie Joined: Aug 2012 Irvine Ayrshire
    #26
    I had one of these for 12 years, and covered 148 , 000 miles in it. Great handling car without any mods. Mine leaked water also - the drain holes for the sunroof rust then the rubber hoses fall off. The rubber seal for the front windscreen also leaked, this was only £40 for the local windscreen place to change - no bonded windscreens to worry about.

    Looks like a straight car , just needing some tlc,will keep an eye on your progress.
  27. Saxperience Post Whore Joined: Oct 2005 Sydney Posts: 8525 Mango Westcoast
    #27
    Sandy also had one of these with a type R engine in the front, was epic!
  28. Established Member Joined: Apr 2008 Dudley Posts: 1634 106 GTI
    #28
    Looks fantastic mega love for this
  29. West Midlands Joined: Nov 2005 Nuneaton (West Mids) Posts: 13835 '64 Volvo V40 R’Design, '89 Ph1 309 GTi, ‘97 Mk1 S
    #29
    Spent a couple of hours this morning trying out my new wet vac on the carpet, nothing like breaking it in gently ey.

    Here's before



    And here's drivers side in progress. The water that I'm chucking away has gone from extreme mud bath to milky latte in consistency so still a little way to go yet

  30. Established Member Joined: Jan 2013 Portsmouth Posts: 1335 1997 Mk1 VTS
    #30
    Looks like the wet vac did a good job considering how bad it was. Did you not jet wash it before the wet vac?
  31. Saxperience Addict Joined: Dec 2009 Posts: 11714 A6 Le Mans tuned/A3 TFSI tuned
    #31
    Always had a soft spot for these, a few friends of mine ll had these. Slightly slower than the 205 but much more stable.

    Quote:
    Originally Posted by willsy View Post
    I'm sure the sunroof is the culprit with the drainage all blocked with foliage
    certainly looks like it was left under a tree for a while. As long as it's not rusty it's all good.
  32. L-plater Joined: Oct 2009 Manchester Posts: 35 Citroen Saxo Vts MK1 red
    #32
    Good luck with the project.pretty sure it will worth!

    Sent from my GT-N7105 using Tapatalk
  33. West Midlands Joined: Nov 2005 Nuneaton (West Mids) Posts: 13835 '64 Volvo V40 R’Design, '89 Ph1 309 GTi, ‘97 Mk1 S
    #33
    Afternoon all, been busy all day again today, I have finally finished getting the carpet clean and up to scratch. It's taken me roughly 8 hours to get it to this level having cleaned it several times, there is still some staining behind the heel piece in the drivers side but after drowning it in vanish this is as good as it'll get, plus it'll be underneath some plush mats so I'm happy.
    Some bright spark Frenchman had also decided to glue the sound deadening to the underside of the carpet too so that took a great deal of effort to remove every last piece of it









    I'll probably get some of the interior plastics cleaned up this evening.
    Still waiting for the XSi to go before I can get the 309 in the garage
  34. Established Member Joined: Jan 2013 Portsmouth Posts: 1335 1997 Mk1 VTS
    #34
    Wow great job on the carpet, really surprised no one has snapped up the XSi
  35. West Midlands Joined: Nov 2005 Nuneaton (West Mids) Posts: 13835 '64 Volvo V40 R’Design, '89 Ph1 309 GTi, ‘97 Mk1 S
    #35
    Brand new steering wheel arrived in the post earlier



    The chap I bought the car off also kindly gave me 4 brand new lights! Hugely pleased with that as those who know how much a pair cost me for my old AX will know (AX GT and 309 use the same ones)



    And I've just spent the last hour taking apart and cleaning this piece of the dash/gear stick console. It was covered in muck and some minor mould! It's cleaned up just like new :-)



    Hopefully have cleaned up some more interior pieces tomorrow
  36. Established Member Joined: Dec 2010 Aberdeen Posts: 2129 Race: 106 Rallye 16v. Road: Mercedes Vito 120 CDI
    #36
    Good work!
  37. Saxperience Addict Joined: Jan 2008 west london Posts: 13810
    #37
    brilliant work on that carpet
  38. Infrequent Poster Joined: Mar 2013 Stourbridge/Dudley Posts: 135 Saxo 1.1i 2002
    #38
    Good job on the carpet, surprised it didn't disintegrate after all that cleaning lol!
  39. Established Member Joined: Apr 2008 Dudley Posts: 1634 106 GTI
    #39
    Wow nice work Matt really like it
  40. Saxperience Forum Bum Joined: Jun 2009 Jonathan Tonk's yard. Posts: 4232 '85 Opel Manta '88 Manta GT/E '87 Rayleigh Roadi
    #40
    That shit looks new man, good job.

    Just out of interest what did you use on the centre console thing?
  41. West Midlands Joined: Nov 2005 Nuneaton (West Mids) Posts: 13835 '64 Volvo V40 R’Design, '89 Ph1 309 GTi, ‘97 Mk1 S
    #41
    Quote:
    Originally Posted by manta View Post
    That shit looks new man, good job.

    Just out of interest what did you use on the centre console thing?
    Cheers mate, centre console had to start off with a good scrub with baby wipe/quick detailer combo, then a few coats of Autoglym Vinyl and Rubber care. Leaves a nice finish.
  42. West Midlands Joined: Nov 2005 Nuneaton (West Mids) Posts: 13835 '64 Volvo V40 R’Design, '89 Ph1 309 GTi, ‘97 Mk1 S
    #42
    More progress from today on various interior pieces.

    First up the carpeted dash pieces which fit behind the gearstick console. They'd developed mould and we're disgusting on both sides



    And after





    Then moved on to the lower rear bench. Again stained, covered in bits and slight mould



    Satisfying results again, loads of muck came out of them. Slight damage to one but it is repairable fortunately





    Another piece cleaned up on the gearstick housing. New gaiter is on it's way too as the old ones started to fall apart



    Handbrake piece dismantled and cleaned up too. Also serves as a cool feature of two independent cable levers to open the rear windows, and the fuel flap release





    The Mrs is taking it remarkably well considering our living room is currently filled with interior pieces.
  43. Regular Poster Joined: Feb 2012 Cambridgeshire Posts: 344 Evo 2 GSR, Saxo VTR, Mini Cooper S
    #43
    Brilliant work!
  44. Saxperience Addict Joined: Jan 2008 west london Posts: 13810
    #44
    brilliant work
    the pieces literally look like new

    what's direction are going with the car itself? original factory condition or subtley modified?
  45. West Midlands Joined: Nov 2005 Nuneaton (West Mids) Posts: 13835 '64 Volvo V40 R’Design, '89 Ph1 309 GTi, ‘97 Mk1 S
    #45
    Quote:
    Originally Posted by LSOfreak View Post
    brilliant work
    the pieces literally look like new

    what's direction are going with the car itself? original factory condition or subtley modified?
    Cheers mate, direction is purely to original factory condition. Hoping it'll be really tidy by the time I've completed it :-)
  46. Saxperience Forum Bum Joined: Mar 2012 Posts: 3593
    #46
    Everything looks great so far!

    I'm shocked at how you get everything to look so new!
  47. Saxperience Hardcore! Joined: Dec 2007 smurfland. Posts: 17346 Ex saxo owner.
    #47
    I`ve just done similar with the saxo & found that spraying on vanish letting it settle then working it with a nail brush works wonders.Good progress mate.
  48. Newbie Joined: Feb 2013 Castelo Branco/Portugal Posts: 1 Citroën Ax 1.4D Citroën Berlingo 2.0 HDi Toyot
    #48
    wow! Very nice!
  49. West Midlands Joined: Nov 2005 Nuneaton (West Mids) Posts: 13835 '64 Volvo V40 R’Design, '89 Ph1 309 GTi, ‘97 Mk1 S
    #49
    Cheers guys :-)
    Stevo you're right Vanish does work wonders, leaving it to soak in a bit then working it in with an old toothbrush and leaving a bit longer was quite effective

    Finally got the 309 in the garage this evening and my god I have my work cut out. Here's some lovely pictures of the engine bay, this'll need a good few hours, maybe days worth of cleaning up



  50. Saxperience Hardcore! Joined: Dec 2007 smurfland. Posts: 17346 Ex saxo owner.
    #50
    I`d be tempted to take the engine out & clean up the bay with it removed,then you`ll be also to see any corrosion.
  51. West Midlands Joined: Nov 2005 Nuneaton (West Mids) Posts: 13835 '64 Volvo V40 R’Design, '89 Ph1 309 GTi, ‘97 Mk1 S
    #51
    Quote:
    Originally Posted by stevo67 View Post
    I`d be tempted to take the engine out & clean up the bay with it removed,then you`ll be also to see any corrosion.
    I think I probably will to be fair. Whilst it's all in I'll get it running first so I'm happy with it then strip it all down.
  52. Established Member Joined: Apr 2008 Dudley Posts: 1634 106 GTI
    #52
    Wow that's going to need a lot of work I take it a full service prior starting it ?
  53. West Midlands Joined: Nov 2005 Nuneaton (West Mids) Posts: 13835 '64 Volvo V40 R’Design, '89 Ph1 309 GTi, ‘97 Mk1 S
    #53
    Yes definitely the most sensible thing to do.
  54. Saxperience Post Whore Joined: Oct 2005 Sydney Posts: 8525 Mango Westcoast
    #54
    Great work on the interior so far Matt, and you've got your work cut out with that engine bay. But if anyone can sort it out it's you and your anal cleaning ways
  55. Newbie Joined: Feb 2013 Castelo Branco/Portugal Posts: 1 Citroën Ax 1.4D Citroën Berlingo 2.0 HDi Toyot
    #55
    I vote to take Engine out, clean everyting, and replace any belts an bearing! The water pump, and the clutch since it is out. Oil filter/oil, air filter too. That engine need a litle of care. It´s not expensive in this car´s to change the basics.
  56. Frequent Poster Joined: Jul 2009 Littlehampton, West Sussex Posts: 613 1997 Amazon Green VTS
    #56
    This is shaping up well already, agree with above post on the engine removal and overhaul.
  57. West Midlands Joined: Nov 2005 Nuneaton (West Mids) Posts: 13835 '64 Volvo V40 R’Design, '89 Ph1 309 GTi, ‘97 Mk1 S
    #57
    Some more small updates at the moment, I've just had the odd hour here and there over the last few days so I've mostly been taking bits off to clean up whilst watching TV at night.

    The 309 is finally in my garage now though so progress will be much quicker being in the dry with light all day :-)

    Lovely stuff


    There was part of a bush growing behind the piece between the rear lights




    Just a quick dabble with the cleaning products before the Mrs arrived home with dinner, so only a quick hint of more to come





  58. Established Member Joined: Jan 2013 Portsmouth Posts: 1335 1997 Mk1 VTS
    #58
    I want one, looks so therapeutic
  59. Established Member Joined: Mar 2011 Torbay Posts: 1285 Mauritius Vts, 206 Gti 180
    #59
    This is awesome work! Very keen to see what you manage with the bay after seeing the AX pictures too

    I really enjoy doing things like this, its hard to stop once you start removing things and cleaning them up haha.
  60. Established Member Joined: Mar 2010 Bradford Posts: 1490 '02 VTR, '92 106 XSI 16v
    #60
    Very nice work buddy!
    I am gutted that you're getting rid of the XSI
    But this seems an awesome project! I can see why you chose this over the 106.
    I will be keeping an eye on this thread
  61. Frequent Poster Joined: Jul 2009 Littlehampton, West Sussex Posts: 613 1997 Amazon Green VTS
    #61
    309 ftw
  62. West Midlands Joined: Nov 2005 Nuneaton (West Mids) Posts: 13835 '64 Volvo V40 R’Design, '89 Ph1 309 GTi, ‘97 Mk1 S
    #62
    Got one of my priority 'to do' jobs completed this morning and it did end up taking most of the morning- the passenger door wouldn't open.

    Stripped everything off the door to gain access to the lock mechanism inside the door, everything bloody solid and seemingly the strike pin bit was also stuck. Eventuly got it freed up, door open at last.

    Met with a mass of muck and dirt and a very poorly neglected mechanism so with the door open I could now remove it, clean it up and apply some lubricant. The door now functions perfectly as it should do - job well done

    Pics will come once I've cleaned the disgraceful mess around the door seal & door shut.
  63. Saxperience Addict Joined: Jan 2008 west london Posts: 13810
    #63
    i love how regular the updates are with these resto threads lol
  64. West Midlands Joined: Nov 2005 Nuneaton (West Mids) Posts: 13835 '64 Volvo V40 R’Design, '89 Ph1 309 GTi, ‘97 Mk1 S
    #64
    Quote:
    Originally Posted by LSOfreak View Post
    i love how regular the updates are with these resto threads lol
    Lol every opportunity I get at the moment I'm pottering in the garage, really enjoying this one already :-) this month will be mostly spent with general cleaning and maintenance in particular getting the interior cleaned and dry.

    Then when the XSi sells I'll get cracking on servicing the engine and hopefully spring some life back into it.
  65. West Midlands Joined: Nov 2005 Nuneaton (West Mids) Posts: 13835 '64 Volvo V40 R’Design, '89 Ph1 309 GTi, ‘97 Mk1 S
    #65
    Really happy to have found a brand new genuine full lock & ignition set aswel with the correct Peugeot logo embossed keys.



    I had one key for the drivers door, a different key for the boot lock, another key for the ignition switch and no key atall for the passenger lock - nightmare.
  66. Newbie Joined: Feb 2013 Castelo Branco/Portugal Posts: 1 Citroën Ax 1.4D Citroën Berlingo 2.0 HDi Toyot
    #66
    Great news men! In my Citroën AX, i took out the lock mechanism and after i clean up with water and detergents, i clean again when dry with WD-40, and after that i put selicone oil! Was a reall big Job, but it´s perfect!
  67. Saxperience Forum Bum Joined: Sep 2011 Doncaster Posts: 2627 Fabia VRS, mk1 fiesta + some others
    #67
    I think a strip down and rebuild may be the best option, not literaly rebuild, but just to strip so that access to clean is better!

    The progress so far is good though! Good luck!
  68. Saxperience Post Whore Joined: Jan 2006 Posts: 9363 Focus ST & 206 GTI180
    #68
    Quote:
    Originally Posted by m4tt274 View Post
    I think a strip down and rebuild may be the best option, not literaly rebuild, but just to strip so that access to clean is better!

    The progress so far is good though! Good luck!
    I think I agree on all.

    This project has potential!
  69. L-plater Joined: Feb 2014 Preston Posts: 61 mk1 vts
    #69
    Cant wait to see more updates from this looks great!!
  70. West Midlands Joined: Nov 2005 Nuneaton (West Mids) Posts: 13835 '64 Volvo V40 R’Design, '89 Ph1 309 GTi, ‘97 Mk1 S
    #70
    Cheers guys, been down to London for a few days so not much to update on yet. Had a few hours tonight though which I spent washing and starting to clean up the window seals which I'd taken out of the passenger door, all takes time and not particularly interesting as an update but given that they were covered in conifer, moss and mould they're coming up really well. Leaving them to soak in hot water & washing up liquid makes them nice and supple again.
    They're drying off now then I'll treat with some rubber care tomorrow. The soft flocked type texture on the inner seals seems fine and there's no cracking or degradation of the rubber seals due to its age or neglect so I am pleased.
  71. West Midlands Joined: Nov 2005 Nuneaton (West Mids) Posts: 13835 '64 Volvo V40 R’Design, '89 Ph1 309 GTi, ‘97 Mk1 S
    #71
    And as many have said or suggested I am doing a complete strip down and rebuild in stages. Some parts will just need some cleaning and tlc but it'll definitely allow me to be very thorough with it.
  72. Saxperience Post Whore Joined: Oct 2005 Sydney Posts: 8525 Mango Westcoast
    #72
    you've got a massive job on your hands here Matt, but if anyone can do it - you can!

    Once complete it will be one of the best 309's in the UK

    Good luck mate, I hope to come and see it in the summer and see the progress
  73. West Midlands Joined: Nov 2005 Nuneaton (West Mids) Posts: 13835 '64 Volvo V40 R’Design, '89 Ph1 309 GTi, ‘97 Mk1 S
    #73
    Oh I know mate, this is much much more of a challenge than the last projects.

    Spent most of the day again today doing more bits and bobs.
    Got the passenger door window seals finished, they look almost new :-)





    Then thought I'd continue to clean up the passenger door, despite it being hidden this kind of mess annoys me


    Some hours later and the panels looking much better


    And I cleaned out no end of crap from within the bottom of the door and cleared the drainage holes


    Door accomplished I used the remainder of the pack of baby wipes to start on this


    To this


    Got a bit cold outside then so spent the last hour before dinner cleaning some more interior trim in the warmth of the house




    And this'll do for the day
    3 users thanked this post: , ,
  74. Frequent Poster Joined: Jan 2012 Cheshire Posts: 872 Nothing fun anymore....
    #74
    Absolutely loving progress on this, keep giving me inspiration for mine lol!

    Think I'll be bringing in the interior piece by piece now it's in my garage.

    Keep it up dude great work.
    1 user thanked this post:
  75. West Midlands Joined: Nov 2005 Nuneaton (West Mids) Posts: 13835 '64 Volvo V40 R’Design, '89 Ph1 309 GTi, ‘97 Mk1 S
    #75
    Quote:
    Originally Posted by vtectransplant View Post
    Think I'll be bringing in the interior piece by piece now it's in my garage.
    I keep telling my Mrs that having an assembled car interior in the living room is modern art lol, I have quite a bit of it assembled in there now & it's looking good :-)
  76. Frequent Poster Joined: Jan 2012 Cheshire Posts: 872 Nothing fun anymore....
    #76
    Quote:
    Originally Posted by willsy View Post
    I keep telling my Mrs that having an assembled car interior in the living room is modern art lol, I have quite a bit of it assembled in there now & it's looking good :-)

    Lol! Should've seen my wife's face when I brought the Accord TypeR rear seats in before! She actually suggested we get rid of one of the couches!
  77. Newbie Joined: Aug 2012 Irvine Ayrshire
    #77
    Down inside the rear quarters, at the seat belt anchor points was where the rust started on mine. After your clean up, that looks solid, lovin the effort your putting in.
  78. West Midlands Joined: Nov 2005 Nuneaton (West Mids) Posts: 13835 '64 Volvo V40 R’Design, '89 Ph1 309 GTi, ‘97 Mk1 S
    #78
    Cheers Tom, the passenger side in the rear quarter bit seems pretty good. Hopefully the drivers side is ok too. We'll see how things progress
  79. Newbie Joined: Feb 2013 Castelo Branco/Portugal Posts: 1 Citroën Ax 1.4D Citroën Berlingo 2.0 HDi Toyot
    #79
    Perfect!
  80. Frequent Poster Joined: Jan 2008 West Bromwich Posts: 828
    #80
    Loving this progress thread, always loved 309's, I really should motivate myself to clean up and service the 205.
  81. Infrequent Poster Joined: Jul 2006 West Sussex Posts: 116 Citroen Saxo Vts
    #81
    Very inspiring work mate, Ive always struggled keeping the interior of my cars at a good standard, whats your methods on bringing the internal panels up to scratch? I can never get my dash etc to look that clean.
  82. Saxperience Post Whore Joined: Feb 2008 wirral Posts: 6348 Icelandic vtr turbo
    #82
    Going to subscribe to this, got a soft spot for 309's just never been able to find one when I've had money. Can't wait to see it all done mate, your cars are always class when your through with them
  83. Frequent Poster Joined: Jan 2012 Cheshire Posts: 872 Nothing fun anymore....
    #83
    Quote:
    Originally Posted by willsy View Post
    Cheers mate, centre console had to start off with a good scrub with baby wipe/quick detailer combo, then a few coats of Autoglym Vinyl and Rubber care. Leaves a nice finish.


    Quote:
    Originally Posted by dobsd001 View Post
    Very inspiring work mate, Ive always struggled keeping the interior of my cars at a good standard, whats your methods on bringing the internal panels up to scratch? I can never get my dash etc to look that clean.

    There ya go
    1 user thanked this post:
  84. West Midlands Joined: Nov 2005 Nuneaton (West Mids) Posts: 13835 '64 Volvo V40 R’Design, '89 Ph1 309 GTi, ‘97 Mk1 S
    #84
    Evening all, some more progress will come over the next few days. Not sure exactly which bit I fancy working on yet though, although I may actually Hoover the engine bay lol.

    Started taking the headlights and grille panel out to inspect behind them for what is a common rusty area. Although not perfect I'm quite pleased that there's nothing horrendous to tackle. The moss has been evicted from below the headlights too.

    Here's a few 'before' pictures before I get cracking











  85. West Midlands Joined: Nov 2005 Nuneaton (West Mids) Posts: 13835 '64 Volvo V40 R’Design, '89 Ph1 309 GTi, ‘97 Mk1 S
    #85
    Well today I got a bit more done on the 309. Started the day by hoovering the engine bay to get rid of all the conifer, I actually managed to fill the dyson!

    I then thought I'd get the sunroof working again, another thing that didn't work due to neglect and an infestation of shrubbery blocking everything. It does now open but I want to figure out how to remove it entirely to clean things up properly. To give you an idea of what I've had to clear out....





    I'll post up more pics of that once I've finished it.

    I then carried on removing some interior trim for some more cleaning



    Cleaned the rear bench area up easy enough



    Funky old skool feature alert, the levers here open and close the rear windows



    More to be done tomorrow
  86. Saxperience Hardcore! Joined: Sep 2007 Jail - Whitby Posts: 15034 520bhp Honda Jazz
    #86
    The things you do to cars amazes me! I'd have cleaned one bit, and just given up!
  87. West Midlands Joined: Nov 2005 Nuneaton (West Mids) Posts: 13835 '64 Volvo V40 R’Design, '89 Ph1 309 GTi, ‘97 Mk1 S
    #87
    Lol cheers mate, it does take a fair bit of time and determination.
    I've been fortunate enough to have had a decent size garage to do most of the work in, without that it would be very difficult. Much easier when the cars aren't daily drivers too, I can take much longer doing jobs without rushing to get it back together again for work the following day etc.
  88. Newbie Joined: Oct 2013 near Manchester Posts: 8 Ax gti, T reg saxo vtr from new...
    #88
    Love them cable operated rear window openers!
  89. Saxperience Hardcore! Joined: Sep 2007 Jail - Whitby Posts: 15034 520bhp Honda Jazz
    #89
    Quote:
    Originally Posted by willsy View Post
    Lol cheers mate, it does take a fair bit of time and determination.
    I've been fortunate enough to have had a decent size garage to do most of the work in, without that it would be very difficult. Much easier when the cars aren't daily drivers too, I can take much longer doing jobs without rushing to get it back together again for work the following day etc.
    Totally get that, think i would find it easier to work on cars if i wasn't laid outside, on the ground, with the wind blowing through the garden!

    Hopefully one day i will have a decent size garage where i can keep a project and take my time and work through it! With some heating in there too!
  90. West Midlands Joined: Nov 2005 Nuneaton (West Mids) Posts: 13835 '64 Volvo V40 R’Design, '89 Ph1 309 GTi, ‘97 Mk1 S
    #90
    Another day of progress to begin shortly. Think I'll aim to finish sorting the sunroof out and clean the backrest part of the rear bench as today's tasks.

    Other than that I need to sort out and list for sale all my 106 XSi spares to free up some funds
  91. West Midlands Joined: Nov 2005 Nuneaton (West Mids) Posts: 13835 '64 Volvo V40 R’Design, '89 Ph1 309 GTi, ‘97 Mk1 S
    #91
    Spent most of the day tinkering with the 309 again.

    Managed to get the back rest parts of the rear seats cleaned up with the wet vac, they've come up brilliantly so very pleased with those.

    The rest of the day was spent dismantling the sunroof and starting to clean everything up, goddam conifer & sludge everywhere



    Got this far before calling it a day

  92. L-plater Joined: Feb 2014 Preston Posts: 61 mk1 vts
    #92
    i am loving this! the effort you put into the cleaning is great. can't wait to see it all back together!!!
  93. Infrequent Poster Joined: Apr 2012 newcastle Posts: 206
    #93
    Is that a new sunroof?!? Ha! Loving the the progress mate, your putting some effort into it


    Sent from my iPhone using Tapatalk
  94. West Midlands Joined: Nov 2005 Nuneaton (West Mids) Posts: 13835 '64 Volvo V40 R’Design, '89 Ph1 309 GTi, ‘97 Mk1 S
    #94
    Cheers Anton, it's painstakingly slow progress but well worth it.
    I'll get everything cleaned up eventually and get it running again. This year will be spent doing that and making sure I've got all the parts/best ones I can find.
    Ultimately though I won't be happy until I've saved up for a full respray, but that'll likely be next year as I'll want strip it right the way back to do a bare shell respray on it.
    1 user thanked this post:
  95. West Midlands Joined: Nov 2005 Nuneaton (West Mids) Posts: 13835 '64 Volvo V40 R’Design, '89 Ph1 309 GTi, ‘97 Mk1 S
    #95
    Quote:
    Originally Posted by shaund123 View Post
    Is that a new sunroof?!? Ha! Loving the the progress mate, your putting some effort into it
    Lol everything in the pic is original except the replacement nuts and bolts, I've got loads of high tensile A4 marine grade stainless bits so it's always nice to replace knowing that things will come apart easily in future.

    I spend quite a bit of time cleaning out existing threads here and there aswel, popping a final tap through cleans out any muck & rusty residue that old bolts leave behind.
    1 user thanked this post:
  96. Saxperience Addict Joined: Jan 2008 west london Posts: 13810
    #96
    good job on the sunroof. Like new
  97. Frequent Poster Joined: Dec 2009 E yorkshire Posts: 947 53 black vtr
    #97
    Liking this progress thread. It just shows ya ya dont need to go out and spend shit loads of money just a lot of elbow grease lol. I must admit after seeing the 106 and this ive been cleaning my car a lot more thoroughly lately. Nice one
  98. West Midlands Joined: Nov 2005 Nuneaton (West Mids) Posts: 13835 '64 Volvo V40 R’Design, '89 Ph1 309 GTi, ‘97 Mk1 S
    #98
    Cheers mate, always nice to know my efforts inspire others a bit too.
    It is amazing how far a little bit of attention to detail can go.

    Rest days coming up again after today so I should get a few more bits done. I should probably stick with finishing a bit and then carry on, I tend to wander off on a tangent & start doing random bits. Ideally I want to get the interior finished and refitted, it's amazing how much room it takes up when it's out the car. Then I'll see about getting the engine serviced & running.
  99. Saxperience Hardcore! Joined: Mar 2008 Posts: 31279 Citroen Saxo VTS, S60 D5
    #99
    Awesome.
  100. Saxperience Hardcore! Joined: Dec 2007 smurfland. Posts: 17346 Ex saxo owner.
    #100
    Looking good mate,i`ll be interested to see how the engine runs.
  101. West Midlands Joined: Nov 2005 Nuneaton (West Mids) Posts: 13835 '64 Volvo V40 R’Design, '89 Ph1 309 GTi, ‘97 Mk1 S
    #101
    Spent today removing more interior to clean up along with cleaning of the boot area.

    The boot floor was disgusting for starters, removed traces of the old carpet glue on the arches too. Found a little bit of rust tucked up in the offside rear inner arch area under where the jack is stored. This is a common area, so much so that Peugeot did make a replacement piece for this area, havnt checked to see if they still stock them yet.

    Anyway here's the before pics after I'd removed the boot carpets (those will get vac'd and shampood over the next few days







    And the afters









    Popped the sunroof back into place to test it aswel. I've cleaned it to death and it finally has nice smooth operation and no longer needs the assistance of a rubber mallet.



    That's it for today folks
  102. Established Member Joined: Mar 2011 Birmingham Posts: 2148 Rover BRM, Rover 800 Coupe, Mk6 golf.
    #102
    Amazing work mate.

    You must have the patience of a saint... and then some!
  103. Saxperience Post Whore Joined: Apr 2011 Posts: 9100 Amazon green VTR 16v, Inferno RS clio 182
    #103
    Or a time machine. Pop back to when the car was new, snap photos and come back to the present?

    In all seriousness it's excellent work, attention to detail is off the scale. Kudos to you


    Sent from my iPhone using Tapatalk
  104. Saxperience Hardcore! Joined: Sep 2007 Jail - Whitby Posts: 15034 520bhp Honda Jazz
    #104
    Quote:
    Originally Posted by jasonmayall View Post
    Amazing work mate.

    You must have the patience of a saint... and then some!
    Thought this so many times! I'd be sat there mumbling to myself "stupid fucking french bastards putting all this fucking shit on the floor, why not just use velcro or something, cunts"
    2 users thanked this post: ,
  105. West Midlands Joined: Nov 2005 Nuneaton (West Mids) Posts: 13835 '64 Volvo V40 R’Design, '89 Ph1 309 GTi, ‘97 Mk1 S
    #105
    That was exactly my thoughts Smith, they weren't shy with the bloody glue either, took me hours to get it all off & Velcro will be used instead when refitting.

    Another annoyance is that Peugeot seemingly used thread lock on every sodding bolt, along the entire length of the bolts too.
  106. West Midlands Joined: Nov 2005 Nuneaton (West Mids) Posts: 13835 '64 Volvo V40 R’Design, '89 Ph1 309 GTi, ‘97 Mk1 S
    #106
    Spoiler off today! Utter utter filth underneath it



    Clean enough for now



    Another car day tomorrow, undecided on what to do. Id like to get the rear windows out to clean them and the seals etc
  107. West Midlands Joined: Nov 2005 Nuneaton (West Mids) Posts: 13835 '64 Volvo V40 R’Design, '89 Ph1 309 GTi, ‘97 Mk1 S
    #107
    Boot carpets had a good clean with the wet vac earlier aswel. The usual before pics as follows







    And afters with a little more drying required overnight





  108. L-plater Joined: Feb 2014 Preston Posts: 61 mk1 vts
    #108
    That wet vac is unreal!!! Can you tell me what it is please?
  109. West Midlands Joined: Nov 2005 Nuneaton (West Mids) Posts: 13835 '64 Volvo V40 R’Design, '89 Ph1 309 GTi, ‘97 Mk1 S
    #109
    Quote:
    Originally Posted by Anton_vts View Post
    That wet vac is unreal!!! Can you tell me what it is please?
    Hey mate, it's a Karcher Puzzi 8/1C. Seems to be doing a great job so far. Front seats next
    1 user thanked this post:
  110. Infrequent Poster Joined: Jul 2006 West Sussex Posts: 116 Citroen Saxo Vts
    #110
    Wow Willsy thats quite an expensive piece of kit! Very nice
  111. Established Member Joined: Aug 2012 Posts: 2009 Saxò VTS 16v
    #111
    Your attention to details are unbelievable,i am seriously amazed,kudos to you for that!
  112. Infrequent Poster Joined: Jul 2005 Glasgow United Kingdom (Scotland) Posts: 107 2 saxo vts , ax vts , 4.7 V8 jeep
    #112
    Love these !
  113. Saxperience Post Whore Joined: Jul 2007 Nuneaton Posts: 6476 RB RS 200
    #113
    Matt my clio and my 309 need wetvac goodness!!
  114. West Midlands Joined: Nov 2005 Nuneaton (West Mids) Posts: 13835 '64 Volvo V40 R’Design, '89 Ph1 309 GTi, ‘97 Mk1 S
    #114
    Quote:
    Originally Posted by LEE_VTR1 View Post
    Matt my clio and my 309 need wetvac goodness!!
    I have the weekend off on 15th/16th mate, I say cleaning day/s followed by that pint/s at the local?
  115. Forum Section Moderator Joined: Aug 2006 Westgate on Sea/Bexley Posts: 17223 Series 1 Rallye
    #115
    Any updates?
  116. West Midlands Joined: Nov 2005 Nuneaton (West Mids) Posts: 13835 '64 Volvo V40 R’Design, '89 Ph1 309 GTi, ‘97 Mk1 S
    #116
    Quote:
    Originally Posted by Dan-Subtle View Post
    Any updates?
    None since Dan, currently in Egypt til Thursday night. I am then still off on annual leave for a further 4 days so expect some good progress to be up over next weekend :-)
  117. Saxperience Hardcore! Joined: Dec 2007 smurfland. Posts: 17346 Ex saxo owner.
    #117
    Enjoying this thread.
  118. Saxperience Hardcore! Joined: Oct 2008 Birtley Posts: 22253 VTR Turbo, 106 xsi track slag, Transit recovery, B
    #118
    dunno how you find the time matt but as always, hats off for the effort
  119. Forum Section Moderator Joined: Aug 2006 Westgate on Sea/Bexley Posts: 17223 Series 1 Rallye
    #119
    Quote:
    Originally Posted by willsy View Post
    None since Dan, currently in Egypt til Thursday night. I am then still off on annual leave for a further 4 days so expect some good progress to be up over next weekend :-)
    Blimey, enjoy the holiday. Look forward to the updates.
    1 user thanked this post:
  120. West Midlands Joined: Nov 2005 Nuneaton (West Mids) Posts: 13835 '64 Volvo V40 R’Design, '89 Ph1 309 GTi, ‘97 Mk1 S
    #120
    Back from holiday so tomorrow progress shall resume

    Removed the scuttle panelling earlier as that'll be first port of call to sort this shambles





    Disgusting as expected. A few small bits of surface rust in there but It is completely solid so I should be able to remove the majority with a wire attachment on the drill, treat accordingly and keep progression at bay until eventual full strip down and respray.

    I also want to get the dash out to clean it and finish drying off the interior, the sound deadening behind the dash was quite wet too when I got it so that's still causing a pond like smell.

    Rear windows need to come out too as the seals are covered in smelly conifer gunk aswel.

    I'll get updates up again by tomorrow evening with progression
  121. West Midlands Joined: Nov 2005 Nuneaton (West Mids) Posts: 13835 '64 Volvo V40 R’Design, '89 Ph1 309 GTi, ‘97 Mk1 S
    #121
    Evening all. Right well more progress today, I have literally spent from 9 til 5 on the car and I am knackered. Progress based on the pictures looks pretty slim but again bare in mind the bits I have done have involved stripping down to every last individual piece, to clean up, free up (wiper spindles were seized solid they've taken some work to rectify). It took me 2 hours alone to clean up one of the rear window seals to give an idea.

    I started off with the scuttle area, see previous post for 'before' pictures. Here's with parts removed and the trough cleaned. Unfortunately there is some unsightly surface rust that needs attention, but rest assured I've thoroughly checked that that is all that it is so when I get chance to pop and get a wire attachment for the drill I'll clean it back, and treat it. I won't actually be spraying it until warmer weather arrives.





    Temporarily refitted wiper assembly and vacuum tank for the sunroof





    Then moved onto the passenger rear window. Removed it to find this





    And after





    The seal was so caked in muck that I left it to soak in hot water with a high concentration of fairy liquid and degreaser, it works wonders and makes the rubber nice & supple again especially with the hardened dry muck removed. Once dry I coated it in a selection of autoglym rubber care products.

    I ended with a quickie job of removing the old fog/driving lamps. It's just as well that I have 2 new pairs as the backing pieces were entirely unuseable



    I did strip them down though to salvage spares, in particular the glass as none of them are smashed or have cracks so they might be ideal spares for someone with these lights getting harder to come by and increasingly more expensive.

    And that's as far as 8 hours pretty much none stop got me
  122. Forum Section Moderator Joined: Aug 2006 Westgate on Sea/Bexley Posts: 17223 Series 1 Rallye
    #122
    Loving the progress on this, you have some serious patience.

    Have you set a deadline for getting it finished or just as long as it takes?

    What's the plan for when its finished? Concourse shows or just enjoy driving it around.
  123. Frequent Poster Joined: Jan 2012 Cheshire Posts: 872 Nothing fun anymore....
    #123
    I wish you'd stop with all these immense updates it's making me embarrassed about my lack of effort lol!

    Only joking, keep it up its so good to see!
  124. North West Joined: Apr 2009 Warrington, Cheshire Posts: 5733 PH2 Peugeot 106 "race" car - Currently in pieces
    #124
    Lea might have them for his??

    Awesome work so far dude. Keep it going.
  125. West Midlands Joined: Nov 2005 Nuneaton (West Mids) Posts: 13835 '64 Volvo V40 R’Design, '89 Ph1 309 GTi, ‘97 Mk1 S
    #125
    Cheers guys, slow and steady but definitely in the right direction so far :-)

    Quote:
    Originally Posted by Dan-Subtle View Post
    Have you set a deadline for getting it finished or just as long as it takes?

    What's the plan for when its finished? Concourse shows or just enjoy driving it around.
    No deadline as such Dan, this year I won't have such funds available to put into the paintwork as ideally it'll need a respray, with cars this old and with my eagle eye I could never settle with just doing the odd panels and never getting a decent colour match. So that's a job I'll save for to do properly. So perhaps next summer for that.

    This year though I'd like to get it running and make sure everything works as it should. Parts such as trim are becoming quite hard to come by with some new genuine ones commanding a premium already. So this year will be spent getting all the trim and bits on the car mint, and sourcing mint ones for bits which I'm not 100% happy with.

    Above all with this one I do aim to use it at least once a week and more in the summer to enjoy it. Something which I havnt done with the last projects, AX was too low mileage to put regular miles on at 25,000. At 89,000 currently on the 309 extra mileage won't really effect the value but I will aim for a standard that I'd at least be happy to call mint. I can happily put in Concours hours into the car but not the Concours money to match it
  126. West Midlands Joined: Nov 2005 Nuneaton (West Mids) Posts: 13835 '64 Volvo V40 R’Design, '89 Ph1 309 GTi, ‘97 Mk1 S
    #126
    Slight modification here to improve on the rear window piece being riveted to the B pillar. I have instead installed rivet nuts



    For easy fitting and dismantling for regular cleaning with M4 button head bolts



    And voila

  127. Newbie Joined: Jun 2012 Posts: 6
    #127
    Great attention to detail, love the rear window mechs on these.
  128. West Midlands Joined: Nov 2005 Nuneaton (West Mids) Posts: 13835 '64 Volvo V40 R’Design, '89 Ph1 309 GTi, ‘97 Mk1 S
    #128
    Just a quick update as I havnt spent any time on the car over the last week due to 12 hour shifts.
    However I have increased my stock of A4 marine grade stainless bits and bobs with the nuts and bolts being the A4-80 high tensile ones. This'll make things much easier to work on on the car :-)



    And I've managed to find someone selling an original Clarion radio/cassette from the same year. It works, has all the wiring in tact and it's got the original key code and user manual. Very happy with that



    I will have a more meaningful update soon.
  129. Regular Poster Joined: Feb 2012 Cambridgeshire Posts: 344 Evo 2 GSR, Saxo VTR, Mini Cooper S
    #129
    Loving that tape player!!
  130. West Midlands Joined: Nov 2005 Nuneaton (West Mids) Posts: 13835 '64 Volvo V40 R’Design, '89 Ph1 309 GTi, ‘97 Mk1 S
    #130
    A little more progress today. Thought I'd carry on with the front end a bit and get a few bits refitted to tidy up the garage a bit.

    I've made a start on restoring the front bumper to how it should be. This is how it started as faded, a little moss stained in places and plenty of muck to remove.



    A few hours later, I won't bore you all with the process I've used unless anyone's particularly interested, and this is the passenger side done



    Also the headlamps, front indicators, driving lamps and the fog lights are all brand new genuine ones.

    Whilst the fogs & driving lamps were out I've fitted new chimney nuts



    And sorted out the knackered old connections which are mostly corroded



    With new genuine ones. Never one for settling for cheap alternative spade connections which had been used previously on the outer lamp



    All in all quite pleased with the results so far
  131. Frequent Poster Joined: May 2012 Reading Posts: 804 Icelandic Furio
    #131
    I'm amazed how clean you get things! What are the main products you use?

    Your attention to detail is top class, great work
  132. West Midlands Joined: Nov 2005 Nuneaton (West Mids) Posts: 13835 '64 Volvo V40 R’Design, '89 Ph1 309 GTi, ‘97 Mk1 S
    #132
    My collection of products is almost all Auto Glym based, I keep hearing of better products but I've always been satisfied with the results from AG & they're very reasonably priced.

    To get the bumper back how it should be I did start by using a toothbrush and AutoSmart Tardis to clean all the muck, tar, green moss stains off so it was perfectly clean.
    I've then used a heat gun to go over it which brings the pigment back up to its original colour, it's the first time I've tried it and it was very quick & easy. This should only need to be done once as I'll keep it regularly treated with AG products & it won't be left neglected in the sun now.
    Whilst still hot AG vinyl & rubber care was then liberally applied and worked in, apparently the moisture & product is absorbed better into the plastic. Once cooled I've applied another coat.
    Finally I've gone over it with AG bumper gel and worked that in quite well.
    It took me all morning just to do that one half of the bumper, definitely well worth it though :-)
    2 users thanked this post: ,
  133. Saxperience Post Whore Joined: Jul 2007 Nuneaton Posts: 6476 RB RS 200
    #133
    Looks absolute epic tbh mate. Such a transformation
  134. West Midlands Joined: Nov 2005 Nuneaton (West Mids) Posts: 13835 '64 Volvo V40 R’Design, '89 Ph1 309 GTi, ‘97 Mk1 S
    #134
    Cheers lee, bet you can't wait for us to get your interior spankingly clean this week too :-)

    Love this for a comparison pic following some tlc

  135. Saxperience Forum Bum Joined: Oct 2009 Nottingham Posts: 3954 Stage 1 Mitsubishi Evo 6
    #135
    That car really could not be in better hands, credit to you for the effort and time you're investing in it!
  136. Saxperience Post Whore Joined: Aug 2010 Little Mill, South Wales Posts: 7547 Mondeo ST TDCI Saxo VTS
    #136
    Love seeing threads like this. No cutting corners and improvements being made for ease of use rather than styling.

    Great job.
  137. North West Joined: Apr 2009 Warrington, Cheshire Posts: 5733 PH2 Peugeot 106 "race" car - Currently in pieces
    #137
    Really good work on that plastic!

    I might have to try applying some heat to the missus rear bumper as that has a few pale areas and see if that works better than daubing it in back to black lol.
  138. Saxperience Addict Joined: Jan 2008 west london Posts: 13810
    #138
    did you remove the old tired number plate when doing the bumper?

    a fresh pair of plates does so much
  139. West Midlands Joined: Nov 2005 Nuneaton (West Mids) Posts: 13835 '64 Volvo V40 R’Design, '89 Ph1 309 GTi, ‘97 Mk1 S
    #139
    Cheers for the kind comments :-)

    Number plate will of course be replaced at some point, one of the last things before it's eventual return to an MOT centre
  140. West Midlands Joined: Nov 2005 Nuneaton (West Mids) Posts: 13835 '64 Volvo V40 R’Design, '89 Ph1 309 GTi, ‘97 Mk1 S
    #140
    Brief pause in 309 progress- my new garage flooring has arrived so I'll assemble that tomorrow morning. Taster pic as follows

  141. Saxperience Post Whore Joined: Jul 2010 Morley, Leeds Posts: 8469 Civic ep3 type r powered by TDI NORTH
    #141
    Quote:
    Originally Posted by willsy View Post
    Brief pause in 309 progress- my new garage flooring has arrived so I'll assemble that tomorrow morning. Taster pic as follows
    Is that the flooring they have in jtf at the mo mate £10 per 4 tiles?
  142. West Midlands Joined: Nov 2005 Nuneaton (West Mids) Posts: 13835 '64 Volvo V40 R’Design, '89 Ph1 309 GTi, ‘97 Mk1 S
    #142
    Quote:
    Originally Posted by Bedford126 View Post
    Is that the flooring they have in jtf at the mo mate £10 per 4 tiles?
    Hey mate, no it's not those ones. Ordered from http://www.ecotileflooring.com not sure what the JTF ones are made of (seen a lot of foam based stuff) these were £35 for 4 tiles.
  143. West Midlands Joined: Nov 2005 Nuneaton (West Mids) Posts: 13835 '64 Volvo V40 R’Design, '89 Ph1 309 GTi, ‘97 Mk1 S
    #143
    Evening all, another meaningful update finally.

    I've spent this afternoon removing the GTi trim pieces from the passenger side of the car. Took out the red stripes in order to clean all the pieces fully. Used the same method as I did on the front bumper and it's made a huge difference. The panel behind the kit pieces was also filthy.

    Before


    After the first piece was done


    Here's how bad things looked behind the trim


    Soon sorted that




    All done






    Rear bumper needs tackling


    Ive also managed to remove the dash now so I've started cleaning that up too, stripped everything down to each individual piece again. Here's the switch console piece after I'd reassembled it, quite like the finish :-)


    And that'll do for tonight's update.
  144. Forum Section Moderator Joined: Aug 2006 Westgate on Sea/Bexley Posts: 17223 Series 1 Rallye
    #144
    Wow, that's all I can say haha.
  145. Saxperience Post Whore Joined: Jul 2007 Nuneaton Posts: 6476 RB RS 200
    #145
    Insane how awesome its transforming!! Especially after seeing it in person and working on this car myself!!
  146. West Midlands Joined: Nov 2005 Nuneaton (West Mids) Posts: 13835 '64 Volvo V40 R’Design, '89 Ph1 309 GTi, ‘97 Mk1 S
    #146
    Cheers mate, it's definitely coming along nicely now.

    So chuffed that the electric windows are up and running, nice for something to be so easy to retrofit for once :-)
  147. West Midlands Joined: Nov 2005 Nuneaton (West Mids) Posts: 13835 '64 Volvo V40 R’Design, '89 Ph1 309 GTi, ‘97 Mk1 S
    #147
    Garage floor is looking good, making working on the car so much nicer than rolling around & kneeling on concrete. Still some more to buy until it's finished but I can get on with the car again in the meantime :-)





  148. West Midlands Joined: Nov 2005 Nuneaton (West Mids) Posts: 13835 '64 Volvo V40 R’Design, '89 Ph1 309 GTi, ‘97 Mk1 S
    #148
    Evening all, had another productive day on the 309 today. After doing the passenger side trim panels last week the state of the rear bumper looks awful in comparison.

    So what follows has taken me well in excess of 8 hours to achieve today but I was determined. Rear bumper taken off revealed this...







    Under all the muck the passenger side seems pretty good. I havnt made it round to the drivers side yet but I know the rear bumper mount on that side is knackered and some welding will be required, it's a common rust area though and I knew that bit needed doing when I bought it so it's no surprise.

    Anyway cleaned up the passenger side & I'm pleased with the result







    Nice new rear light cluster too



    Then moved on to the rear bumper......
  149. West Midlands Joined: Nov 2005 Nuneaton (West Mids) Posts: 13835 '64 Volvo V40 R’Design, '89 Ph1 309 GTi, ‘97 Mk1 S
    #149
    The rear bumper was horrendous, this is how if looked before I started

















    Finished pics to follow in a moment
  150. West Midlands Joined: Nov 2005 Nuneaton (West Mids) Posts: 13835 '64 Volvo V40 R’Design, '89 Ph1 309 GTi, ‘97 Mk1 S
    #150
    Several hours later here it is finished





    Cleaned inside aswel as out





    And back on the car for now







    Over the weekend id done a bit more on the dash aswel



    And that's the end of today's update :-)
  151. North West Joined: Apr 2009 Warrington, Cheshire Posts: 5733 PH2 Peugeot 106 "race" car - Currently in pieces
    #151
    That is crazy!! I honestly can't believe the difference in the plastics once you have finished with them! Such good work although I can't help thinking you must have shares in bluroll or something!! lol.
  152. Established Member Joined: Jan 2013 Portsmouth Posts: 1335 1997 Mk1 VTS
    #152
    The work on that rear bumper is the best you have done yet, it would pass for brand new.
  153. Established Member Joined: Mar 2010 Bradford Posts: 1490 '02 VTR, '92 106 XSI 16v
    #153
    Coming along nicely!

    How do you get your bumpers to look that spotless?! .. What's the secret?
  154. Frequent Poster Joined: May 2012 Reading Posts: 804 Icelandic Furio
    #154
    You amaze me with every update! Great work
  155. Established Member Joined: Nov 2011 Newcastle Posts: 1698 Range Rover Sport
    #155
    quality work, what sort of mileage is on the car?
  156. West Midlands Joined: Nov 2005 Nuneaton (West Mids) Posts: 13835 '64 Volvo V40 R’Design, '89 Ph1 309 GTi, ‘97 Mk1 S
    #156
    Cheers guys :-) I am very pleased with it. The bumper does have a few small scuffs and light scratches still but they don't look half as noticeable now I've spent some time on it and got it as good as it can possibly get

    Quote:
    Originally Posted by DavidsVTR View Post
    How do you get your bumpers to look that spotless?! .. What's the secret?
    Stage 1 - clean them with Autosmart Tardis and work it in with a toothbrush. I've gone over every inch of it until it's as clean as possible. That's the time consuming part as I've literally cleaned it to death until no residue is noticeable on the baby wipes used for wiping down
    Stage 2 - heat gun used to go over the plastic, almost immediately the natural pigment returns to the surface and it's back to its true colour. In theory this should only need to be done once to give it a 'fresh start' regular care after that will keep it tip top.
    Stage 3 - whilst the plastic is still warm apply Auto Glym Vinyl & rubber care. The bumper will absorb the product well and the moisture that's lost over the years whilst it's fading in the sun is replenished a bit.
    Stage 4 - when cool apply a second cost of AG vinyl & rubber care
    Stage 5 (optional) apply AG bumper gel as a nice top coat.

    And that's it. It took hours for me to clean the bumper at stage 1. So much moss stains, tar and general road crap to remove. Worth every minute spent though :-)
    2 users thanked this post: ,
  157. Saxperience Post Whore Joined: Jul 2011 Newcastle upon Tyne Posts: 7779 Phase 2 VTS , E61 M5
    #157
    Talk to me about that flooringzzzz
  158. West Midlands Joined: Nov 2005 Nuneaton (West Mids) Posts: 13835 '64 Volvo V40 R’Design, '89 Ph1 309 GTi, ‘97 Mk1 S
    #158
    Quote:
    Originally Posted by deano_123 View Post
    quality work, what sort of mileage is on the car?
    Cheers Deano. It's on 90,000 miles. Not bad really for a G reg, works out at 3,600 per year average
  159. West Midlands Joined: Nov 2005 Nuneaton (West Mids) Posts: 13835 '64 Volvo V40 R’Design, '89 Ph1 309 GTi, ‘97 Mk1 S
    #159
    Quote:
    Originally Posted by MuZiZZle View Post
    Talk to me about that flooringzzzz
    Flooring is from http://www.ecotileflooring.com very pleased with that too. Went for the 7mm thick option. It's quite pricey though.
  160. Established Member Joined: Nov 2011 Newcastle Posts: 1698 Range Rover Sport
    #160
    Quote:
    Originally Posted by willsy View Post
    Cheers Deano. It's on 90,000 miles. Not bad really for a G reg, works out at 3,600 per year average
    Sweet, some serious dedication to get that looking like new again
  161. Saxperience Post Whore Joined: Jan 2006 Posts: 9363 Focus ST & 206 GTI180
    #161
    Looking very nice mate appreciate the effort! I definitely need something like this in my life. Every weekend on the way to see the gffff I drive past a 205 gti 1.9 in black, never moves. One day I'm going to end up stopping and leaving my number on the windshield lol!

    Keep up the good work!
  162. Saxperience Addict Joined: Feb 2009 Middlesbrough Posts: 10620
    #162
    Quote:
    Originally Posted by Jamie View Post
    Looking very nice mate appreciate the effort! I definitely need something like this in my life. Every weekend on the way to see the gffff I drive past a 205 gti 1.9 in black, never moves. One day I'm going to end up stopping and leaving my number on the windshield lol!

    Keep up the good work!
    You should probably do that sooner rather than later, then you wont have to drive a 206 any more...

    Car is looking good Matt. Did you get your bits from France? Always amazed how well you're making these old scruffy parts look though. I think I'd take one look at them and admit defeat!
    1 user thanked this post:
  163. Saxperience Post Whore Joined: Aug 2010 Little Mill, South Wales Posts: 7547 Mondeo ST TDCI Saxo VTS
    #163
    Quote:
    Originally Posted by Giraffe View Post
    I think I'd take one look at them and admit defeat!
    This! I do this when washing my car never mind restoring one.
  164. West Midlands Joined: Nov 2005 Nuneaton (West Mids) Posts: 13835 '64 Volvo V40 R’Design, '89 Ph1 309 GTi, ‘97 Mk1 S
    #164
    Quote:
    Originally Posted by Giraffe View Post
    Car is looking good Matt. Did you get your bits from France? Always amazed how well you're making these old scruffy parts look though. I think I'd take one look at them and admit defeat!
    Cheers mate, hoping for a dry few days as I want to get it out the garage and get the interior finished, need to find someone that can do a bit of welding and has their equipment mobile - seat mount needs fixing.

    The parts from France just arrived today, a bit of delay with bank hol but really pleased they've arrived :-)
  165. Newbie Joined: Feb 2013 Castelo Branco/Portugal Posts: 1 Citroën Ax 1.4D Citroën Berlingo 2.0 HDi Toyot
    #165
    Nice Work man!!!
  166. Newbie Joined: Mar 2014 Bristol Posts: 4 2000 Saxo VTR
    #166
    I wish I had the patience and eye for detail you have, the difference already is amazing!
  167. West Midlands Joined: Nov 2005 Nuneaton (West Mids) Posts: 13835 '64 Volvo V40 R’Design, '89 Ph1 309 GTi, ‘97 Mk1 S
    #167
    Spent today turning this



    Into this



    Took me most of the day, fortunately most of the rust was just surface based that was quickly cleared back to clean metal with a wire wheel drill attachment and some kurust treatment. There is a small couple of holes just to the left of the drainage hole. I'll get those sorted before painting.

    Then turned to removing the heater assembly. The matrix is knackered & leaking so that needs replacing & the box itself needs a good clean. The prolonged damp has made the control cables a bit stiff so I'll tend to those aswel
  168. West Midlands Joined: Nov 2005 Nuneaton (West Mids) Posts: 13835 '64 Volvo V40 R’Design, '89 Ph1 309 GTi, ‘97 Mk1 S
    #168
    Heater box out this morning



    To clean up and remove the leaking matrix



    Had to remove most of the sound deadening behind the dash which was still soaking and hadn't dried out despite the car not seeing water since I bought it. Annoyingly I've found my first nasty surprise behind it :-( need to find a mobile welder

  169. Newbie Joined: Feb 2013 Castelo Branco/Portugal Posts: 1 Citroën Ax 1.4D Citroën Berlingo 2.0 HDi Toyot
    #169
    not good news...

    But it´s a easy fix
  170. Newbie Joined: Jun 2013 Posts: 26
    #170
    Loving the work so far on this and great to see that people also like to see OEM projects on here.

    Keep up the good work/updates please!

    Kind regards

    Danny
  171. West Midlands Joined: Nov 2005 Nuneaton (West Mids) Posts: 13835 '64 Volvo V40 R’Design, '89 Ph1 309 GTi, ‘97 Mk1 S
    #171
    Evenin all, finally another update. House DIY had taken over for the last few weeks.

    So today I returned to the 309 and continued where I left off. The heater box is now all cleaned and fully functioning, the cables operating the flaps had become a bit stiff so I've taken the time to apply some lubricating oil and have worked it in. All sorted now :-)

    I then carried on claying and polishing a few panels, although I will get it resprayed eventually it's enabling me to see properly all the defects, carpark dents etc. any dents I'll get removed properly prior to considering paintwork as I'd much rather they were removed rather than simply filled.

    I then decided to start some work on the underside of the car, the passenger front arch is first up and that took me a fair few hours til I was happy with it.

    Before









    Afters











    Not the best pics this time round unfortunately, the sun was making it difficult to get a decent shot without any glare.

    That arch will do for now, I'll finish it once I get the front suspension and subframe off in the near future.

    Also fitted some new side repeaters and a new grille badge so I'm happy with today's efforts.
  172. Infrequent Poster Joined: Apr 2012 Posts: 115
    #172
    Inspiring work for sure!

    I'm on the look out for a 1.8 or 1.9 diesel just as a run about but this does tempt me towards a GTI...
  173. Newbie Joined: Jun 2013 Posts: 26
    #173
    That's come up very well Willsy. Fortunate that there is hardly any surface rust!
  174. West Midlands Joined: Nov 2005 Nuneaton (West Mids) Posts: 13835 '64 Volvo V40 R’Design, '89 Ph1 309 GTi, ‘97 Mk1 S
    #174
    Something that a fair few people might be interested in... I bought a badge refreshing kit that an eBay member 'Rjuhar' has been advertising on eBay. Initially it was a set of 3 on offer for a 205 GTI but I persuaded him to make 309 ones up too.

    Made a start on the 309 badge this evening.

    1 washed out tatty looking spare 309 badge



    I t-cut the old coating off, cleaned it thoroughly and degreased it to give a good surface for the vinyl to adhere to



    Then applied the new numbers. They are very precise and do require a steady hand to line them up accurately. Very pleased with the result and applied some vinyl care to the black backing so that it looks as good as new



    He will do any kind of badges providing that he can get an original to work with for the template. Turnaround time was just under 1 week.
  175. West Midlands Joined: Nov 2005 Nuneaton (West Mids) Posts: 13835 '64 Volvo V40 R’Design, '89 Ph1 309 GTi, ‘97 Mk1 S
    #175
    Continued where I left off today and did the peugeot badge, the GTI badge and the other 309 badge that's on the car





    Since fitting the new rear light clusters I've been unsure on the shade of them. I preferred the darker appearance of the originals which matched the reflective boot plinth piece. So as the front piece of the lens is removable I've swapped the lens over and fitted it to the new main unit.

    With new lighter lenses


    Back to original lenses


    A pic of the rear end as it currently stands. Much better than when I got it
  176. North West Joined: Apr 2009 Warrington, Cheshire Posts: 5733 PH2 Peugeot 106 "race" car - Currently in pieces
    #176
    Yep, the darker ones are much better.
    1 user thanked this post:
  177. West Midlands Joined: Nov 2005 Nuneaton (West Mids) Posts: 13835 '64 Volvo V40 R’Design, '89 Ph1 309 GTi, ‘97 Mk1 S
    #177
    eBay has come up trumps again. I won a pair of front GTI seats for £20 that I thought I'd take a punt on incase they were better than my current ones. They looked filthy in the picture and they are even more filthy up close. However there are no rips or tears or any significant worn bits. I'm pretty confident that I can have these looking great with a day spent on them with the valeting vac
    Both of them have working tilt levers too.









    Now the only thing different that I'm hoping someone can advise me on are the headrests

    These Are the standard ones on the original seats which seem to match material.



    And these are ones fitted to the new seats. Material differs and they have a tilt function too



    Looking at the mounting rods they do look like they have been adjusted to fit the seats.

  178. Infrequent Poster Joined: Jul 2005 Glasgow United Kingdom (Scotland) Posts: 107 2 saxo vts , ax vts , 4.7 V8 jeep
    #178
    I love this thread
  179. Newbie Joined: Jun 2013 Posts: 26
    #179
    love it
  180. West Midlands Joined: Nov 2005 Nuneaton (West Mids) Posts: 13835 '64 Volvo V40 R’Design, '89 Ph1 309 GTi, ‘97 Mk1 S
    #180
    Cheers :-) made a start on cleaning the seats this morning.

    Here's the eBay listing pic



    And a close up


    Took the subframe off to clean that up seperately then got as far as doing the drivers seat. It's had 3 cycles of cleaning with the valeting vac with detergent and a fresh water cycle to finish. It needed it but I'm hugely pleased with the results, arguably the best £20 I've spent on the car so far by taking a chance on the seats







  181. West Midlands Joined: Nov 2005 Nuneaton (West Mids) Posts: 13835 '64 Volvo V40 R’Design, '89 Ph1 309 GTi, ‘97 Mk1 S
    #181
    Courier arrived this morning with a present.....

    Brand new Phase 1 spoiler. Popped it on for a quick photo.



  182. West Midlands Joined: Nov 2005 Nuneaton (West Mids) Posts: 13835 '64 Volvo V40 R’Design, '89 Ph1 309 GTi, ‘97 Mk1 S
    #182
    Nice afternoon in the sun today combined with some more cleaning of interior trim, I swear it's never ending.





  183. West Midlands Joined: Nov 2005 Nuneaton (West Mids) Posts: 13835 '64 Volvo V40 R’Design, '89 Ph1 309 GTi, ‘97 Mk1 S
    #183
    Made a start on the drivers side of the car today as that had been largely untouched.

    First up the rear window out, much muck, conifer residue removed again, no change there from the passenger side.
    Had the same rusty staining on the paint where the rear door card mounting clips were


    The only time where t-cut has been beneficial, nothing else would touch it.




    Then took everything off the drivers door to be cleaned up. Cleaned out the inside of the door aswel






    There is a bugger of a dent in the front of the door which I'll look to get repaired properly. I could happily seek to replace the door but the doors open/close and hang perfectly which seems to be a rarity without some lengthy messing about with so I'd rather keep the original doors that work well.


    The wing and kit piece are entirely unmarked and original so it looks like something had fell against the door to cause the dent rather than any failure of the check strap etc.

    And that's taken me all day again.
  184. Newbie Joined: Feb 2013 Castelo Branco/Portugal Posts: 1 Citroën Ax 1.4D Citroën Berlingo 2.0 HDi Toyot
    #184
    Nice Work!

    Good clean men!
  185. Saxperience Hardcore! Joined: Mar 2008 Posts: 31279 Citroen Saxo VTS, S60 D5
    #185
    Shame about the door. You might get away with it with a dent guy.. as you'll know. If its creased/cracked the paint :/ swap with Lea?
  186. West Midlands Joined: Nov 2005 Nuneaton (West Mids) Posts: 13835 '64 Volvo V40 R’Design, '89 Ph1 309 GTi, ‘97 Mk1 S
    #186
    Here we are again folks. Fancied getting dirty again today so in for some more arch cleaning, next up being the passenger side rear.

    Here's how it started







    All nice and clean









    Spent a bit of time giving the beam a bit of a clean and the caliper. Also cleaned out all of the threads



    Tapped into Various European EBay sites aswel which seem to be a great source of new old stock. Nice new genuine GTi back box bargain of the week at £40



    That's it for today again
  187. L-plater Joined: Nov 2011 bloxwich Posts: 41 mgzr td, saxo furio,206 hdi wifey
    #187
    great progress. always liked these but never actually bought 1. Would love a GOODWOOD!
  188. West Midlands Joined: Nov 2005 Nuneaton (West Mids) Posts: 13835 '64 Volvo V40 R’Design, '89 Ph1 309 GTi, ‘97 Mk1 S
    #188
    Underside has had some more attention today, toothbrush and Autosmart Tardis with an abundance of baby wipes always works wonders

    Floor plan cleaning commenced



  189. Established Member Joined: Nov 2011 Newcastle Posts: 1698 Range Rover Sport
    #189
    your patience and attention to detail is mind boggling
  190. Saxperience Forum Bum Joined: Apr 2013 Jarrow Posts: 4022 2003 Icelandic Grey 16v VTR 1991 Daihatsu GTti
    #190
    Willsy, hurry up and get this finished so you can sell it to me.
  191. Saxperience Post Whore Joined: Jan 2006 Posts: 9363 Focus ST & 206 GTI180
    #191
    Looking good mate.
  192. Saxperience Hardcore! Joined: Nov 2005 Coventry Posts: 17782 Fiesta ST150
    #192
    Matt....you spend far too much time cleaning these cars haha. I just wouldn't have the patience to do it! What you clean the arches with out of curiosity?
  193. Regular Poster Joined: Nov 2008 Alnwick/Northumberland Posts: 258 Cobalt Blue 106
    #193
    Quote:
    Originally Posted by willsy View Post
    toothbrush, Autosmart Tardis, baby wipes
    This all you use for doing the underside/arches?

    Gonna be cleaning up a low mileage 106 soon so this progress blog is great inspiration.
  194. West Midlands Joined: Nov 2005 Nuneaton (West Mids) Posts: 13835 '64 Volvo V40 R’Design, '89 Ph1 309 GTi, ‘97 Mk1 S
    #194
    Cheers lads :-) it's coming along nicely.

    And yep all you need to do the arches is an old toothbrush, Autosmart Tardis is an amazing product, then baby wipes to remove the muck.
    Only other thing I use is a bit of quick detailer and a cloth to wipe off the last bits of residue.
  195. Saxperience Addict Joined: Feb 2009 Middlesbrough Posts: 10620
    #195
    I can't imagine cleaning anything but my teeth with a toothbrush, and even that makes me impatient... This has now gone beyond my comprehension so I'll check in in a few months to see if it's finished!
  196. Saxperience Hardcore! Joined: Oct 2008 Birtley Posts: 22253 VTR Turbo, 106 xsi track slag, Transit recovery, B
    #196
    good stuff for the arches etc to save on masses of baby wipes..start with a stiff hand brush and some soapy water to get most of the mud and shite off, then move onto the tardis or other products
  197. Saxperience Post Whore Joined: Jan 2006 Posts: 9363 Focus ST & 206 GTI180
    #197
    Quote:
    Originally Posted by blackie_2k5 View Post
    good stuff for the arches etc to save on masses of baby wipes..start with a stiff hand brush and some soapy water to get most of the mud and shite off, then move onto the tardis or other products
    ^ just make sure the brush isn't too stiff to avoid damaging the paint in the arches.

    However, if the car is movable... I'd pressure wash the arches after applying various potions to soften the muck and then start with the more laborious side of the clean!

    It's nay a bad idea to seal the paint with a decent sealant too, muck will be easier to shift next clean and keep them easier to maintain.
  198. West Midlands Joined: Nov 2005 Nuneaton (West Mids) Posts: 13835 '64 Volvo V40 R’Design, '89 Ph1 309 GTi, ‘97 Mk1 S
    #198
    Passenger side all done as far as I can reach without jacking up



  199. Saxperience Forum Bum Joined: Mar 2009 Morpeth Posts: 2539 BMW 116d Regional Toner Sales Edition
    #199
    Quote:
    Originally Posted by westwell_22 View Post
    This all you use for doing the underside/arches?

    Gonna be cleaning up a low mileage 106 soon so this progress blog is great inspiration.
    Give me your trimzzzz
  200. West Midlands Joined: Nov 2005 Nuneaton (West Mids) Posts: 13835 '64 Volvo V40 R’Design, '89 Ph1 309 GTi, ‘97 Mk1 S
    #200
    Had a bash at the drivers side rear bumper mounting point this morning, I was well aware that this area needed some surgery, always annoying when the other side is perfectly fine. Could be worse and should be relatively east to fix, but still not pretty to look at for a 'before' pic :-(

  201. Newbie Joined: Feb 2013 Castelo Branco/Portugal Posts: 1 Citroën Ax 1.4D Citroën Berlingo 2.0 HDi Toyot
    #201
    It need attention.
    1 user thanked this post:
  202. West Midlands Joined: Nov 2005 Nuneaton (West Mids) Posts: 13835 '64 Volvo V40 R’Design, '89 Ph1 309 GTi, ‘97 Mk1 S
    #202
    This morning I've spent removing the rest of the stone chip around my rusty bit on the drivers side rear rusty bit, fortunately it doesn't seem to have spread much past the small spot welded in panel



    In keeping with wanting to repair it as best as possible I'd rather not simply patch a repair. I'll drill out the spot welds, clean it up and I've made templates for the bits to be replaced



    And offered up into place





    The task over the next few mornings will be to make the pieces up to be welded in and remove the old rusty piece of panel
  203. West Midlands Joined: Nov 2005 Nuneaton (West Mids) Posts: 13835 '64 Volvo V40 R’Design, '89 Ph1 309 GTi, ‘97 Mk1 S
    #203
    My templates have worked out nicely. Just a bit of tweaking and tidying up of the edges and then they'll be weld ready, hopefully tomorrow fingers crossed.





  204. West Midlands Joined: Nov 2005 Nuneaton (West Mids) Posts: 13835 '64 Volvo V40 R’Design, '89 Ph1 309 GTi, ‘97 Mk1 S
    #204
    Welding finally in progress :-)
  205. Saxperience Post Whore Joined: Oct 2005 Sydney Posts: 8525 Mango Westcoast
    #205
    Awesome work mate!
  206. West Midlands Joined: Nov 2005 Nuneaton (West Mids) Posts: 13835 '64 Volvo V40 R’Design, '89 Ph1 309 GTi, ‘97 Mk1 S
    #206
    Cheers Josh

    The welding that I wanted doing has all been done, it'll allow me to get the interior finished and back together in the coming weeks. Sure I'll find more at some point when I investigate further underneath, we'll see.

    Got the rear bumper bracket all ready for paint today, whizzed over the new metal with a variety of wire drill attachments, went all around the seams with seam sealer (the stuff is evil is all I'll say) then applied some OE stone chip.



    Just need to finish the top spot welds now, they're ground down just needs finishing.


    And inside


    Front seat mounts next. The original piece that snapped off was clean enough to weld back in then some small plates were welded over each of the drivers seat front mounting points to strengthen it up.






    I should be able to fly through the interior prep now before giving it a bit of paint before reassembly :-)
  207. Saxperience Hardcore! Joined: Oct 2008 Birtley Posts: 22253 VTR Turbo, 106 xsi track slag, Transit recovery, B
    #207
    as always, attention to detail is full of win matt
  208. Newbie Joined: Feb 2013 Castelo Branco/Portugal Posts: 1 Citroën Ax 1.4D Citroën Berlingo 2.0 HDi Toyot
    #208
    Very impressive Work!

    That look really nice man!

    Keep Going
  209. Infrequent Poster Joined: Aug 2013 Peterborough Posts: 136 Citroen Saxo 1.1 Forte
    #209
    Jesus how do you have the patience, are you some sort of restoration saint?
  210. West Midlands Joined: Nov 2005 Nuneaton (West Mids) Posts: 13835 '64 Volvo V40 R’Design, '89 Ph1 309 GTi, ‘97 Mk1 S
    #210
    Aha not quite, but I do have the patience of a Saint. I just need to find some motivation to get the prep work finished on the interior so that I can paint it. Prep work bores me to tears :-(
  211. Infrequent Poster Joined: Aug 2013 Peterborough Posts: 136 Citroen Saxo 1.1 Forte
    #211
    Do it, I'm loving the updates when they come!

    I wish I was that much of a perfectionist, when stuff is done right it always looks so much better
  212. Infrequent Poster Joined: Aug 2013 Peterborough Posts: 136 Citroen Saxo 1.1 Forte
    #212
    I've sent you a PM as well Willsy
  213. West Midlands Joined: Nov 2005 Nuneaton (West Mids) Posts: 13835 '64 Volvo V40 R’Design, '89 Ph1 309 GTi, ‘97 Mk1 S
    #213
    Busy bee again today. Cracked on with the interior prep now that the welding is out the way.
    Decided to crack on with bits in segments for the prep stage as it's more manageable and less boring than slaving away for hours without seeing much result.

    First up I did the rear boot panel, all straight and no dents which was good however loose luggage over the years had scratched and chipped the paint in several areas which had developed slight surface rust. Easily stripped back with a quick skim with the wire drill attachments, treated and primered



    The boot floor is near perfect so no lengthy prep required there.
    Next up was the rear bench trough. I suspect that his had been wet at some point and the poor paint finish had started to degrade and lift in places with a number of scratches which had developed a thin layer of surface rust again. It didn't look too bad after a general degrease and clean, but having starting to sand away at the scratches the old paint seemed to be very powdery and only took a mere tickle with the sandpaper. I wasn't happy with it so decided to strip that right back to the bare metal in the end, treated again and primered



    Much better


    Then onto the drivers rear footwell. Several areas I'd already tended to and treated previously, in the middle of the footwell the OE finish is stone chip texture so I have reapplied some over the bits which I've tidied up before primering to retain as best as I can the OE finish. Here's progress so far

  214. Saxperience Forum Bum Joined: Feb 2007 Posts: 3068
    #214
    Progress on this looks awesome!!! Really wish I had the patience to tidy up my cars like this!

    How did this go? Get that patched up?

    Quote:
    Originally Posted by willsy View Post
  215. West Midlands Joined: Nov 2005 Nuneaton (West Mids) Posts: 13835 '64 Volvo V40 R’Design, '89 Ph1 309 GTi, ‘97 Mk1 S
    #215
    Yes mate, that little issue was sorted too. I'd ground it down and the majority of it around the hole was just surface rust but took the wise decision to cut it all out and replace the lot, I'll grab a pic next time I'm in the garage.
  216. West Midlands Joined: Nov 2005 Nuneaton (West Mids) Posts: 13835 '64 Volvo V40 R’Design, '89 Ph1 309 GTi, ‘97 Mk1 S
    #216
    Been very busy lately on the 309, before putting the interior back together I wanted to do a proper job of the interior paintwork. Peugeot did cover quite well when it left the factory but with scratches, uncoated bits, some paint looking a bit flaky and the odd slight bit of surface rust here and there I'll be so much happier with it knowing it'll be spot on in the long run. It is a shame that just about all of it is hidden, never mind.

    Here's my progress so far











    1 user thanked this post:
  217. West Midlands Joined: Nov 2005 Nuneaton (West Mids) Posts: 13835 '64 Volvo V40 R’Design, '89 Ph1 309 GTi, ‘97 Mk1 S
    #217
    Started to tackle one of the 309's rust related Achilles heels this evening. This being the 4 sunroof drain tubes which suffer if the tubes become blocked. The rears in particular seem to be an issue as when fully assembled the sunroof blind housing pinches the drain tube to half it's natural diameter.

    Anyway all 4 of mine were needing attention. This being one of the better condition front ones


    A basic guide on 309 owners suggests trimming the tubes then bonding in a suitable length of of 10mm plumbing pipe..... Here's the pics from the guide







    I figured that I could better that a little more accurately and with a 10mm OD the new 8mm ID just looked too small. The hole in the existing tube is 12mm diameter, It'll be regularly maintained and won't see much wet so I've bought some 12mm diameter (10mm ID) 316 marine grade stainless tube. This'll act as a perfect insert rather than completely removing the old tube too, so still similar to the guide. Only the ends were knackered so 15mm length of the existing tube remains.

    New stainless cut to length


    The insert then fits into the old tube with some gentle persuasion. A light smear of metal araldite was applied to bond it permanently. And voila



    Nice and snug from the top too


    All in all very happy and that's another job ticked off the list
    2 users thanked this post: ,
  218. Forum Section Moderator Joined: Aug 2006 Westgate on Sea/Bexley Posts: 17223 Series 1 Rallye
    #218
    The attention to detail on this car is ridiculous, most people would have sorted the outside look wise and tidied the inside a little but never have gone to the detail you have.

    Have you set a budget to get the complete project finished? I know your probably not considering selling it anytime soon but what do these go for in pristine condition?
  219. West Midlands Joined: Nov 2005 Nuneaton (West Mids) Posts: 13835 '64 Volvo V40 R’Design, '89 Ph1 309 GTi, ‘97 Mk1 S
    #219
    Cheers Dan, I'm certainly enjoying the challenge. Budget wise there isn't one, it'll take as much as it takes to do it to what I hope will be a high standard.

    I've seen a few so far be advertised between 4-5k they've been in good original condition visibly. There's only one I know of that's been fully restored to a very high spec, that's not likely to be for sale again anytime soon though and I'm not sure how much he paid for it off the bloke who did the original resto, I'd imagine it was a hefty fee though
  220. Regular Poster Joined: Nov 2008 Alnwick/Northumberland Posts: 258 Cobalt Blue 106
    #220
    Are you using rattle cans for the painting?
  221. West Midlands Joined: Nov 2005 Nuneaton (West Mids) Posts: 13835 '64 Volvo V40 R’Design, '89 Ph1 309 GTi, ‘97 Mk1 S
    #221
    Yep perfectly good for the interior provided that you spend a good amount of time on the prep and buy the better quality options. I've done the same on most of my previous cars which has always improved the often half arsed standard finish. Obviously exterior work will be a booth job
  222. Super Moderator Joined: Aug 2006 Staffs Posts: 3778 207 HDi GT
    #222
    You love fixing things with araldite
  223. Newbie Joined: Feb 2013 Castelo Branco/Portugal Posts: 1 Citroën Ax 1.4D Citroën Berlingo 2.0 HDi Toyot
    #223
    Like the interior and the tubes... Details who makes the car better!
  224. Regular Poster Joined: Nov 2008 Alnwick/Northumberland Posts: 258 Cobalt Blue 106
    #224
    Quote:
    Originally Posted by willsy View Post
    Yep perfectly good for the interior provided that you spend a good amount of time on the prep and buy the better quality options. I've done the same on most of my previous cars which has always improved the often half arsed standard finish. Obviously exterior work will be a booth job
    Looks great for a rattle can job, same with the Saxo you did I'm hoping I can get as good a finish with mine.
  225. West Midlands Joined: Nov 2005 Nuneaton (West Mids) Posts: 13835 '64 Volvo V40 R’Design, '89 Ph1 309 GTi, ‘97 Mk1 S
    #225
    Drivers side all done.
    With both sides and the roof all done that's the hard bit done. Just the main boot floor and footwells to do then I can finally start to reassemble.



  226. Saxperience Forum Bum Joined: Mar 2009 Stoke-on-trent Posts: 2640 Mk5 Golf GTTDI Mk2 VTR Project
    #226
    Would love a project like this just have to wait for our garage to be built first.. Haha, very nice work though especially like the new welding very tidy!
  227. West Midlands Joined: Nov 2005 Nuneaton (West Mids) Posts: 13835 '64 Volvo V40 R’Design, '89 Ph1 309 GTi, ‘97 Mk1 S
    #227
    If the weathers favourably warm tomorrow I'm hoping I might have the boot floor and under the rear bench area prepped and painted.

    In the meantime I've painted the drivers inner rear quarter where I had the new piece welded in. I am really pleased with the final result



    And the passenger side which is still good and original has also had a fresh lick of paint



    Almost finished doing the sunroof drain repairs too so the roof lining will be back in shortly
  228. West Midlands Joined: Nov 2005 Nuneaton (West Mids) Posts: 13835 '64 Volvo V40 R’Design, '89 Ph1 309 GTi, ‘97 Mk1 S
    #228
    Kept myself amused with some more painting today. Boot floor and rear bench area now done. Just the footwells to go :-)











  229. Saxperience Post Whore Joined: Jan 2007 Shropshire Posts: 9994 Moonstone Blue 106 GTi
    #229
    looks great, if anything your retirement job should be car restoration
    4 users thanked this post: , , ,
  230. West Midlands Joined: Nov 2005 Nuneaton (West Mids) Posts: 13835 '64 Volvo V40 R’Design, '89 Ph1 309 GTi, ‘97 Mk1 S
    #230
    Aha cheers Gav, that would suit me nicely. I'm pretty good at most basics now but I really would like to learn how to weld for future projects, it's definitely my Achilles heel at the mo
  231. West Midlands Joined: Nov 2005 Nuneaton (West Mids) Posts: 13835 '64 Volvo V40 R’Design, '89 Ph1 309 GTi, ‘97 Mk1 S
    #231
    Soooo close to finishing the interior paint now, did the rear footwells and inner sills today. Just the front of the footwell to finish.









  232. Frequent Poster Joined: Oct 2013 Bridgend, South Wales Posts: 948 Mk1 VTS, FF BG 182
    #232
    Restoration porn, with willsy.
  233. Established Member Joined: Mar 2010 Bradford Posts: 1490 '02 VTR, '92 106 XSI 16v
    #233
    Love seeing the updates to this thread.. The attention to detail is spot on!
    Keep up the good work, it'll sure be worth it in the long run
  234. West Midlands Joined: Nov 2005 Nuneaton (West Mids) Posts: 13835 '64 Volvo V40 R’Design, '89 Ph1 309 GTi, ‘97 Mk1 S
    #234
    Cheers for the positive feedback folks, I must be on the right track with it :-)

    I've finally finished the interior paintwork, it feels like it's taken me forever but I can now start to make some headway refitting bits.





  235. Newbie Joined: Feb 2013 Castelo Branco/Portugal Posts: 1 Citroën Ax 1.4D Citroën Berlingo 2.0 HDi Toyot
    #235
    More Good Work!
  236. West Midlands Joined: Nov 2005 Nuneaton (West Mids) Posts: 13835 '64 Volvo V40 R’Design, '89 Ph1 309 GTi, ‘97 Mk1 S
    #236
    A quick couple of snaps from today's work.

    Started off cleaning up all the small interior fittings/fixtures etc before reassembling.
    To give an idea these were the gearstick surround captive bolts, I'd already cleaned the first one here


    All done


    And refitted


    Then started reassembling the rear section of the interior, progress by the end of today doesn't look much but it's a big improvement I think


  237. West Midlands Joined: Nov 2005 Nuneaton (West Mids) Posts: 13835 '64 Volvo V40 R’Design, '89 Ph1 309 GTi, ‘97 Mk1 S
    #237
    Picked up my first batch of parts today that I've had powder coated. Just a couple of pics here, I'm very pleased with the finish :-)
    Just need to find somewhere good that does zinc playing now then I'll be a happy man, failing that I'll dig out my own kit again to do it (extremely time consuming though)



  238. Saxperience Post Whore Joined: Jan 2007 Shropshire Posts: 9994 Moonstone Blue 106 GTi
    #238
    I need a willsy spec car some day
  239. Saxperience Addict Joined: Jul 2005 Solihull / Bournemouth Posts: 14233 2015 Lapiz Blue Golf R
    #239
    Quote:
    Originally Posted by Sophia_Bush View Post
    I need a willsy spec car some day
    Agreed - if I bought an Evo VI TME you think he'd restore it for me!?
  240. West Midlands Joined: Nov 2005 Nuneaton (West Mids) Posts: 13835 '64 Volvo V40 R’Design, '89 Ph1 309 GTi, ‘97 Mk1 S
    #240
    Quote:
    Originally Posted by raunchz View Post
    Agreed - if I bought an Evo VI TME you think he'd restore it for me!?
    Haha you're damn right I would, I'd do this full time if I was spending someone else's money :-)
  241. Saxperience Forum Bum Joined: Dec 2012 Perth Posts: 3665 Peugeot 106 1.1 Turbo Peugeot 106 1.5D Turbo Peuge
    #241
    This is fucking cool!
  242. Saxperience Addict Joined: Jul 2005 Solihull / Bournemouth Posts: 14233 2015 Lapiz Blue Golf R
    #242
    Quote:
    Originally Posted by willsy View Post
    Haha you're damn right I would, I'd do this full time if I was spending someone else's money :-)
    http://www.ebay.co.uk/itm/1114506186...%3AMEBIDX%3AIT

    or

    http://www.ebay.co.uk/itm/2214885090...%3AMEBIDX%3AIT

    Looking like great investments, very tempting .......
  243. Newbie Joined: Dec 2012 East Yorkshire Posts: 6 Citroen Saxo VTR 2004
    #243
    What a brilliant read, practically every car I have owned I stripped it all down cleaned and stripped most parts inside, underneath etc. The 309 GTi is an awesome choice. Love it!
    Keep up the good work!
  244. Saxperience Post Whore Joined: Mar 2009 Isle of Man Posts: 9844 92 Eunos
    #244
    Stunning Willsy. Not been on in ages so going to see how the AX ended up. Picked up lots of tips for when I start pulling the MX5 apart
  245. West Midlands Joined: Nov 2005 Nuneaton (West Mids) Posts: 13835 '64 Volvo V40 R’Design, '89 Ph1 309 GTi, ‘97 Mk1 S
    #245
    Finally another update, the interiors going back together nicely. I'll just let the pictures do all the talking for once. Rear door cards you'll see aren't fitted fully yet (the plastics are though) as I want to get a few dents removed on the rear quarters first before I fit them fully.







































  246. North West Joined: Apr 2009 Warrington, Cheshire Posts: 5733 PH2 Peugeot 106 "race" car - Currently in pieces
    #246
    My God it looks good! You must be properly pleased getting all the nice clean and shiny bits back together? It really does look like it's factory fresh.
  247. Established Member Joined: Jan 2005 Up North Posts: 1642
    #247
    Great progress
  248. Saxperience Post Whore Joined: Oct 2005 Sydney Posts: 8525 Mango Westcoast
    #248
    Awesome Matt, looks basically new inside! Lol
  249. Saxperience Forum Bum Joined: Apr 2013 Jarrow Posts: 4022 2003 Icelandic Grey 16v VTR 1991 Daihatsu GTti
    #249
    What Yamaha is that in the background? Looks 80's from the lights??
  250. West Midlands Joined: Nov 2005 Nuneaton (West Mids) Posts: 13835 '64 Volvo V40 R’Design, '89 Ph1 309 GTi, ‘97 Mk1 S
    #250
    Latest transformation is with some very tired, faded mirrors. I'd already sourced a NOS passenger one but no new drivers ones exist, so obtained some vgc used ones

    Rear of one cleaned up


    Here's how the front started


    Process for this was as follows;
    1) Autosmart Tardis + toothbrush
    2) Clean with baby wipes (cheap, easy to see when there's no more muck present & good at removing previous product residue)
    3) Heat gun lightly to bring original colour back permanently
    4) Apply AutoGlym Vinyl care whilst still warm, plastic absorbs the product and moisture back in
    5) Apply Auto Finesse Revive


    And the drivers side
  251. Saxperience Addict Joined: Feb 2009 Middlesbrough Posts: 10620
    #251
    I think you have succeeded in making a second hand mirror look newer than a new mirror.
    1 user thanked this post:
  252. West Midlands Joined: Nov 2005 Nuneaton (West Mids) Posts: 13835 '64 Volvo V40 R’Design, '89 Ph1 309 GTi, ‘97 Mk1 S
    #252
    For those of you who have read all the way through the thread so far you'll know that I'd cleaned up the original carpet, it's clean, but it's not without it's faults and isn't good enough for me. So I got hold of a much better one



    And after a few hours cleaning I'm now very happy



  253. Regular Poster Joined: Feb 2012 Cambridgeshire Posts: 344 Evo 2 GSR, Saxo VTR, Mini Cooper S
    #253
    That mirror is incredible!!!
  254. West Midlands Joined: Nov 2005 Nuneaton (West Mids) Posts: 13835 '64 Volvo V40 R’Design, '89 Ph1 309 GTi, ‘97 Mk1 S
    #254
    Quote:
    Originally Posted by Mickswan View Post
    What Yamaha is that in the background? Looks 80's from the lights??
    Not sure tbh mate, it's my Dad's little side project to do up and get a bit of profit from. I can only confirm that it is a Yamaha and that it's on a 51 plate & that's as far as my knowledge goes with it :-)
  255. Newbie Joined: Jun 2013 Gloucestershire
    #255
    Absolutely immense job you're doing there Matt! Keep up the good work!
  256. West Midlands Joined: Nov 2005 Nuneaton (West Mids) Posts: 13835 '64 Volvo V40 R’Design, '89 Ph1 309 GTi, ‘97 Mk1 S
    #256
    Cheers Tom :-)

    Really pleased with my latest find all the way from Venice

    NOS mats

    Forgot to get a pic with rears too
  257. Newbie Joined: Feb 2013 Castelo Branco/Portugal Posts: 1 Citroën Ax 1.4D Citroën Berlingo 2.0 HDi Toyot
    #257
    Cool!!

    Very Good!
  258. West Midlands Joined: Nov 2005 Nuneaton (West Mids) Posts: 13835 '64 Volvo V40 R’Design, '89 Ph1 309 GTi, ‘97 Mk1 S
    #258
    Well this updates been overdue, since the last update I'd barely done anything until today whilst waiting for bits and pieces to arrive.

    Everything refitted now, rear window opening levers fully functioning again, removed the old black tape from the wiring and tidied with conduit instead





    Secured the wiring to the front of the seat mounting piece with some black anodised P clips. Quite pleased with this bit



    A host of new fittings and fixtures and a NOS door seal



    At last the carpet is in :-) newly powder coated rear seat brackets fitted



    New carpet clips, handbrake housing refitted







    New pedal rubbers and mats

  259. Established Member Joined: Nov 2011 Newcastle Posts: 1698 Range Rover Sport
    #259
    Absolutly awesome work, very impressive
  260. North West Joined: Apr 2009 Warrington, Cheshire Posts: 5733 PH2 Peugeot 106 "race" car - Currently in pieces
    #260
    Unbelievable the difference in the car mate. Before it was a tired old motor, now it's having a rebirth as a stunning show car! Can't wait to see it complete and hopefully at some shows next year.
  261. West Midlands Joined: Nov 2005 Nuneaton (West Mids) Posts: 13835 '64 Volvo V40 R’Design, '89 Ph1 309 GTi, ‘97 Mk1 S
    #261
    Cheers mate :-) it's finally looking like a decent car again.

    Today, for the first time in my ownership I've actually sat in the car after refitting the drivers seat, such a satisfying feeling

  262. Regular Poster Joined: Feb 2012 Cambridgeshire Posts: 344 Evo 2 GSR, Saxo VTR, Mini Cooper S
    #262
    Willsy do you think a hairdryer will work as good/almost as good on bringing the colour out in tired plastics? I have a door mirror needs attention too and a hairdryer is easily to hand thanks to the misses
  263. West Midlands Joined: Nov 2005 Nuneaton (West Mids) Posts: 13835 '64 Volvo V40 R’Design, '89 Ph1 309 GTi, ‘97 Mk1 S
    #263
    I'd say that it'll depend on the plastic type. I did try a hair dryer previously and it didn't work, thinner plastics it may do but even with the heat gun it can take a bit more heat persistence on some items than others. Worth a go but a heat gun can be bought quite cleaply
  264. Regular Poster Joined: Feb 2012 Cambridgeshire Posts: 344 Evo 2 GSR, Saxo VTR, Mini Cooper S
    #264
    Looks like i'll be investing in one then, thanks bud
  265. Saxperience Post Whore Joined: Mar 2007 Conwy Posts: 7982 Fwee Fiddy Z, 182Cup, 106 GTaiiii, School Bus.
    #265
    Awesome stuff... Wish I had the time/skills/patience to do something like this.
  266. North West Joined: Apr 2009 Warrington, Cheshire Posts: 5733 PH2 Peugeot 106 "race" car - Currently in pieces
    #266
    Don't know if you have mentioned before but what heat gun do you use? I want to get the bumper back to original colour on the missus golf as it's almost white in places!
  267. Saxperience Post Whore Joined: Jul 2011 Newcastle upon Tyne Posts: 7779 Phase 2 VTS , E61 M5
    #267
    This is amazing, fair play to you for saving cars like this
  268. Regular Poster Joined: Feb 2012 Cambridgeshire Posts: 344 Evo 2 GSR, Saxo VTR, Mini Cooper S
    #268
    Quote:
    --------------------------------------------------------------------------------

    Don't know if you have mentioned before but what heat gun do you use? I want to get the bumper back to original colour on the missus golf as it's almost white in places!
    Ditto, toss up between an ebay cheapy for a tenner or spending a bit more on a Bosch or Black an Decker here
  269. West Midlands Joined: Nov 2005 Nuneaton (West Mids) Posts: 13835 '64 Volvo V40 R’Design, '89 Ph1 309 GTi, ‘97 Mk1 S
    #269
    Got a few bits and bobs done today, firstly the old steering column has gone



    Courtesy of Ed for this vgc replacement with new ignition barrel fitted


    Tidied up the drivers front arch after that, stripped the caliper down and cleaned it up a bit and cleaned out all of the threads within the hub assembly.


    Then got round to removing the old Exhaust centre section.
    Whilst in the drivers arch I checked that the engine turns over ok, and it does so that's a good start and the first step to getting it running
  270. Saxperience Post Whore Joined: Jul 2011 Newcastle upon Tyne Posts: 7779 Phase 2 VTS , E61 M5
    #270
    I lways get excited when I seethis updated!

    I have my own semi resto project now
  271. West Midlands Joined: Nov 2005 Nuneaton (West Mids) Posts: 13835 '64 Volvo V40 R’Design, '89 Ph1 309 GTi, ‘97 Mk1 S
    #271
    Wasn't the most thrilling of updates picture wise but I've regained the motivation again now that the garage is in a better/tidier state. Hopefully I'll get a few more hours on it tomorrow evening.
    What have you got for your Resto project Muz?
  272. Saxperience Post Whore Joined: Jul 2011 Newcastle upon Tyne Posts: 7779 Phase 2 VTS , E61 M5
    #272
    Quote:
    Originally Posted by willsy View Post
    Wasn't the most thrilling of updates picture wise but I've regained the motivation again now that the garage is in a better/tidier state. Hopefully I'll get a few more hours on it tomorrow evening.
    What have you got for your Resto project Muz?
    Any progress is progress man!

    I got a totally standard 03 VTS, I'm going to run it until I sort out what I'm doing carwise, then I fancy lashing it in my mams garage and making it 100% minty fresh.
  273. West Midlands Joined: Nov 2005 Nuneaton (West Mids) Posts: 13835 '64 Volvo V40 R’Design, '89 Ph1 309 GTi, ‘97 Mk1 S
    #273
    A few more bits & bobs completed over the last week or so.

    Drivers side window has a new runner, also a new electric window mechanism & motor








    Then today I've whipped off the front bumper to assess the front panels. There was a few spots here and there of surface rust as you'd expect. After winter I'll rub it down & paint it but I wanted to eliminate any hint of rust & treat it now before it gets too cold

    Here's some before's just with a quick wipe down to see what's what







    All in all pretty good, just one small bit that'll require a little welding.
    I've then treated it. Partially reassembled with the new brackets



    Payday arrives tomorrow so I can buy a new battery and the last remaining service based bits to crack on with the engine
  274. West Midlands Joined: Nov 2005 Nuneaton (West Mids) Posts: 13835 '64 Volvo V40 R’Design, '89 Ph1 309 GTi, ‘97 Mk1 S
    #274
    Yay double posted
  275. Saxperience Forum Bum Joined: Dec 2012 Perth Posts: 3665 Peugeot 106 1.1 Turbo Peugeot 106 1.5D Turbo Peuge
    #275
    Quote:
    Originally Posted by MuZiZZle View Post
    Any progress is progress man!

    I got a totally standard 03 VTS, I'm going to run it until I sort out what I'm doing carwise, then I fancy lashing it in my mams garage and making it 100% minty fresh.
    One does not simply talk about making a minty fresh Saxo on willsys thread.

    It'll still look like a shed next to the 309
  276. Newbie Joined: Feb 2013 Castelo Branco/Portugal Posts: 1 Citroën Ax 1.4D Citroën Berlingo 2.0 HDi Toyot
    #276
    More good work to see! Great!

    Engine
  277. West Midlands Joined: Nov 2005 Nuneaton (West Mids) Posts: 13835 '64 Volvo V40 R’Design, '89 Ph1 309 GTi, ‘97 Mk1 S
    #277
    Fancied doing some engine bay pottering today. Cleaned up around the expansion tank and replaced some bits for NOS parts aswel.

    Before







    New parts











    And as far as I've got today







  278. Infrequent Poster Joined: Nov 2013 Posts: 168
    #278
    excellent looks spot on
  279. West Midlands Joined: Nov 2005 Nuneaton (West Mids) Posts: 13835 '64 Volvo V40 R’Design, '89 Ph1 309 GTi, ‘97 Mk1 S
    #279
    Only had a quick hour in the garage today, fitted a new Valeo heater matrix





    And started to refit the heater box. I can start to tame the wiring now hopefully

    1 user thanked this post:
  280. Saxperience Forum Bum Joined: Dec 2012 Perth Posts: 3665 Peugeot 106 1.1 Turbo Peugeot 106 1.5D Turbo Peuge
    #280
    Who'd have though.

    so many new parts still able to obtain! lol
    1 user thanked this post:
  281. Saxperience Post Whore Joined: Aug 2008 The wrong carpark Posts: 5152 Xantia 1.9TD
    #281
    The matrix definately a dash out job ALA xantia? Good job you're doing it now!
  282. West Midlands Joined: Nov 2005 Nuneaton (West Mids) Posts: 13835 '64 Volvo V40 R’Design, '89 Ph1 309 GTi, ‘97 Mk1 S
    #282
    Quote:
    Originally Posted by MartinObviously View Post
    Who'd have though.

    so many new parts still able to obtain! lol
    Lol you'd be amazed what's still available. Just because it's noted as NFP on the Peugeot service box (same with Citroen) doesn't mean it's not there, it's just most dealerships can't be bothered to look further afield to help out enthusiasts. Most of the parts which I've got courtesy of a modern day Santa contact have come from within Europe.

    Quote:
    Originally Posted by chinkostu View Post
    The matrix definately a dash out job ALA xantia? Good job you're doing it now!
    Apparently on the 309s it can be removed easily without taking the dash out, much rather the ease of doing it now though that's for sure, nice & gentle without risk of damaging any fins trying to squeeze it in through a tight gap.
  283. Saxperience Post Whore Joined: Aug 2008 The wrong carpark Posts: 5152 Xantia 1.9TD
    #283
    Try having a v6 xantia, apparantly most parts are listed as NFP lol

    Luckily mines a derv so parts coming out of my ears
  284. West Midlands Joined: Nov 2005 Nuneaton (West Mids) Posts: 13835 '64 Volvo V40 R’Design, '89 Ph1 309 GTi, ‘97 Mk1 S
    #284
    Well a long overdue update but so far it comes with good news.

    Spent the day on the 309 yesterday with Eddie (309ownersclub) who kindly offered to change my cambelt and water pump for me & spend the day hoping to get it's first startup in my ownership & at least the previous 2 years prior to it.

    With cambelt and pump changed by Ed, I finished the easier tasks of changing the remaining basic service items of oil/filter & spark plugs & cleaning up bits which he'd removed along the way before it was refitted. I'd already fitted NOS ignition leads, coil, ignition amp. We also fitted the new centre section & backbox

    Then stage 1 of pre key turn checks went well - cranked over nicely and we had a good spark
    Then stage 2 check we've got fuel - we had nothing.

    Tried a direct feed to the pump, still nothing, then checked with a multimeter which provided us with a nice signal. So after some head scratching we decided to lower the fuel tank slightly enough to be able to remove the pump assembly retaining collar and extract the pump, If it was dead it would have needed to come out anyway, the plan being to give it a tap and provide some power directly to from the battery again, the tap came first after accidently dropping it which seemed to do the trick nicely, now seems to run perfectly fine.

    Refitted it, fuel came nicely through the rail, and then went for it....... and if fired up first time. Ran perfectly well for a few minutes before we discovered a leaky fuel return hose which had cracked a little & perished. I've been and bought some replacement hose today so hopefully tomorrow I'll swap that & get it up to temperature with coolant system bled etc.

    So far so good & I can't thank Ed enough for his help. With the engine now running it's certainly helped boost the motivation which is easy to lose over winter with the cold weather.
    1 user thanked this post:
  285. North West Joined: Apr 2009 Warrington, Cheshire Posts: 5733 PH2 Peugeot 106 "race" car - Currently in pieces
    #285
    Great news Willsy!! bet you can't wait for the drier weather to get it out for a test drive now!?
  286. West Midlands Joined: Nov 2005 Nuneaton (West Mids) Posts: 13835 '64 Volvo V40 R’Design, '89 Ph1 309 GTi, ‘97 Mk1 S
    #286
    Definitely can't wait for my first drive of it. Hopefully today I'll have time to change the perished fuel line, pick up a new alternator belt and fit that with the new alternator then let it run some more and see whether the clutch & gearbox are in reasonable order. If so I may change the brakes next & take it for a cheeky MOT to see how it gets on before I start on the suspension
  287. Newbie Joined: Feb 2013 Castelo Branco/Portugal Posts: 1 Citroën Ax 1.4D Citroën Berlingo 2.0 HDi Toyot
    #287
    Great news willsy! That type of engine are really very reliable! The idea of first service the engine was very good. I don't remember, but, do you change the thermostat? With that age could not work nicely. Congratuations.
  288. West Midlands Joined: Nov 2005 Nuneaton (West Mids) Posts: 13835 '64 Volvo V40 R’Design, '89 Ph1 309 GTi, ‘97 Mk1 S
    #288
    Thanks Andre :-) I have fitted a new thermostat, I also have new genuine coolant hoses, and a new heater matrix. The only original coolant based bit at the moment is the radiator which seems in pretty good condition.

    Got a little more done today, replaced the leaky fuel hose, this'll be the culprit



    Then removed the old alternator, it seems to be in good order but I already had a new one


    Fitted the new one with a new belt. Here's the engine bay as it stands.


    To do list over the next few days involves refitting the dash wiring and clocks so that I can plug stuff in and check that it all works before refitting the dash, also with the clocks fitted I can ensure that the temperature is all good whilst the engines running & bleeding the coolant.
    Sort the leaky joint between the exhaust manifold and the centre section, seems the new fitting kit varies slightly to the old one and I'm not able to tighten the bolts sufficiently to seal the gap.
    Once that's done get in and see if the gearbox/clutch is operating as it should so I can drive it in & out of the garage
    2 users thanked this post: ,
  289. Newbie Joined: Feb 2013 Castelo Branco/Portugal Posts: 1 Citroën Ax 1.4D Citroën Berlingo 2.0 HDi Toyot
    #289
    More good work! You did well in changing the cooling system parts. It's very important, and usually people don't give to mutch importance. Keep up the good work!
  290. West Midlands Joined: Nov 2005 Nuneaton (West Mids) Posts: 13835 '64 Volvo V40 R’Design, '89 Ph1 309 GTi, ‘97 Mk1 S
    #290
    Well it's getting close to a years ownership already, plenty done in that time that's for sure.

    Still havn't done the 'to do' list detailed in the previous post, that'll be my plan towards the end of the week on my days off.
    In the meantime though I've started to reassemble the front end and continued to tidy bits up.

    Drivers side lighting associated wiring


    To this


    Looks a fair bit better than it originally did at least; before and progress so far pics as follows



    Just need the good warm weather to return now so that I can paint the engine bay

    Cleaned up some rubber trim that fits below the headlights next, the originals were full of muck and moss


    I did buy some new genuine ones to fit but the design has changed a little at some point and the new fitting is shite in comparison & they don't stay on. So I set about cleaning up the originals


    Moved onto cleaning up the fan housing after that


    Refitted the slam panel


    Reapplied one of the new stickers that I've got



    A quick reminder of how it was a year ago


    And a final picture of how I've finished up for the day.
  291. Saxperience Post Whore Joined: Jan 2010 Stourbridge Posts: 7338 Nissan 200sx S14a
    #291
    I love this thread.

    I'm not a fan of French cars of this era and I'd certainly never choose a 309 Gti. So I don't think it's the car that's drawing me into the thread. It's the outstanding level of detail that you're going to. I get a sense of satisfaction every time I check this thread and see that you've tidied up another part of the car to a better than new standard.

    Please keep it up, it's the only thread on here that I'm still subscribed to. Fingers crossed you can put some miles on her this summer and really enjoy it.

    Tom.
  292. West Midlands Joined: Nov 2005 Nuneaton (West Mids) Posts: 13835 '64 Volvo V40 R’Design, '89 Ph1 309 GTi, ‘97 Mk1 S
    #292
    Cheers Tom, glad you're enjoying the read :-) I try to be as thorough and interesting as possible with the posts too

    I made some more progress today, plugged in the dash loom and clocks etc and left it running for about 15 mins, it's idling consistently at 1200rpm, however it should be under 1000rpm. I need to give the throttle body a clean and fully fit the induction assembly and hopefully it'll be where it should be after that.

    I've also fitted an 82degree thermostat rather than the 89degree one that was in there, service box says that it should be 82degree for pre90. Coolant systems bled and fan kicks in nicely.

    I had been getting a fair bit of vapour from the exhaust upon startup, more than you'd expect to see upon startup from cold. However the NOS genuine exhaust has been sat doing nothing for years and the longest I'd ran it up until today was about 5 minutes, not long enough to clear. It seemed to completely clear after it had been running for a while. Crucially no blueness and no unburnt fuel smells.

    Other bits and bobs for me to check include checking the oil pressure sensor & connections (it does look pretty filthy) the oil pressure gauge operates quite low on the gauge, manual suggests midway is ideal
    Here's a pic, it didn't go any higher than the first bar



    The low coolant light that's on was an easy fix, the terminals on the sensor on top of the expansion tank were a bit green, cleaned those up with some contact cleaner and wet&dry paper.

    Lastly I decided to see if I could drive it out the garage & it does go forward and backwards ok, gears go in easily although clutch pedal was quite stiff but it did seem to free up a bit after I'd pumped the pedal a few times, stiff through lack of use perhaps. I do have a NOS cable to fit if required
    1 user thanked this post:
  293. West Midlands Joined: Nov 2005 Nuneaton (West Mids) Posts: 13835 '64 Volvo V40 R’Design, '89 Ph1 309 GTi, ‘97 Mk1 S
    #293
    Just keeping up appearances today. Quite pleased to have found a little gem in the way of a NOS genuine bonnet :-) for once I didn't have to travel far to get it either, just 20 miles

  294. Newbie Joined: Feb 2013 Castelo Branco/Portugal Posts: 1 Citroën Ax 1.4D Citroën Berlingo 2.0 HDi Toyot
    #294
    Very good found!
  295. Newbie Joined: Jun 2013 Posts: 26
    #295
    Love this thread
  296. West Midlands Joined: Nov 2005 Nuneaton (West Mids) Posts: 13835 '64 Volvo V40 R’Design, '89 Ph1 309 GTi, ‘97 Mk1 S
    #296
    Annual leave underway, started with refitting the door cards and various fixtures




    Next up some more new bits, front bumper;


    New inserts

    Voila!
  297. Saxperience Forum Bum Joined: Dec 2012 Perth Posts: 3665 Peugeot 106 1.1 Turbo Peugeot 106 1.5D Turbo Peuge
    #297
    Cool as fuck
    1 user thanked this post:
  298. Saxperience Forum Bum Joined: Apr 2013 Jarrow Posts: 4022 2003 Icelandic Grey 16v VTR 1991 Daihatsu GTti
    #298
    Quote:
    Originally Posted by MartinObviously View Post
    Cool as fuck
    Amen!!
  299. West Midlands Joined: Nov 2005 Nuneaton (West Mids) Posts: 13835 '64 Volvo V40 R’Design, '89 Ph1 309 GTi, ‘97 Mk1 S
    #299
    Spent today under the car again, drivers side floor plans I'd not yet touched.

    Before







    And afters. Between both sets of pics I havn't fitted anything else new, all I've done is clean stuff up







    Popped on the new front bumper



  300. Saxperience Forum Bum Joined: Apr 2013 Jarrow Posts: 4022 2003 Icelandic Grey 16v VTR 1991 Daihatsu GTti
    #300
    How long till you think it'll be ready?
  301. Newbie Joined: Feb 2014 Posts: 22
    #301
    Loving this
  302. West Midlands Joined: Nov 2005 Nuneaton (West Mids) Posts: 13835 '64 Volvo V40 R’Design, '89 Ph1 309 GTi, ‘97 Mk1 S
    #302
    Quote:
    Originally Posted by Mickswan View Post
    How long till you think it'll be ready?
    Ready to be on the road by Summer
    Ready for a show appearance by next Summer
  303. Saxperience Forum Bum Joined: Apr 2013 Jarrow Posts: 4022 2003 Icelandic Grey 16v VTR 1991 Daihatsu GTti
    #303
    Nice, Im looking forward to seeing photos outside the garage.
  304. Established Member Joined: Nov 2011 Newcastle Posts: 1698 Range Rover Sport
    #304
    I don't have anything to say but I certainly appreciate your time and hard work, looks awesome
  305. Saxperience Post Whore Joined: Aug 2008 The wrong carpark Posts: 5152 Xantia 1.9TD
    #305
    'Scuse me, I need to change my pants.

    Where the hell are you getting parts from!! The work underneath looks brilliant, giving me ideas on tidying up the xantia
  306. West Midlands Joined: Nov 2005 Nuneaton (West Mids) Posts: 13835 '64 Volvo V40 R’Design, '89 Ph1 309 GTi, ‘97 Mk1 S
    #306
    The parts have literally come from far and wide, I could probably tick off a majority of Europe. Germany has been the supplier of the bulk.
  307. West Midlands Joined: Nov 2005 Nuneaton (West Mids) Posts: 13835 '64 Volvo V40 R’Design, '89 Ph1 309 GTi, ‘97 Mk1 S
    #307
    Today's been a long day. I finally decided to start tackling cleaning up the rest of the front end. It's particularly greasy and needs taking apart for a thorough check over. There's evidence of a few leaks here and there which I need to figure out if they're still actively seeping and where exactly from.

    It also gives me change to do pre MOT checks on the front suspension and renew a few parts.
    Anyway here's what I'm dealing with;











    Today's progress only got as far as removing and cleaning up the subframe. It's taken hours to clean it up properly in all the crevices.



    I'll get it powder coated at some point but for now it's good enough to stay as it is and keep the funds going into MOT prep



  308. Saxperience Hardcore! Joined: Dec 2007 smurfland. Posts: 17346 Ex saxo owner.
    #308
    Blimey that's come up clean,well done keep the pics coming.
  309. Saxperience Post Whore Joined: Aug 2008 The wrong carpark Posts: 5152 Xantia 1.9TD
    #309
    that can't be the same subframe!
  310. West Midlands Joined: Nov 2005 Nuneaton (West Mids) Posts: 13835 '64 Volvo V40 R’Design, '89 Ph1 309 GTi, ‘97 Mk1 S
    #310
    Another very long days work today, which was mainly taken by cleaning up the gearbox from this









    To this, the best I can really do with it being in situe







    Back of the engine block started



    And got the lower bulkhead cleaned up on the passenger side





  311. West Midlands Joined: Nov 2005 Nuneaton (West Mids) Posts: 13835 '64 Volvo V40 R’Design, '89 Ph1 309 GTi, ‘97 Mk1 S
    #311
    Quote:
    Originally Posted by chinkostu View Post
    that can't be the same subframe!
    Came up well didn't it, it did take me the best past of 4-5 hours though
  312. Newbie Joined: Feb 2013 Castelo Branco/Portugal Posts: 1 Citroën Ax 1.4D Citroën Berlingo 2.0 HDi Toyot
    #312
    Like always, you are doing a very good job on this car. The sub-frame was resprayed?
  313. West Midlands Joined: Nov 2005 Nuneaton (West Mids) Posts: 13835 '64 Volvo V40 R’Design, '89 Ph1 309 GTi, ‘97 Mk1 S
    #313
    Quote:
    Originally Posted by Andre21 View Post
    Like always, you are doing a very good job on this car. The sub-frame was resprayed?
    Nope it hasn't been sprayed. Nothing but cleaning for the subframe. It was actually in pretty good condition under the road grime
  314. Saxperience Post Whore Joined: Aug 2008 The wrong carpark Posts: 5152 Xantia 1.9TD
    #314
    I can't believe you're cleaning it all whilst its still attached! must be a nightmare for room!
  315. West Midlands Joined: Nov 2005 Nuneaton (West Mids) Posts: 13835 '64 Volvo V40 R’Design, '89 Ph1 309 GTi, ‘97 Mk1 S
    #315
    Quote:
    Originally Posted by chinkostu View Post
    I can't believe you're cleaning it all whilst its still attached! must be a nightmare for room!
    It is tricky, I've managed to get it cleaned to a good enough standard for now. When I get round to whipping the engine out to respray the engine bay I'll finish the job :-)

    Autosmart Tardis, toothbrush selection and the baby wipes have now finished their job on this part of the car.

  316. Saxperience Forum Bum Joined: Dec 2012 Perth Posts: 3665 Peugeot 106 1.1 Turbo Peugeot 106 1.5D Turbo Peuge
    #316
    I bet you get some funny looks buying that many baby wipes! lmao
  317. West Midlands Joined: Nov 2005 Nuneaton (West Mids) Posts: 13835 '64 Volvo V40 R’Design, '89 Ph1 309 GTi, ‘97 Mk1 S
    #317
    Quote:
    Originally Posted by MartinObviously View Post
    I bet you get some funny looks buying that many baby wipes! lmao
    I grabbed a whole box from the shelf at Asda last time, a few times I've been asked;
    Cashier: ahh bless, have you got a bit of a messy one?
    Me: Sadly yes, it's a 25 year old called Peugeot...

    The look of confusion.... Priceless
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  318. Saxperience Hardcore! Joined: Aug 2004 West Mids Posts: 15392 '98 EK9 N1
    #318
    Unbelievable progress so far Matt
    1 user thanked this post:
  319. West Midlands Joined: Nov 2005 Nuneaton (West Mids) Posts: 13835 '64 Volvo V40 R’Design, '89 Ph1 309 GTi, ‘97 Mk1 S
    #319
    Havn't had a great deal of time on this over the last few weeks again. I have however been gathering more parts, the front suspension will effectively be fully rebuilt.

    One result I have had is that I was about to buy some new hubs, largely for the sake of it but I had a few hours spare and was curious about how well I could clean up the 25 year old originals, turns out with some determination they can be returned to pretty good condition

  320. Newbie Joined: Jun 2013 Posts: 26
    #320
    keep up the good work mate
  321. West Midlands Joined: Nov 2005 Nuneaton (West Mids) Posts: 13835 '64 Volvo V40 R’Design, '89 Ph1 309 GTi, ‘97 Mk1 S
    #321
    New suspension is taking shape nicely. I didn't want to modify the car in any way but out of necessity I've have done slightly in the interests of better quality parts.

    I couldn't find any original genuine dampers and most aftermarket OE replacements now seem to be mostly cheap unknown makes. So I've opted for Bilstein B4's which are 20% increase on standard damping rates & importantly other than the Bilstein sticker appear 'stock'

    Same scenario with the springs, after recommendation I've gone for the Eibach Pro springs which have a subtle 20-30mm drop allegedly. And as before they're black to appear 'stock' other than an Eibach stamp on the rear of one of the coils.

    Also managed to get a complete Genuine new old stock top mount assembly & bearing. I just need some new dust covers and bump stops now then they'll be complete to mate up with the hub section

  322. Saxperience Forum Bum Joined: Apr 2013 Jarrow Posts: 4022 2003 Icelandic Grey 16v VTR 1991 Daihatsu GTti
    #322
    This car is the biggest cock tease
  323. West Midlands Joined: Nov 2005 Nuneaton (West Mids) Posts: 13835 '64 Volvo V40 R’Design, '89 Ph1 309 GTi, ‘97 Mk1 S
    #323
    I've almost finished the process of gathering and refurbing bits of the front suspension. The subframe and ARB went to the powder coaters this afternoon. I spent some time prepping the subframe first, the production process doesn't seem to care too much for a tidy finish so I've flatted down all of the stray weld spatter and rounded the edges on some of the harsher corners of the individual parts.



    I've been to Peugeot & ordered a complete set of replacement fittings.

    I've also sent off a V888 Request for vehicle information to DVLA, hopefully they'll be able to provide me with some bits & bobs to replenish the lost history for the car and old MOT's as I still don't know when it was last 'on the road'
  324. Established Member Joined: Aug 2009 King's lynn Posts: 2073 Turbocharged vtr
    #324
    Really like reading this thread! I love your work
  325. West Midlands Joined: Nov 2005 Nuneaton (West Mids) Posts: 13835 '64 Volvo V40 R’Design, '89 Ph1 309 GTi, ‘97 Mk1 S
    #325
    Nice freshly refurbished steering wheel to add to my ever growing 'to fit' list.

  326. Saxperience Post Whore Joined: Aug 2008 The wrong carpark Posts: 5152 Xantia 1.9TD
    #326
    Quote:
    Originally Posted by willsy View Post
    Nice freshly refurbished steering wheel to add to my ever growing 'to fit' list.
    is it your own wheel refurbed or an ebay/your magic contacts find? as it looks mint

    the welding splatter, is that on the subframe?
  327. West Midlands Joined: Nov 2005 Nuneaton (West Mids) Posts: 13835 '64 Volvo V40 R’Design, '89 Ph1 309 GTi, ‘97 Mk1 S
    #327
    Yes the weld spatter was on the subframe, apparently having asked 205/309 owners the spatter was on all of them, seems Peugeot weren't too bothered about cosmetic appearance on the subframes

    The steering wheel isn't my original, a leather restorer was selling one that he'd done already. So the original ones now spare.

    More bits back from being powder coated.











    No more crappy welding spatter spots



    Also got my original front bumper mounting leafs coated as the new ones that I got re coated vary slightly
  328. Saxperience Forum Bum Joined: Apr 2013 Jarrow Posts: 4022 2003 Icelandic Grey 16v VTR 1991 Daihatsu GTti
    #328
    All in the detail
  329. Established Member Joined: Nov 2011 Newcastle Posts: 1698 Range Rover Sport
    #329
    I know its a Goodwood but this is apparently concourse and warranting 10 grand, if the level of detail and finish of yours so far is continued then it completely blows the Goodwood apart

    http://www.ebay.co.uk/itm/2914330375...671&rmvSB=true
    1 user thanked this post:
  330. Saxperience Post Whore Joined: Aug 2008 The wrong carpark Posts: 5152 Xantia 1.9TD
    #330
    Quote:
    Originally Posted by deano_123 View Post
    I know its a Goodwood but this is apparently concourse and warranting 10 grand, if the level of detail and finish of yours so far is continued then it completely blows the Goodwood apart

    http://www.ebay.co.uk/itm/2914330375...671&rmvSB=true
    The goodwood is rarer however

    This car gives me a proper stiffy. Need to have a real gander at the underside of my Xant as it's had a liberal coating of LHM and diesel from perished pipes
  331. West Midlands Joined: Nov 2005 Nuneaton (West Mids) Posts: 13835 '64 Volvo V40 R’Design, '89 Ph1 309 GTi, ‘97 Mk1 S
    #331
    Quote:
    Originally Posted by chinkostu View Post
    The goodwood is rarer however
    It's a shame 'how many left' doesn't distinguish between Phase 1 and Phase 2 GTi's as I rekon the Phase 1's would be close, if not have the edge over the Goodwood in the rarity stakes. Not many left of either though sadly.

    I know a good recipe for success to use on your Xant if you have the time/patience for it :-) toothbrush and Autosmart Tardis really has worked wonders
  332. Saxperience Post Whore Joined: Jan 2010 Stourbridge Posts: 7338 Nissan 200sx S14a
    #332
    How many left is wholly inaccurate bud, there have been member's clubs with more cars on their show stands than should even exist lol
  333. Saxperience Post Whore Joined: Aug 2008 The wrong carpark Posts: 5152 Xantia 1.9TD
    #333
    Quote:
    Originally Posted by holdawayt View Post
    How many left is wholly inaccurate bud, there have been member's clubs with more cars on their show stands than should even exist lol
    Depends on how they've been marked on the reg docs. Misspellings and missing/added trims soon bump up numbers.


    Willsy it's more the space than anything. From the looks of it, might be off the road for a few weeks soon so can easily get it on ramps and get underneath it! Plus the fact it's a daily means it will get dirty fast.
  334. West Midlands Joined: Nov 2005 Nuneaton (West Mids) Posts: 13835 '64 Volvo V40 R’Design, '89 Ph1 309 GTi, ‘97 Mk1 S
    #334
    More goodies arriving from Peugeot. Half of the order towards completing the nut/bolt rebuild of the front suspension





    Off with the old spring/damper assembly



    Still waiting for a few bits to arrive but to keep the garage tidy-ish I popped the new ones back on for a photo after cleaning the remainder of the arch





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  335. Saxperience Post Whore Joined: Aug 2008 The wrong carpark Posts: 5152 Xantia 1.9TD
    #335
    This is looking really tidy!
  336. West Midlands Joined: Nov 2005 Nuneaton (West Mids) Posts: 13835 '64 Volvo V40 R’Design, '89 Ph1 309 GTi, ‘97 Mk1 S
    #336
    Just waiting for the last few bits to arrive for the suspension. I've decided to replace the clutch aswel whilst everything's off, seems like a good idea to do it now.

    I have been tending to the strut tops aswel, as is common between the inner turret and the top mount which is metal on these there was some surface rust that was beginning. This looks worse with the rusty metal from the old top mount fusing with the inner turret. Apparently it's not uncommon for rust here to be terminal. Fortunately mines at very early stages so there's no problem treating it properly and getting it back as it should have originally been. I've wire brushed (drill attachments) as much as I could then I've been applying some rust removal gel to get all the last bits off. One more application of that should complete it then I'll apply the necessary layers of paint etc.

    Only started the drivers side so far


    Old suspensions had it's day


    New assembly


    And after lying on the floor under the car got a bit much for the day I spent some time getting this up to scratch which was a bit more leisurely. From this

    To this
    1 user thanked this post:
  337. Administrator Joined: Dec 2002 Glasgow United Kingdom (Scotland) Posts: 26097 Chelski Traktor
    #337
    Seriously. Best thread ever.
    2 users thanked this post: ,
  338. West Midlands Joined: Nov 2005 Nuneaton (West Mids) Posts: 13835 '64 Volvo V40 R’Design, '89 Ph1 309 GTi, ‘97 Mk1 S
    #338
    I've had my reply from the DVLA today after my submission of a V888 request for vehicle information form.
    I informed DVLA that I was seeking copies of any documents held from first registration, and for any information surrounding it's use on the road, when it was last officially 'on the road' due to a previous owner losing everything. I hoped I might find some clues from old MOT information as to what caused it to become condemned to a long stretch of neglect prior to my purchase of it.

    I now have copies of the first certificate of registration, all subsequent V5 documents. The first of which confirms what I'd been told, in that my GTi was first registered as a demo car for Renwicks, (what was a main Peugeot dealership in Exeter) for 7 months. It then stayed with keeper 2 from 1990 until 2012. Keeper 3 had it for 2 years & did bugger all with it, it was one of several restoration projects that the guy had bought but hadn't got around to starting. Then I became keeper 4 in 2014.

    Sadly with the introduction of the computerised system of MOT's not beginning until 2005 they were unable to send me any old MOT information or copies of old certificates. They havn't confirmed exactly when it last had an MOT on it. Excise licence data gives a clue perhaps in that it was last taxed up until 31/05/2005- it has been SORN since then so it has almost spent 10 years off the road.

    Hopefully it'll return to an 'on the road' status pretty soon.
  339. West Midlands Joined: Nov 2005 Nuneaton (West Mids) Posts: 13835 '64 Volvo V40 R’Design, '89 Ph1 309 GTi, ‘97 Mk1 S
    #339
    Been sorting out my folder of documents this evening for the GTi. Considering I started my ownership with nothing more than a V5C I've managed to gather some of the old history thanks to DVLA, and with parts purchased and replaced in the last 12 months is well on the way to filling a large folder already.



    I've also got a separate folder whereby I've printed off all the relevant diagrams and parts list/prices from service box. I've colour coded the highlighting based on new genuine, new other, refurbished, mint original so that I can fully document the restoration as much as possible



  340. L-plater Joined: Dec 2012 Kent Posts: 45 106 gti itb, saxo vtr
    #340
    So much love for the 309 GTI. Its going to be one of the best around when its complete
  341. Infrequent Poster Joined: Apr 2012 Posts: 115
    #341
    The attention to detail on every single part is absolutely incredible well done.

    Out of interest do you actually make a profit on any of them?

    I know you get top whack for them but with so many new parts - especially OEM I couldn't imagine that there would be a margin left at the end.
  342. West Midlands Joined: Nov 2005 Nuneaton (West Mids) Posts: 13835 '64 Volvo V40 R’Design, '89 Ph1 309 GTi, ‘97 Mk1 S
    #342
    Quote:
    Originally Posted by Steve_GTI View Post
    So much love for the 309 GTI. Its going to be one of the best around when its complete
    Cheers Steve. This one has set the standard for 309's and is widely regarded as the best at the moment, it's still being worked on. The progress thread for that it well worth a read too if you have an hour spare.

    http://www.309ownersclub.com/forum/v...php?f=34&t=714
  343. West Midlands Joined: Nov 2005 Nuneaton (West Mids) Posts: 13835 '64 Volvo V40 R’Design, '89 Ph1 309 GTi, ‘97 Mk1 S
    #343
    Quote:
    Originally Posted by Mash View Post
    The attention to detail on every single part is absolutely incredible well done.

    Out of interest do you actually make a profit on any of them?

    I know you get top whack for them but with so many new parts - especially OEM I couldn't imagine that there would be a margin left at the end.
    I do pride myself on the attention to detail, really appreciate the compliments :-)

    I've never bought one with the intention of selling for a profit margin. I did make a good profit on the red AX but that was such low mileage all it really needed was a good detail and some small parts. I miss that car though.

    This one will be a keeper, and you're quite right it costs a fortune, there's definitely no way I'd ever make my money back on this one
  344. Infrequent Poster Joined: Apr 2012 Posts: 115
    #344
    Quote:
    Originally Posted by willsy View Post
    Cheers Mash :-)

    The red AX GT that I had prior I did make a very very good margin on, but that was such low mileage all it really needed was a good detail and some small parts.

    This one will be a keeper, and you're quite right it costs a fortune for all of these new Genuine Peugeot parts. I'm currently working my way through a spreadsheet for my spending so far, I'm pretty sure that this one has exceeded £5,000 already and I'm still not at MOT stage yet.

    I dare say I'll have no trouble getting into 5 figures. Certainly no one would pay that for one at the moment unless it's near concours with a collector showing some interest.
    If you're planning on keeping it then completely ignore me - I'm more than happy to spend loads on a car as long as it's going to stay after.

    I don't think that's too unreasonable, there's a goodward on ebay at the moment for over 10 grand but I think the owner is pretty optimistic - claims it's concours condition but I'm sure you would show him the true meaning of the phrase!
  345. Infrequent Poster Joined: Apr 2012 Posts: 115
    #345
    Goodwood* excuse my poor spelling..
  346. West Midlands Joined: Nov 2005 Nuneaton (West Mids) Posts: 13835 '64 Volvo V40 R’Design, '89 Ph1 309 GTi, ‘97 Mk1 S
    #346
    Quote:
    Originally Posted by Mash View Post
    There's a goodward on ebay at the moment for over 10 grand but I think the owner is pretty optimistic - claims it's concours condition but I'm sure you would show him the true meaning of the phrase!
    Very optimistic. I'm no expert on Goodwood's, but the general consensus on it from various Goodwood owners is that in it's current state 'very good condition' would be better described. Plenty to be attended to before that could be upped to mint/immaculate (I'd be happy to achieve that). Concours is literally as if it left the factory yesterday
  347. Infrequent Poster Joined: Apr 2012 Posts: 115
    #347
    Exactly, it looks pretty clean on the outside till you look in the engine bay. Nice condition admittedly, but no where near the effort you have put in to this one.
    1 user thanked this post:
  348. Saxperience Post Whore Joined: Aug 2008 The wrong carpark Posts: 5152 Xantia 1.9TD
    #348
    Quote:
    Originally Posted by willsy View Post
    Cheers Steve. This one has set the standard for 309's and is widely regarded as the best at the moment, it's still being worked on. The progress thread for that it well worth a read too if you have an hour spare.

    http://www.309ownersclub.com/forum/v...php?f=34&t=714
    Nice! Both up to a nice standard, although I think yours is a bit cleaner
    1 user thanked this post:
  349. West Midlands Joined: Nov 2005 Nuneaton (West Mids) Posts: 13835 '64 Volvo V40 R’Design, '89 Ph1 309 GTi, ‘97 Mk1 S
    #349
    Here we go again folks.

    Today I decided to dig out my zinc plating kit that I last used on my AX GT.

    Started off with these 2 bits


    First stage is to clean using electrolysis, much more effective than other methods and the only way to guarantee being rust and grime free without the harshness of blasting


    Doesn't take long til the solution is full of rusty particles and old aged coating


    First one cleaned


    And onto the zinc plating


    Jobs a gudden





    Quite pleased with it. Of course there is some minor pitting left by the rust removal but it's just as nice to retain and refurbish some of the cars original parts as it is to fit new ones. Restoring bits yourself is much more rewarding.
    2 users thanked this post: ,
  350. West Midlands Joined: Nov 2005 Nuneaton (West Mids) Posts: 13835 '64 Volvo V40 R’Design, '89 Ph1 309 GTi, ‘97 Mk1 S
    #350
    And some more done

    Before


    After
  351. Saxperience Post Whore Joined: Aug 2008 The wrong carpark Posts: 5152 Xantia 1.9TD
    #351
    Fucking incredible.


    Dude, do my car.

    haha
  352. West Midlands Joined: Nov 2005 Nuneaton (West Mids) Posts: 13835 '64 Volvo V40 R’Design, '89 Ph1 309 GTi, ‘97 Mk1 S
    #352
    Quote:
    Originally Posted by chinkostu View Post
    Dude, do my car.
    I'd love to do someone else's car, it'll save my bank balance for a bit then :-)
  353. North West Joined: Apr 2009 Warrington, Cheshire Posts: 5733 PH2 Peugeot 106 "race" car - Currently in pieces
    #353
    I think the slight pitting gives the part a bit more character as well. It shows that it has been restored and not just all brand new bits fitted. Cracking job! Just need a bucket big enough to dip my whole car in next!
    1 user thanked this post:
  354. West Midlands Joined: Nov 2005 Nuneaton (West Mids) Posts: 13835 '64 Volvo V40 R’Design, '89 Ph1 309 GTi, ‘97 Mk1 S
    #354
    Only got a few more bits plated today. Factory fitted air horn bracket and one of the PAS reservoir brackets



  355. Infrequent Poster Joined: Jun 2012 bristol Posts: 168 Mk1 (mk2 in disguise) vtr turbo.. sort of. (N3 EBH
    #355
    I bet your mot tester loves you! Do you just show up in the car drive straight back out with the certificate? Absolutely incredible work and a great read! 👍👍
  356. West Midlands Joined: Nov 2005 Nuneaton (West Mids) Posts: 13835 '64 Volvo V40 R’Design, '89 Ph1 309 GTi, ‘97 Mk1 S
    #356
    Quote:
    Originally Posted by elliotthorwood View Post
    I bet your mot tester loves you! Do you just show up in the car drive straight back out with the certificate? Absolutely incredible work and a great read! 👍👍
    That'll be nice if that happens :-) this one hasn't had an MOT for over 10 years, I'm getting closer to being ready for one though
  357. West Midlands Joined: Nov 2005 Nuneaton (West Mids) Posts: 13835 '64 Volvo V40 R’Design, '89 Ph1 309 GTi, ‘97 Mk1 S
    #357
    Well progress has been steady again, I've started working my way through the MOT'able bits and checking through the electrics.

    Bizarre place to start was to get the factory option air horns working again. Working through the bits independently the old compressor was no longer capable of producing the amount of compressed air required



    So I managed to source a near identically designed one to retain the original appearance and fitted it to the newly plated bracket.



    Refitted the horns & now they work perfectly.



    I then tried to tidy up the engine bay wiring a little. One of my hates is messy wiring and the setup on these are terrible, other than some subtle re routing and refreshing the conduit there's nothing more I can do to this....



    Of course the paintwork will have to be excused for a while longer, but the passenger side is mostly complete and up to scratch

    Before


    As it stands
  358. Saxperience Addict Joined: Sep 2008 Swansea / Chippenham Posts: 10872 306 diesel shed broken vts
    #358
    incredible this, the patience you have doing absolutely everything is mind boggling!
  359. Saxperience Post Whore Joined: Jul 2009 Costa Del Posts: 8010
    #359
    I will keep saying this throughout this build, just wow. The rust treatment and zinc plating looks incredible, and the attention to detail is second to none all over this car. Well done Matt!
  360. West Midlands Joined: Nov 2005 Nuneaton (West Mids) Posts: 13835 '64 Volvo V40 R’Design, '89 Ph1 309 GTi, ‘97 Mk1 S
    #360
    Cheers :-) I've just ordered a new genuine clutch kit which I want to get fitted whilst the front suspension and subframe is off, and I've ordered the last remaining front suspension bits from Peugeot aswel as some new bits for the steering assembly.
    With all that lot finished the front end will just need the calipers sending off to BigRedd for a refurb with new discs & pads then it'll be just about compete I think.
  361. West Midlands Joined: Nov 2005 Nuneaton (West Mids) Posts: 13835 '64 Volvo V40 R’Design, '89 Ph1 309 GTi, ‘97 Mk1 S
    #361
    Frustrating day today, had full intentions to get the gearbox off, swap the clutch, reassemble and maybe have some of the front suspension back on again at last.

    But.... As ever nothing is that simple. My displeasure in the XU setup has only been enhanced, I really do miss the ease of TU that I've been accustomed to in the past. Eventually after plenty of arsing around negotiating the gearbox removal past the nest of wiring, hoses etc the gearbox eventually came off.

    Now those who have read through my progress will remember how much of an oily state the underside of the gearbox was, and that with so much gunk and dried oil buildup I had no chance of identifying where the cause of the problem was. Well the top of the gearbox and inside the housing was the same.

    Really did need seeing to prior to refitting




    Nuts anyone?


    And the clutch fork (thank god I did decide to do the clutch now) was actually semi broken. The rear of the clutch fork that fits onto a pivot point ball had begun to detach with one of the welds having broke.

    So until a replacement can be sourced I've started to clean up the gearbox. About 3 hours later and here's where I've got to





    Still room for improvement. So very much feeling like 1 step forward but 3 steps backwards after today. *sigh*
  362. Saxperience Post Whore Joined: Aug 2008 The wrong carpark Posts: 5152 Xantia 1.9TD
    #362
    I know the feeling man, it'll be worth it in the end. Mine needs a clutch ideally and im dreading it as they're a pig to do. You're almost there


    At least it hasn't decided to leak fuel everywhere!
  363. Saxperience Post Whore Joined: Oct 2005 Sydney Posts: 8525 Mango Westcoast
    #363
    Much tidier now Willsy
  364. West Midlands Joined: Nov 2005 Nuneaton (West Mids) Posts: 13835 '64 Volvo V40 R’Design, '89 Ph1 309 GTi, ‘97 Mk1 S
    #364
    So the other day I got round to replacing the dizzy o ring which was brittle and already in 3 pieces. Replaced the vacuum advance for a new one. Cleaned off all remaining traces of oil spillage.
    Then moved on to the steering rack, started off by replacing some very worn bushes in the PAS ram





    Then fitted new bellows, clips, track rods and track rod ends & cleaned the rack up





    All of the remaining new suspension bits have now arrived, mounts, ARB bushes and all new genuine nuts & bolts. Partly assembled the subframe to make sure everything is there prior to refitting.





    New clutch fork arrived yesterday, this one was due for imminent failure



    New rear bumper also arrived, fitted the new red trims and number plate lamps





    Got as far as resting it in place on the car for now. Will whip it back off again to spruce the rear end up before MOT





    And finished a few other odd jobs. Fuel filter, PAS reservoir brackets plated and finished the horn assembly with some new tubing, along with a replacement dizzy cap and rotar arm.









    Next job back to refitting the clutch & gearbox so the front end can finally be reassembled
    2 users thanked this post: ,
  365. Newbie Joined: Jun 2013 Posts: 26
    #365
    cracking update
  366. Saxperience Hardcore! Joined: Aug 2004 West Mids Posts: 15392 '98 EK9 N1
    #366
    Matt, cars coming along so well. Need to sort another get together so we can catch up. I can introduce your OCD to my cars too.
  367. West Midlands Joined: Nov 2005 Nuneaton (West Mids) Posts: 13835 '64 Volvo V40 R’Design, '89 Ph1 309 GTi, ‘97 Mk1 S
    #367
    Cheers Rushy, and yes we do it's long overdue again. I wish more people would let me loose on their cars, it's a shame there's no market in it to go into such detail on other peoples cars & do this as a job- I'd love it though
  368. West Midlands Joined: Nov 2005 Nuneaton (West Mids) Posts: 13835 '64 Volvo V40 R’Design, '89 Ph1 309 GTi, ‘97 Mk1 S
    #368
    Finally I have all the remaining parts to crack on with refitting the gearbox.

    I've had plenty of time to clean the gearbox up, degreaser and metal polish were used in abundance.
    I've fitted a host of new (Genuine Peugeot) parts by way of; new seals to the input shaft, the old ones were fine but for the sake of a few quid it's worth doing whilst the gearbox is off. Failed clutch fork replaced, the additional clutch lever found on the BE1 box has been replaced, that was virtually seized with the rusty bolt and bushes passing through it. New clutch cable fitted, reverse sensor replaced too.





    I'd had a new starter motor sitting as one of the first things I bought for the car. The old one still works but again with the gearbox off it was an ideal opportunity to fit the new one. The old one is quite a lot heavier and more bulky.

  369. Established Member Joined: Aug 2009 King's lynn Posts: 2073 Turbocharged vtr
    #369
    Gearbox looks great compared to what it looked like before
  370. West Midlands Joined: Nov 2005 Nuneaton (West Mids) Posts: 13835 '64 Volvo V40 R’Design, '89 Ph1 309 GTi, ‘97 Mk1 S
    #370
    Slow progress at the mo, mainly due to the heat being unbearable.

    I have started buying all the bits to do the brake system with. I've invested in a flaring kit.
    Here's my tester. Combination of A4 Marine Stainlesd fittings and cupronickel lines

  371. West Midlands Joined: Nov 2005 Nuneaton (West Mids) Posts: 13835 '64 Volvo V40 R’Design, '89 Ph1 309 GTi, ‘97 Mk1 S
    #371
    Just a couple of photos from the last few days.

    New master cylinder fitted along with the brake lines which I made up. Cleaned out the brake fluid reservoir and cap which were pretty grubby too

    This is the best 'before' pic that I have



    And a selection of 'So far's' Servo can wait til I strip out and respray the engine way







    And gearbox refitted. From this;


    To this


    New clutch lever bits


    Other than that I've just been trawling through all the wiring checks.
  372. Saxperience Post Whore Joined: Aug 2010 Little Mill, South Wales Posts: 7547 Mondeo ST TDCI Saxo VTS
    #372
    Fairplay I love reading your restoration threads.

    Epic work, wish I had (a) the money and (b) the time to do things like this.
  373. West Midlands Joined: Nov 2005 Nuneaton (West Mids) Posts: 13835 '64 Volvo V40 R’Design, '89 Ph1 309 GTi, ‘97 Mk1 S
    #373
    Quote:
    Originally Posted by Brettles1986 View Post
    Fairplay I love reading your restoration threads.

    Epic work, wish I had (a) the money and (b) the time to do things like this.
    Cheers mate, it is a huge labour of love. Even the simplest things take a lot of time and patience to resolve.... As my next update demonstrates
  374. West Midlands Joined: Nov 2005 Nuneaton (West Mids) Posts: 13835 '64 Volvo V40 R’Design, '89 Ph1 309 GTi, ‘97 Mk1 S
    #374
    I've made a return to the electrical checks today, starting with the front wipers and washer neither of which were working.

    I'd already replaced the wiper arm spindles which are well renowned for seizing up on these. Next up was replacing the relay, still nothing.
    Then took the wiper stalk apart, cleaned up the connections a few of which were definitely in need of it, still nothing.
    Next up I wired the motor up directly and it worked fine, as did the washer motor which was new.
    So that just left the wiring and connections
    Out came the rotary tool with a small brass wire brush, electrical contact cleaner and metal polish.

    Turns out they clean up quite well. Cleaned up the outside aswel as the inner surface for no reason other than it was quite satisfying




    As good as new


    And the hard work paid off. Front wipers and washer are now fully functional :-)

    Next up was the rear wiper. On the Phase 1 309's the power travels through the boot gas struts (Good old peugeot) with a spade terminal on either end. I'd already fixed the lower ones as the wires had snapped at the terminal, I've got exact OE terminals so they were an easy fix. The rears work off a button on the dash rather than the stalk. Washer motor worked fine but no life from the wiper.
    Took the motor and spindle apart, fitted a new motor. The old one did work after all so it'll retire to being a spare. Remembered to refit the upper terminals on the gas struts and still had nothing.
    Eventually realised that the boot has to be fully closed for it to work. Job done

    Apologies for the essay anyway. Just goes to show how long it can take to complete some of these jobs. It's taken me 6 hours of diagnosis and tinkering to get the wipers and washers fully functional so I'm now relieved and feeling quite pleased.
  375. Saxperience Post Whore Joined: Aug 2008 The wrong carpark Posts: 5152 Xantia 1.9TD
    #375
    Suprised you didn't just suspend the plug in a pot of contact cleaner. Although i'm not sure how much fuzz it would have removed!
  376. West Midlands Joined: Nov 2005 Nuneaton (West Mids) Posts: 13835 '64 Volvo V40 R’Design, '89 Ph1 309 GTi, ‘97 Mk1 S
    #376
    Finally turned a corner, all MOTable electrics (lights, washers etc) are now fully functional. I just have a few final switches to check and then I can get the dash and remaining interior refitted.

    It's been so time consuming and it's not really anything that I can take some pics of without boring everyone to death.

    Rest assured though, progress is good just need to finish the brake refurb and then hopefully the big day will soon arrive
  377. Saxperience Forum Bum Joined: Dec 2012 Perth Posts: 3665 Peugeot 106 1.1 Turbo Peugeot 106 1.5D Turbo Peuge
    #377
    All MOTable electrics?

    That means a bulb will blow at the MOT
  378. West Midlands Joined: Nov 2005 Nuneaton (West Mids) Posts: 13835 '64 Volvo V40 R’Design, '89 Ph1 309 GTi, ‘97 Mk1 S
    #378
    Quote:
    Originally Posted by MartinObviously View Post
    All MOTable electrics?

    That means a bulb will blow at the MOT
    That would be just typical :-)
  379. West Midlands Joined: Nov 2005 Nuneaton (West Mids) Posts: 13835 '64 Volvo V40 R’Design, '89 Ph1 309 GTi, ‘97 Mk1 S
    #379
    Been trying to get some key front end bits cleaned up and treated that have contact with new suspension bits before fitting them. The rest will be done when I respray the engine bay etc at a later date.

    The upper suspension turret had some surface rust where the contacts been with the old top mount


    Got as far as cleaning all the rust off with drill & wire attachment. Any remains have been treated with Bilt Hamber rust removal gel to ensure it's a perfectly clean surface. Then two coats of Bilt Hamber electrox high zinc primer as my base



    Onto the front subframe mounting points. Again minor surface rust to contend with



    Cleaned it all up and again treated with the Bilt Hamber stuff to ensure it's perfectly clean. Zinc primer applied straight after this pic



    And a final pic after some paint and lacquer has been applied

  380. Saxperience Post Whore Joined: Aug 2008 The wrong carpark Posts: 5152 Xantia 1.9TD
    #380
    hope you'll be doing the same to that brake pipe bracket

    I don't think anyones car will match this level of detail!
  381. Regular Poster Joined: Nov 2008 Alnwick/Northumberland Posts: 258 Cobalt Blue 106
    #381
    Bilt Hamber

    Love reading updates on this, think I've also convinced myself to get a plating kit.
  382. West Midlands Joined: Nov 2005 Nuneaton (West Mids) Posts: 13835 '64 Volvo V40 R’Design, '89 Ph1 309 GTi, ‘97 Mk1 S
    #382
    Definitely worth getting one, it's time consuming but worth it.

    .......

    Slow progress at the moment, however the dashboard and remainder of the interior should be refitted this week is my plan.

    Gathered a few more bits for the brake system aswel, new rear brake compensators and stainless Goodridge hoses

  383. Saxperience Hardcore! Joined: Dec 2005 Bradford Posts: 26687 '15 Focus ST-2
    #383
    Hi Matt,

    Long time no speak!

    I have just read through this whole thread and wow, I love what you've done! The attention to detail you have is fantastic, will follow this one with great attention to detail!
    1 user thanked this post:
  384. West Midlands Joined: Nov 2005 Nuneaton (West Mids) Posts: 13835 '64 Volvo V40 R’Design, '89 Ph1 309 GTi, ‘97 Mk1 S
    #384
    Cheers Luke! Long time no see aswel, hope all is well :-)
  385. Newbie Joined: Jun 2013 Posts: 26
    #385
    Any updates Matt?
  386. West Midlands Joined: Nov 2005 Nuneaton (West Mids) Posts: 13835 '64 Volvo V40 R’Design, '89 Ph1 309 GTi, ‘97 Mk1 S
    #386
    Lots of hours going into it Danny, just feels like slow going.

    I still havn't got the suspension refitted. There's the odd bit of surface rust here and there where new bits would be bolting up to so I've literally spent hours ensuring that every last bit has been removed before giving a few good coats of zinc rich primer. That's been the hard bit as the Bilt Hamber stuff which I've been using to remove the rust is good, but it does require a few coats and some scrubbing to get rid of all rust traces.
    I have now got all those bits prepped for some paint which won't take me long to apply.

    I'll upload some pics in a min, not much to look at considering the hours I've put in but it's still going in the right direction
  387. Newbie Joined: Jun 2013 Posts: 26
    #387
    Quote:
    Originally Posted by willsy View Post
    Lots of hours going into it Danny, just feels like slow going.

    I still havn't got the suspension refitted. There's the odd bit of surface rust here and there where new bits would be bolting up to so I've literally spent hours ensuring that every last bit has been removed before giving a few good coats of zinc rich primer. That's been the hard bit as the Bilt Hamber stuff which I've been using to remove the rust is good, but it does require a few coats and some scrubbing to get rid of all rust traces.
    I have now got all those bits prepped for some paint which won't take me long to apply.

    I'll upload some pics in a min, not much to look at considering the hours I've put in but it's still going in the right direction
    All progress is good progress Matt
  388. West Midlands Joined: Nov 2005 Nuneaton (West Mids) Posts: 13835 '64 Volvo V40 R’Design, '89 Ph1 309 GTi, ‘97 Mk1 S
    #388
    Right here's a few pics that I've took this week. Generally not much to look at but at least it documents some work done

    Steering rack heat shield before


    How it stands. It would originally have been electroplated so if I can fit it in the bucket I'll do that next. Removed the standard rivets holding the clips as they'd worn loose with age



    Rear subframe mounting before's. Can just about make out some surface rust. Very minor but worth eliminating early



    After rust removal and 2 coats of zinc primer




    Drivers side front subframe mount primed. Had to cable tie some of the hoses out the way whilst tackling some of the bulkhead


    Passenger sides done


    Removed the chassis plate to see if there was much I could do with it


    This is about as good as it'll get. Soft metal doesn't allow for much polishing. Pitting doesn't look as bad
  389. West Midlands Joined: Nov 2005 Nuneaton (West Mids) Posts: 13835 '64 Volvo V40 R’Design, '89 Ph1 309 GTi, ‘97 Mk1 S
    #389
    Surface rust evident on the rear of the suspension turret


    Both sides back to bare metal, treated and zinc primed




    Drivers side inner suspension mount almost ready for some paint. Made a template around the top mount and held that in place whilst reapplying some new stone chip. Top mount of course has to mount to a solid surface


    Checked out the underside of the top mount that the chassis plate was riveted through to make sure there was no rust spread from the holes. As it turned out they were perfect.


    Just need to finish getting this bit cleaned back to the bare metal now. This bit was completely hidden under the stone chip and would have festered away unnoticed if I hadn't poked every inch under the arch to feel for loose stone chip or the tell tale crispy notice underneath


    This bit on the drivers side was looking very shabby. I didn't get a before pic however it was mostly brown, and again other than some crunching under the stone chip on the rear edge it was completely hidden
    First session with the rust removal stuff


    Second session, almost there. Unfortunately there 2 holes to attend to but it is fortunately still a solid piece otherwise


    And lastly I had a random spare hour the other day and polished up the terminals on the brake pad wear sensor loom. The terminals are brass so although they looked knackered, they will polish back up with a craft rotary tool with polishing brush attachment and metal polish.


    The one in the above pic which hadn't yet been done polished up to this- should actually allow some current through it now
  390. Newbie Joined: Jun 2013 Posts: 26
    #390
    Great attention to detail Matt. Is the full respray still on the cards?
  391. West Midlands Joined: Nov 2005 Nuneaton (West Mids) Posts: 13835 '64 Volvo V40 R’Design, '89 Ph1 309 GTi, ‘97 Mk1 S
    #391
    Quote:
    Originally Posted by lincolndanny View Post
    Great attention to detail Matt. Is the full respray still on the cards?
    It will be mate but it'll be quite some way off. I've spent a ridiculous amount on the 309 already this year so I'll get it running and continue to perfect underneath.
    The bodyworks going to have to wait til I've done some bits on the house & garden so it's doubtful I'll get round to the respray until after next years out
  392. Newbie Joined: Jun 2013 Posts: 26
    #392
    Quote:
    Originally Posted by willsy View Post
    It will be mate but it'll be quite some way off. I've spent a ridiculous amount on the 309 already this year so I'll get it running and continue to perfect underneath.
    The bodyworks going to have to wait til I've done some bits on the house & garden so it's doubtful I'll get round to the respray until after next years out
    I know that one! Balancing house and cars is always a hard one. Itching to get stuck into the VTS but I know that the sensible thing to do is to leave it for now until I've collected most of the parts I need. Will you strip the whole car back down for a respray or hope that the bodyshop is good at masking?
  393. West Midlands Joined: Nov 2005 Nuneaton (West Mids) Posts: 13835 '64 Volvo V40 R’Design, '89 Ph1 309 GTi, ‘97 Mk1 S
    #393
    I keep looking for a decent VTS but really I'm too committed into this one, it would be a bit crazy for me to start another project alongside it.

    I've almost got past they stage of getting all the bits I need, it's been a long slog! Silly things like making sure I've got the right nuts & bolts. I've printed off and gone through most of the service box diagrams making sure that everything is there as it should be, that's been just as time consuming as the more physical tasks

    When the respray time comes I'll strip the whole thing right back down again. It'll go pretty much as a bare, but rolling shell
  394. Saxperience Post Whore Joined: Aug 2008 The wrong carpark Posts: 5152 Xantia 1.9TD
    #394
    looking good will!
  395. West Midlands Joined: Nov 2005 Nuneaton (West Mids) Posts: 13835 '64 Volvo V40 R’Design, '89 Ph1 309 GTi, ‘97 Mk1 S
    #395
    Been making some more good progress with this, still looks slow going from the pics but I have spent hours cleaning bits up etc

    Dashboard is almost fully reassembled, the first time since I got the car. Pretty much all of the interior is reinstalled now too.





    New genuine clutch cable and speedo cable also fitted.

    And during some paint work rather than watching the paint dry I ended up polishing one of the exhaust heat shields for the fun of it





    Should have some more pictures tomorrow
  396. Newbie Joined: Jun 2013 Posts: 26
    #396
    Looking good Matt, is that the NOS wheel?
  397. West Midlands Joined: Nov 2005 Nuneaton (West Mids) Posts: 13835 '64 Volvo V40 R’Design, '89 Ph1 309 GTi, ‘97 Mk1 S
    #397
    Quote:
    Originally Posted by lincolndanny View Post
    Looking good Matt, is that the NOS wheel?
    Yep that's the new wheel mate, it's restored rather than NOS though, it's that good a job you'd never know the difference though :-)
  398. West Midlands Joined: Nov 2005 Nuneaton (West Mids) Posts: 13835 '64 Volvo V40 R’Design, '89 Ph1 309 GTi, ‘97 Mk1 S
    #398
    Finished the steering rack today.
    After the earlier cleaning and replacing the bushes in the PAS ram it decided to spring a leak from the seal, much to my annoyance!
    The pipes that attach to it also decided to leak.

    So new pipes and PAS ram



    To replace the old



    A little more cleaning of the rack with some metal polish prior to refitting. And it's done
  399. Newbie Joined: Aug 2015 Swindon Posts: 6 Saxo VTR Escort RS Turbo S2
    #399
    Great work, enjoyed reading through the thread.
    Interior looks mint now, look forward to seeing the next lot of resto work.
  400. West Midlands Joined: Nov 2005 Nuneaton (West Mids) Posts: 13835 '64 Volvo V40 R’Design, '89 Ph1 309 GTi, ‘97 Mk1 S
    #400
    Finished painting the drivers side front subframe mount today, how I'd finished up last week



    All done


    Rear mounts both finished too


    The Bilt Hamber rust removal gel has done it's job getting this piece back to bare metal. It does require some agitation with a decent wire brush to speed up the process but it really is the best way to get the panel cleaned up properly without removing any good metal.
    It's also better than using the rust 'converter' treatment stuff which is brush on, having used it previously I really wouldn't rate it again if I'm honest and will be removing the stuff that I'd brushed onto the inner wing earlier in the thread

    I just need to decide how best to get this piece looking as it should again.

    Whilst all the paint was drying and the rust removal stuff was working it's magic I decided to go OTT yet again with an exhaust heat shield. Quite a bit of work went into turning this


    Into this


    Hopefully I'll get some more done tomorrow
  401. Newbie Joined: Jun 2013 Posts: 26
    #401
    I sense we are getting near to a biggish update Matt What are the heat shields made of on the 309? No chance of cleaning the Saxo ones up like that, bloody thin metal
    1 user thanked this post:
  402. West Midlands Joined: Nov 2005 Nuneaton (West Mids) Posts: 13835 '64 Volvo V40 R’Design, '89 Ph1 309 GTi, ‘97 Mk1 S
    #402
    Definitely feels like I'm making progress now Danny. I've got some more painting that I want to do next (finishing the underside of the suspension turret) then I should be able to blast through the front suspension refit, steering, gear linkages (new ones) all in a day or so.

    You'd be surprised with the heat shields, I'm sure I remember the old Saxo ones being do-able. The 309 ones are aluminium I believe
  403. West Midlands Joined: Nov 2005 Nuneaton (West Mids) Posts: 13835 '64 Volvo V40 R’Design, '89 Ph1 309 GTi, ‘97 Mk1 S
    #403
    Been busying myself again this afternoon, refitted a few bits and bobs and took a few pics of the front of the car for the fun of it.



    Hoping to get hold of some new linkages, and I'll be carrying on with the brake lines after my holiday





    2 users thanked this post: ,
  404. Newbie Joined: Jun 2013 Posts: 26
    #404
    Quote:
    Originally Posted by willsy View Post
    PHWOAR!!!!!
  405. North West Joined: Apr 2009 Warrington, Cheshire Posts: 5733 PH2 Peugeot 106 "race" car - Currently in pieces
    #405
    OOOOOFF!!!!!

    Stunning!!
  406. Saxperience Forum Bum Joined: Apr 2007 Lincoln/Newark Posts: 2673 Mercedes C220, Scooby, Saxo VTS
    #406
    You are so patient, I would have got bored a long time ago and gone with the "that will do" attitude.

    That front end picture makes it all look worth while
  407. Saxperience Post Whore Joined: Oct 2005 Sydney Posts: 8525 Mango Westcoast
    #407
    Just updated myself on the last couple of months work Matt - great work as ever.
  408. Saxperience Post Whore Joined: Aug 2010 Little Mill, South Wales Posts: 7547 Mondeo ST TDCI Saxo VTS
    #408
    Fairplay that front end looks brand new!

    Great work, wish I had time,patience and money to do this.
  409. Established Member Joined: Apr 2010 falkirk Posts: 1032 renualt Clio 1.5 dci
    #409
    Thank god the number plate will cover that rusty bolt kidding what a stunning restoration keep up the excellent work. Would a nice gti6 running gear fit easily ?
  410. Saxperience Post Whore Joined: Aug 2008 The wrong carpark Posts: 5152 Xantia 1.9TD
    #410
    Fit!

    Can't wait to see this all finished. Whats up with the brake lines?
  411. West Midlands Joined: Nov 2005 Nuneaton (West Mids) Posts: 13835 '64 Volvo V40 R’Design, '89 Ph1 309 GTi, ‘97 Mk1 S
    #411
    Cheers guys


    Brettles id definitely say that patience is the hardest attribute to work on out of the three.
    Chinkostu I've started replacing all the brake lines, with it having been off the road for so long it seemed sensible; corrosion on the brake lines is still an MOT failure right?
    Sn3ddon I'm not sure, I know a lot of stuff is the same or interchangeable with the 205 and 309, but I havnt had any experience with a 306.

    A few odds and ends was all I got done today.
    First up was some other new bits for the speedo sender



    Then finished de rusting this bit within the inner arch. It's such a pain that there a hole to get repaired as it cleaned up well otherwise



    Still, until I can get the repair done it needs protecting so I've still applied the two coats of zinc primer anyway so it's fully protected



    Whilst I was working within the drivers arch this bit kept glaring at me, this appears to be the worst of any corrosion



    Made a start on it with the rust removal gel. It's not half as bad as it looked, shouldn't take too much longer to have it back to clean metal



    Another annoying bit is the manifold. It's rusty as hell to look at (new ones are bloody expensive so I'll have to put up with this one for the time being)
    However I wasn't going to ignore the nuts and studs!

    They look in terrible order


    Removed the studs completely, cleaned them up, reinserted and got some new nuts out. I will probably replace with new genuine at some point but I am content for now.


  412. Saxperience Post Whore Joined: Aug 2008 The wrong carpark Posts: 5152 Xantia 1.9TD
    #412
    You would be correct. Seems worth it for futureproofing i guess!!
  413. Saxperience Addict Joined: Sep 2008 Swansea / Chippenham Posts: 10872 306 diesel shed broken vts
    #413
    This is the absolute tops. Loving it, I have no idea how you have so much patience.

    Any idea if Bilt Hamber zinc primer is weldable?
  414. West Midlands Joined: Nov 2005 Nuneaton (West Mids) Posts: 13835 '64 Volvo V40 R’Design, '89 Ph1 309 GTi, ‘97 Mk1 S
    #414
    Not much to report, but I have removed the exhaust manifold (which looked extremely rusty) to assess its condition and see whether there was any cracks etc. Also fitting new studs, nuts and gaskets.

    Here's how the manifold looked





    I could just get it blasted but I didn't want to be too harsh on it initially (new ones are £240!)

    I've cleaned it up to this stage so far. Also cleaned out all the threads which seem to be there for some sort of heat shield to mount on, however there wasn't one fitted when I got it and I havnt been able to find one on service box



  415. West Midlands Joined: Nov 2005 Nuneaton (West Mids) Posts: 13835 '64 Volvo V40 R’Design, '89 Ph1 309 GTi, ‘97 Mk1 S
    #415
    Quote:
    Originally Posted by 0rang3peel View Post
    This is the absolute tops. Loving it, I have no idea how you have so much patience.

    Any idea if Bilt Hamber zinc primer is weldable?
    Cheers mate, I believe that it is weldable (also checked Google and suggestions confirmed it) I havnt welded it myself yet though
  416. West Midlands Joined: Nov 2005 Nuneaton (West Mids) Posts: 13835 '64 Volvo V40 R’Design, '89 Ph1 309 GTi, ‘97 Mk1 S
    #416
    Looking to get the calipers rebuilt this month. Will be sending them to Bigg Red.

    However I'm undecided on what finish to go for. I can either go with:

    A standard silver finish, doesn't offer as good corrosion protection

    Or the premium coating which has much superior corrosion resistance. I originally wanted s silver finish but the premium coat doesn't have silver as an option. So black would be the choice colour.

    The electroplated finish is ruled out as the rear calipers aren't an option for that type of finish they say.

    Price doesn't bother me so do I go for silver in standard finish, or black in the premium?
  417. Established Member Joined: Jan 2013 Portsmouth Posts: 1335 1997 Mk1 VTS
    #417
    I stripped my callipers myself (very easy to do.) and bought the seals from big red.

    Then had the callipers powdercoated which arguably gives the best protection with a great finish, and then reassembled myself. Probably cost me £40 all in to rebuild them and beg the powder coating done.
  418. Saxperience Post Whore Joined: Apr 2005 Teesside Posts: 8800 focus tdci, clio v6
    #418
    stunning mate! first ive seen of it with not being on in a while!
  419. Saxperience Post Whore Joined: Apr 2008 Bicester, Oxfordshire Posts: 5704 Looking for a 205...
    #419
    The bigg red premium finish looks stunning matt, well worth it, and still looks OEM

    James
  420. West Midlands Joined: Nov 2005 Nuneaton (West Mids) Posts: 13835 '64 Volvo V40 R’Design, '89 Ph1 309 GTi, ‘97 Mk1 S
    #420
    Cheers guys, I've checked over the front calipers now, all threads are good, bleed nipples remove fine etc etc. Wanted to make sure that I was sending off some sound calipers.

    I'm still undecided on the finish to go for. I've been reminded that the rear caliper itself is aluminium rather than cast, hence no electroplate and corrosion not being as much of a problem with cast- so arguably they'd be fine with the standard silver finish.

    Now then, I do have brand new genuine carriers for the rear calipers too, they are originally plated in the gold colour.

    Which brings me back to the fronts, I could get these done in the silver electroplate.
    Do I go for a silver/gold combo between caliper and carrier all round? (I'm not sure on the original factory colouring for the fronts) Or send the new rears off to be swapped to silver. I hate these decisions :-)
  421. West Midlands Joined: Nov 2005 Nuneaton (West Mids) Posts: 13835 '64 Volvo V40 R’Design, '89 Ph1 309 GTi, ‘97 Mk1 S
    #421
    Been cracking on with some more painting on the underside, drivers front suspension turret is now completed. A bit that I needed to finish surface rust removal/treatment of before refitting the strut (didn't want to mount the new top mounts against a rusty surface).

    Flashback reminder of 'before'



    After



    I'll paint the rest of the wheel arch eventually, probably next year when I whip the engine out to paint the bay etc. For now I know that the most important bits are sorted.

    Finished painting the rear part of the turret in the engine bay and fitted some A4 stainless rivet nuts to remount the chassis plate (don't like standard rivets)


    Chassis plate remounted. I'm not sure if I can polish the plate up much more than I've already done, the metal is very thin & soft, certainly struggling to do any more with the pit marks
    1 user thanked this post:
  422. West Midlands Joined: Nov 2005 Nuneaton (West Mids) Posts: 13835 '64 Volvo V40 R’Design, '89 Ph1 309 GTi, ‘97 Mk1 S
    #422
    This morning I got the metal polish out, morning well spent I'd say

  423. Newbie Joined: Jun 2013 Posts: 26
    #423
    Quote:
    Originally Posted by willsy View Post
    This morning I got the metal polish out, morning well spent I'd say
    Didn't realise that these were alloy blocked Matt! Good work as always!
  424. West Midlands Joined: Nov 2005 Nuneaton (West Mids) Posts: 13835 '64 Volvo V40 R’Design, '89 Ph1 309 GTi, ‘97 Mk1 S
    #424
    I'm still having a decision crisis over what finish to go with for the brake caliper refurb with Bigg Red.

    I had worked out from the last remaining traces of their original finish that they should be Electroplated Gold



    Bigg Red's sample picture for that finish


    Looks great and my aim still remains that I want to maintain or return as much as possible to an original finish.

    However, they've just released their new and extended range of premium coatings which now includes gold.
    There's not much extra cost involved so that isn't influencing my decision. So do I go strictly original, or favour the more durable and longer lasting premium coat

    Sample pic
  425. West Midlands Joined: Nov 2005 Nuneaton (West Mids) Posts: 13835 '64 Volvo V40 R’Design, '89 Ph1 309 GTi, ‘97 Mk1 S
    #425
    Well the above post has been quickly resolved.

    Electroplated it is!

    First two comments I had for the premium gold was 'look too blingy' and 'a bit like standard paint'
  426. Saxperience Post Whore Joined: Aug 2008 The wrong carpark Posts: 5152 Xantia 1.9TD
    #426
    I wouldn't have the gold colour either. Although i'm unsure about the electroplated ones too! Maybe black?
  427. Newbie Joined: Jun 2013 Posts: 26
    #427
    Electroplated if it were me....
  428. Newbie Joined: Nov 2013 Posts: 21
    #428
    looking good!!!
  429. Newbie Joined: Oct 2015 Posts: 1
    #429
    Chapeau! Very nice job... I will have been the same for a lovely car... The incredible thing is that this car has no rust...
  430. Saxperience Hardcore! Joined: Oct 2008 Birtley Posts: 22253 VTR Turbo, 106 xsi track slag, Transit recovery, B
    #430
    youve done loads on this since i last looked mate
  431. Saxperience Post Whore Joined: Aug 2010 Little Mill, South Wales Posts: 7547 Mondeo ST TDCI Saxo VTS
    #431
    Quote:
    Originally Posted by blackie_2k5 View Post
    youve done loads on this since i last looked mate
    Setting the bar for the manta dude
    1 user thanked this post:
  432. Saxperience Hardcore! Joined: Oct 2008 Birtley Posts: 22253 VTR Turbo, 106 xsi track slag, Transit recovery, B
    #432
    Quote:
    Originally Posted by Brettles1986 View Post
    Setting the bar for the manta dude
    id like it to be this anal

    only time will tell mate

    EDIT- problem with me is.. i usually do all the anal shit.. forget to take pics and am like.. "yeah so i washed it the other day lmao"
  433. West Midlands Joined: Nov 2005 Nuneaton (West Mids) Posts: 13835 '64 Volvo V40 R’Design, '89 Ph1 309 GTi, ‘97 Mk1 S
    #433
    I have been busy, being this anal with it though can be a real pain in the ass. Could have put this back together in no time but I just keep finding bits that I'd like to sort between fitting each piece

    Anyway, I've finally pulled my finger out.

    Passenger side underside front suspension turret is finished.



    Taken right back to bare metal again after several coats of Bilt Hamber Deox Gel to carefully only take back to good metal without grinding any away. Quite impressed with the stuff but it is time consuming



    Anyway all is done



    Which now means that all chassis parts where the subframe and suspension mount to are tip top.

    Expect to see some decent updates coming now as I put the front end back together. There's more bits that I want to paint but it's getting beyond ideal conditions so further paint can wait til Spring when I'll probably whip the engine out and paint the bay.

    For now, back together and try to get an MOT on it. List of things that I've done so far this week;

    I've sourced the last few NOS coolant pipes so I'll refit the remainder of those this week.
    Steering system has been overhauled
    NOS gear linkages sourced
    Brake caliper are at Bigg Red being refurbed.
    Old bushes have been removed from the wishbones so new ones will go in after cleaning up & repairing them.
    Engine mounts have been replaced. NOS genuine uppers and Baker BM group N lower.
  434. Newbie Joined: Aug 2015 Posts: 9
    #434
    Very nice keep up the good work, cant beat a good restoration thread!
  435. West Midlands Joined: Nov 2005 Nuneaton (West Mids) Posts: 13835 '64 Volvo V40 R’Design, '89 Ph1 309 GTi, ‘97 Mk1 S
    #435
    Small update for now but I am in the progess of refitting a lot of bits to the car so there will be more to come shortly.

    Finally got around to finishing the manifold.

    Here's the upper side before


    After many hours cleaning it up


    And after applying POR15 High Temp 'Manifold Grey' paint


    Same for the underside before


    After cleaning


    Also sourced a new set of genuine Peugeot gear linkages


    And pressed the new Baker BM lower engine mount bush into the bracket which id lovingly cleaned earlier


    Plenty more to come
  436. Newbie Joined: Jun 2013 Posts: 26
    #436
    Keep it coming mate, bored at work and could do with something to read....
  437. West Midlands Joined: Nov 2005 Nuneaton (West Mids) Posts: 13835 '64 Volvo V40 R’Design, '89 Ph1 309 GTi, ‘97 Mk1 S
    #437
    I've got 6 weeks off work at the moment so I've got all the time in the world at the moment.

    Stockpiled on a load of boring but easy jobs to do whilst my ankles recovering so a lot of cleaning and painting such as manifold, hub assembly, wishbones etc are being done.

    When I'm a bit more able I should be able to reassemble most of the front end in a good days work
  438. West Midlands Joined: Nov 2005 Nuneaton (West Mids) Posts: 13835 '64 Volvo V40 R’Design, '89 Ph1 309 GTi, ‘97 Mk1 S
    #438
    Wishbones next up.

    The last pic makes for a good before & after pic comparison.
    Fortunately the ball joints on the wishbones were still perfect, as on 205/309's they are not replaceable! (What the heck Peugeot?!) so avoided the cost of two new arms there.

    Anyway the bushes were a pig to remove but got there in the end. Allowing myself a deviation from OE/OE replacement spec here and have gone for the Powerflex purple bushes.

    Spent a while cleaning up the wishbones then, most of the appearance in the before wishbone was just muck.





    Still did a proper job of rubbing them down as above, followed by a coat of etch primer and 3 coats of satin black

  439. Established Member Joined: Aug 2009 King's lynn Posts: 2073 Turbocharged vtr
    #439
    glad to see your still cracking on with this, your work is outstanding
    1 user thanked this post:
  440. West Midlands Joined: Nov 2005 Nuneaton (West Mids) Posts: 13835 '64 Volvo V40 R’Design, '89 Ph1 309 GTi, ‘97 Mk1 S
    #440
    I've been keeping busy again with this, havnt got much to show in the way of pictures yet but I've been spending many hours this week on the hub assembly.

    Here's the before pics.





    Now, I am replacing the bearings as they were a little noisy, couldn't detect any obvious play but they were old and do need replacing for piece of mind.

    This is where you'll all think I'm mad again. Sure I could have just got the hub assembly sand blasted but with so many threads etc I really wanted to clean it up myself and not remove any good material. So the painstaking process of applying Bilt Hambers rust removal gel along with regular passes with a Dremmel size wire wheel and wire cup I am just about at the stage whereby I'm happy it's clean enough to paint.
    The hub 'knuckle' piece will be going Satin black as it originally was.
    The hub piece that the disc/wheel fits into was originally just bare metal as I've managed to get it back to. Thinking I might just clear coat it or do it silver.

    Anyway almost clean enough



  441. Saxperience Forum Bum Joined: Mar 2009 Morpeth Posts: 2539 BMW 116d Regional Toner Sales Edition
    #441
    I like this Willsy, good effort. I've not logged in for ages so it was nice to catch up, it's coming along a treat!
  442. West Midlands Joined: Nov 2005 Nuneaton (West Mids) Posts: 13835 '64 Volvo V40 R’Design, '89 Ph1 309 GTi, ‘97 Mk1 S
    #442
    Finished the hub piece today. After polishing this bit up (not bad for 26 years old) I decided to clear coat it rather than paint it.








    Finally got the Satin done on the knuckle piece. Best picture that I can get until it dries.

  443. Newbie Joined: Jun 2013 Posts: 26
    #443
    Great work on this as usual! Itching to get moving with the vts doing this but Christmas, other car mot's house blah blah. You should post this in the resto section on Detailing world mate.
  444. Saxperience Addict Joined: Jan 2008 west london Posts: 13810
    #444
    This is the only progress thread I come here to regularly check on haha

    Amazing progress , would love to see the finished product
  445. West Midlands Joined: Nov 2005 Nuneaton (West Mids) Posts: 13835 '64 Volvo V40 R’Design, '89 Ph1 309 GTi, ‘97 Mk1 S
    #445
    Cheers Danny, really appreciate the feedback, I've loved reading your updates aswel, especially the welding that really has been some quality work done properly.

    Rekon Detailing World would be interested? I do update this progress on 309owners and AXowners already where I've been a member for years. Easy for me to copy and paste onto detailing world too :-)


    LSOfreak it's good to know that people are popping back regularly to read the updates :-) I'll keep the progress updated. Cheers
  446. West Midlands Joined: Nov 2005 Nuneaton (West Mids) Posts: 13835 '64 Volvo V40 R’Design, '89 Ph1 309 GTi, ‘97 Mk1 S
    #446
    I have now completed buying/refurbishing the entire front end suspension assembly right down to every nut & bolt. I just need to refit it all now.

    Completed list of suspension overhaul as follows;

    Non OE bits are Bilstein B4 dampers, Eibach springs, Powerflex front/rear wishbone bushes, Quinton Hazell wheel bearings.

    Refurbished original bits; subframe powder coated. Hub assembly back to bare metal, cast painted Satin black, hub clear coated,, wishbones painted satin black.

    New genuine Peugeot items; complete top mount assembly, drop links, ARB bushes, every nut & bolt (I have kept all the original nuts & bolts too so that they can be sent for electroplating eventually and kept as spares)


    I've almost completed the front brakes overhaul list too. Everything except the main servo has been refurbished or replaced too. I'll update that shortly. Might actually get cracking reassembling it in the coming weeks
  447. Newbie Joined: Jun 2013 Posts: 26
    #447
    Quote:
    Originally Posted by willsy View Post
    Cheers Danny, really appreciate the feedback, I've loved reading your updates aswel, especially the welding that really has been some quality work done properly.

    Rekon Detailing World would be interested? I do update this progress on 309owners and AXowners already where I've been a member for years. Easy for me to copy and paste onto detailing world too :-)


    LSOfreak it's good to know that people are popping back regularly to read the updates :-) I'll keep the progress updated. Cheers
    Thanks mate, yes they would love it on there. Jigs posted up his VTS rebuild and it got a lot of interest

    I should have a decent year on it in 2016, just collecting nos bits at the moment. I love how the dealers are turfing out stock cheap at the moment

    How deep are you going to go with this? I think I've become obsessed with mine. Even managed to track down a full new set of original Michelin SX GT tyres!
  448. West Midlands Joined: Nov 2005 Nuneaton (West Mids) Posts: 13835 '64 Volvo V40 R’Design, '89 Ph1 309 GTi, ‘97 Mk1 S
    #448
    Perfect I'll take a look and start copy/pasting my updates over on there aswel. If people can appreciate it then I may aswel :-)

    I plan to reach 'immaculate' sort of state with this. Concours is another level and with careful preservation of original paintwork being a non starter (needs a respray) it'll never reach that status even if I can happily buy new genuine parts and don't mind spending hours refurbishing original parts. Immaculate I hope will be a fair comment once it gets there :-)

    You're already finding some gems with yours then, let me know if there's anything that you need, but can't find at your local dealers. I know a man that can find just about everything. There's only 1 part that he hasn't been able to find for me yet (and you can imagine just how many are listed on service box as NFP for the 309!)
  449. Newbie Joined: Jun 2013 Posts: 26
    #449
    Quote:
    Originally Posted by willsy View Post
    Perfect I'll take a look and start copy/pasting my updates over on there aswel. If people can appreciate it then I may aswel :-)

    I plan to reach 'immaculate' sort of state with this. Concours is another level and with careful preservation of original paintwork being a non starter (needs a respray) it'll never reach that status even if I can happily buy new genuine parts and don't mind spending hours refurbishing original parts. Immaculate I hope will be a fair comment once it gets there :-)

    You're already finding some gems with yours then, let me know if there's anything that you need, but can't find at your local dealers. I know a man that can find just about everything. There's only 1 part that he hasn't been able to find for me yet (and you can imagine just how many are listed on service box as NFP for the 309!)
    Great Matt, I'll bare that in mind if I need anything. Because I'm in no rush I'm just picking up bargains as and when they pop up. Picked up some new body kit sections etc the other night.

    Are you interested in tracing the history of it at all? I've sent off a V888 form to the dvla to request all the information they hold on my VTS. They should send back all copies of previous V5's along with the original dealer request to register the car. Then I can get original dealer plates, window decal and tax disc holder made up
  450. West Midlands Joined: Nov 2005 Nuneaton (West Mids) Posts: 13835 '64 Volvo V40 R’Design, '89 Ph1 309 GTi, ‘97 Mk1 S
    #450
    Yep already done that one Danny, when I bought the car I literally just had the new keeper slip. I got back the original dealer request to register, copies of previous V5's (dealer as demo car for 6 months, some old dear until 2012, bloke before me who did absolutely nothing with it then me)
    They sent records of when it had been taxed & SORN. It's been SORN since 2004!!
    As their computer MOT records only began in 2005 I have no MOT history and DVLA records simply show as 'not held' as they don't even know the expiry date of the old one. Can only assume it's been off the road over 10 years.

    I will write to the former keepers though especially the old dear and see if I can get any more original history from them, or even a letter back confirming anything of history value.
  451. West Midlands Joined: Nov 2005 Nuneaton (West Mids) Posts: 13835 '64 Volvo V40 R’Design, '89 Ph1 309 GTi, ‘97 Mk1 S
    #451
    Voila! Just needs the new bearing popping in now



  452. Newbie Joined: Jun 2013 Posts: 26
    #452
    Quote:
    Originally Posted by willsy View Post
    Yep already done that one Danny, when I bought the car I literally just had the new keeper slip. I got back the original dealer request to register, copies of previous V5's (dealer as demo car for 6 months, some old dear until 2012, bloke before me who did absolutely nothing with it then me)
    They sent records of when it had been taxed & SORN. It's been SORN since 2004!!
    As their computer MOT records only began in 2005 I have no MOT history and DVLA records simply show as 'not held' as they don't even know the expiry date of the old one. Can only assume it's been off the road over 10 years.

    I will write to the former keepers though especially the old dear and see if I can get any more original history from them, or even a letter back confirming anything of history value.
    Fantastic stuff! The Vts has had 11 previous owners-I think Facebook will come in handy for once....
  453. West Midlands Joined: Nov 2005 Nuneaton (West Mids) Posts: 13835 '64 Volvo V40 R’Design, '89 Ph1 309 GTi, ‘97 Mk1 S
    #453
    One of the only useful features of Facebook :-)

    Well, I've made an account on Detailing World. Just waiting for admin to allow me to post then I'll start copying and pasting over to there
  454. Newbie Joined: Jun 2013 Posts: 26
    #454
    Quote:
    Originally Posted by willsy View Post
    One of the only useful features of Facebook :-)

    Well, I've made an account on Detailing World. Just waiting for admin to allow me to post then I'll start copying and pasting over to there
    Your efforts will be well recieved Matt
  455. Saxperience Post Whore Joined: Aug 2008 The wrong carpark Posts: 5152 Xantia 1.9TD
    #455
    suprised you didn't buy a new hub seeing as theyre still available! (the part that sits in the bearing that is, not the whole thing!
  456. West Midlands Joined: Nov 2005 Nuneaton (West Mids) Posts: 13835 '64 Volvo V40 R’Design, '89 Ph1 309 GTi, ‘97 Mk1 S
    #456
    Quote:
    Originally Posted by chinkostu View Post
    suprised you didn't buy a new hub seeing as theyre still available! (the part that sits in the bearing that is, not the whole thing!
    I did consider it, and they're not too much money either. They've cleaned up so well that they'd have been a shame to bin, just couldn't bring myself to do it lol
  457. Saxperience Post Whore Joined: Aug 2008 The wrong carpark Posts: 5152 Xantia 1.9TD
    #457
    Understandably! I've got to bin mine, tyre place crossthreaded one side and i fucked the other accidentally!

    How did you press the bearing out anyhow?
  458. West Midlands Joined: Nov 2005 Nuneaton (West Mids) Posts: 13835 '64 Volvo V40 R’Design, '89 Ph1 309 GTi, ‘97 Mk1 S
    #458
    Evening all,

    Some quick fire updates here for you all, for the progress made over the last few weeks.

    Whilst waiting for a few more parts to arrive again before I start reassembling the front end I've been tacking some more of the ugly stuff. In/around the engine bay there's been various bits of surface rust here and there which all needs sorting. Vast majority of it is extremely minor and will wait until I take the engine out to do a full respray on the engine bay.

    However I've wanted to get the worst looking bits restored.

    This bit of the front frame is improved again. Still needs a bit more work yet, you can see the small hole that I need to get welded when the cars mobile again.


    Better than it started anyway


    Next up was to start attacking the scuttle panel area.



    You can just see the surface rust sitting at the bottom of the scuttle too. Some bits were straying under some of the seam sealant which is always a worry but I've neatly trimmed it back a bit and it hasn't strayed anywhere near the actual seam line. Will be easy to resolve.

    Anyway after a few hours scrubbing and a few hours letting Bilt Hambers Deox gel work its magic I've ended the day here







    And the scabby looking bit at the bottom of the scuttle is slowly getting there.


    The other bit which I'd been flicking between was the front brake line bracket within the passenger arch. This bit (and the opposite side) I am tending to for piece of mind. As you can see the surrounding area is plastered with factory stone chip. Whilst this is great when it's sealed, in removing the slider clip that retains the solid line and flexi hose in place, it was obvious that the clip had penetrated the excessive application of stone chip and therefore could have been susceptible to water ingress and may be a potential hidden lurker for rust.

    So I've excavated around it, have cleaned the fixed bracket up and can happily report that there have been no hidden bits of rust so far. I shall reapply the necessary coatings and stone chip safe in the knowledge that it's a confirmed safe zone from rust.

    That's the first update.
  459. West Midlands Joined: Nov 2005 Nuneaton (West Mids) Posts: 13835 '64 Volvo V40 R’Design, '89 Ph1 309 GTi, ‘97 Mk1 S
    #459
    Slow going then over the Christmas/New Year week. I'd mainly been carrying on with some rust removal on the same few parts from the last update. Sure, rust removal gel does work, and it works well, but it does take ages.
    My input has mainly been applying the gel, leaving it a few hours, giving it a good scrub with scotch pads and small tooth brush sized wire brush, repeating the process then wiping clean and reassessing. Several coats are needed generally before I'm completely happy that's it's clean.

    So here's how another days worth of application is panned out (At this stage I ran out of my usual Bilt Hamber Deox so whilst awaiting delivery, I grabbed a similar Hammerite product from Halfords.







  460. West Midlands Joined: Nov 2005 Nuneaton (West Mids) Posts: 13835 '64 Volvo V40 R’Design, '89 Ph1 309 GTi, ‘97 Mk1 S
    #460
    Evening all,

    After a long hard slog, almost a weeks worth of cleaning up the scuttle area (which I might add is a damn awkward job that requires a contortionist to help with looking in all the nooks and crannies) I'm finally happy that it's rust free.

    My earlier update covered some rust that was evident in the passenger side. A similar scenario awaited on the drivers side. Again praying that nothing had developed into a hole



    As you'll recall from earlier in the thread the scuttle was full of rotting conifer debris and had therefore been wet constantly for god knows how long. A worry as it was deep enough for the rust to have started creeping under the seam sealant which spreads about 20mm either side of the seam.

    I've reduced the seam sealant spread to 10mm or so and fortunately no rust extended that far up.

    As a starting point the rest of the drivers side wasn't too bad



    The factory paintwork here is pretty crap anyway, there was never much of a key given to the surface for the paint to stick too and small bits had begun to flake loose. I really spent ages going to town on it all over with the harshest (red) scotch pad. Anything loose was easily shifted.
    Then came several applications of rust removal gel. I'd ran out of the Bilt Hamber Deox Gel so I've been using the Hammerite alternative. It still works well but I've found that it needs longer to do the job and I've got through it much quicker.

    Anyway all done...?




    ....wishful thinking! Ever the one to be thorough I grabbed the trusty mirror (old sun visor mirrors are very handy) and had a look at the underside of the lip.



    Sinking feeling, many more hours of work needed


    Same the other side


    And more rust beginning on the underside of the other ledge just above the seam sealant.


    Oh well best to catch it early. After several more hours of graft I've defeated it


    So to be 100% sure I hadn't missed anything I got the scotch pads out again and gave it one final blitz, followed by some very thorough panel degreasing to clean all traces of the rust removal gel.

    Two thick coats of Bilt Hamber Electrox (95% zinc primer) that they claim offers better protection than the original galvanised factory coating (I hope so!)



    And that's that stage finished





    The electrox is very thick stuff and does seem to fill the majority of the pitting left by the surface rust.
    I'm going to leave it for a few days now to dry fully. Temperature isn't exactly ideal.
    Painting I'm going to have to do in two parts, I'll do the hidden underside first as it's tricky spraying with the can inverted, I'm bound to knock the visible parts a few times in the process so I'll do the visible bit as a second stage when I'm not having to lean over at obscure angles.

    That concludes the fun and games for a few days now.
  461. West Midlands Joined: Nov 2005 Nuneaton (West Mids) Posts: 13835 '64 Volvo V40 R’Design, '89 Ph1 309 GTi, ‘97 Mk1 S
    #461
    Evening all,

    After a long hard slog, almost a weeks worth of cleaning up the scuttle area (which I might add is a damn awkward job that requires a contortionist to help with looking in all the nooks and crannies) I'm finally happy that it's rust free.

    My earlier update covered some rust that was evident in the passenger side. A similar scenario awaited on the drivers side. Again praying that nothing had developed into a hole



    As you'll recall from earlier in the thread the scuttle was full of rotting conifer debris and had therefore been wet constantly for god knows how long. A worry as it was deep enough for the rust to have started creeping under the seam sealant which spreads about 20mm either side of the seam.

    I've reduced the seam sealant spread to 10mm or so and fortunately no rust extended that far up.

    As a starting point the rest of the drivers side wasn't too bad



    The factory paintwork here is pretty crap anyway, there was never much of a key given to the surface for the paint to stick too and small bits had begun to flake loose. I really spent ages going to town on it all over with the harshest (red) scotch pad. Anything loose was easily shifted.
    Then came several applications of rust removal gel. I'd ran out of the Bilt Hamber Deox Gel so I've been using the Hammerite alternative. It still works well but I've found that it needs longer to do the job and I've got through it much quicker.

    Anyway all done...?




    ....wishful thinking! Ever the one to be thorough I grabbed the trusty mirror (old sun visor mirrors are very handy) and had a look at the underside of the lip.



    Sinking feeling, many more hours of work needed


    Same the other side


    And more rust beginning on the underside of the other ledge just above the seam sealant.


    Oh well best to catch it early. After several more hours of graft I've defeated it


    So to be 100% sure I hadn't missed anything I got the scotch pads out again and gave it one final blitz, followed by some very thorough panel degreasing to clean all traces of the rust removal gel.

    Two thick coats of Bilt Hamber Electrox (95% zinc primer) that they claim offers better protection than the original galvanised factory coating (I hope so!)



    And that's that stage finished





    The electrox is very thick stuff and does seem to fill the majority of the pitting left by the surface rust.
    I'm going to leave it for a few days now to dry fully. Temperature isn't exactly ideal.
    Painting I'm going to have to do in two parts, I'll do the hidden underside first as it's tricky spraying with the can inverted, I'm bound to knock the visible parts a few times in the process so I'll do the visible bit as a second stage when I'm not having to lean over at obscure angles.

    That concludes the fun and games for a few days now.
  462. Established Member Joined: Nov 2011 Newcastle Posts: 1698 Range Rover Sport
    #462
    Brilliant work as always, where do you get your bilt hamber stuff from?
  463. West Midlands Joined: Nov 2005 Nuneaton (West Mids) Posts: 13835 '64 Volvo V40 R’Design, '89 Ph1 309 GTi, ‘97 Mk1 S
    #463
    Quote:
    Originally Posted by deano_123 View Post
    Brilliant work as always, where do you get your bilt hamber stuff from?
    Opie Oils (Saxp affiliate) sells it, I've ordered from them the last few times, found it cheaper to buy from them via their eBay listings than off their website though strangely.
  464. Established Member Joined: Nov 2011 Newcastle Posts: 1698 Range Rover Sport
    #464
    Quick delivery?
  465. West Midlands Joined: Nov 2005 Nuneaton (West Mids) Posts: 13835 '64 Volvo V40 R’Design, '89 Ph1 309 GTi, ‘97 Mk1 S
    #465
    The first lot I ordered came next day, but this time round I've been waiting nearly a week! Christmas backlog or extended closing hours over new year perhaps?
  466. Infrequent Poster Joined: Aug 2008 North East Posts: 194 VTS
    #466


    WOW!!!! WOW!!! WOW!!!

    That is amazing! I cant believe ive only just came across this thread.

    Subscribed!
  467. West Midlands Joined: Nov 2005 Nuneaton (West Mids) Posts: 13835 '64 Volvo V40 R’Design, '89 Ph1 309 GTi, ‘97 Mk1 S
    #467
    Today I managed to get the first half of the scuttle painted and lacquered. I'm using the seam line as the halfway point as it's a perfect break between the awkwardness of the bits under each lipped area, and the relative ease of 'stage 2' being the main part of the trough and more visible sections.
    My aim being that despite doing it separately in two parts, I'll be able to finish the job without any visible join (I havnt created a solid line with masking tape here, just enough to cover the bit that I need to, and any paint that went below onto the main section of seam sealant is just a bonus of some extra coverage) - even though this section is still almost completely hidden by trim, I'll still know what's under there, and I want to ensure that I do everything the best standard that I can.

    Enough of my waffle anyway, here's an array of pics

















    And lastly inbetween coats I just about finished this bit of front end box section. One more light coat of rust remover then I can give the centre bit of box section a final clean off and prep it for paint. The triangular piece on the right needs a repair so I'll just give that a good coat in Electrox for now- it'll be nicely preserved until I can drive it to somewhere to do the repair when it's back on the road

  468. West Midlands Joined: Nov 2005 Nuneaton (West Mids) Posts: 13835 '64 Volvo V40 R’Design, '89 Ph1 309 GTi, ‘97 Mk1 S
    #468
    Finally victory over the scuttle area. It's been a long day so I'll just leave the pics here for now.











    2 users thanked this post: ,
  469. North West Joined: Apr 2009 Warrington, Cheshire Posts: 5733 PH2 Peugeot 106 "race" car - Currently in pieces
    #469
    How do you get such a professional finish on all your stuff!? I try to take my time and let layers dry properly but it always look like I let the kids at it with a box of crayons!
  470. Infrequent Poster Joined: Aug 2008 North East Posts: 194 VTS
    #470
    Quote:
    Originally Posted by Alanapone View Post
    How do you get such a professional finish on all your stuff!? I try to take my time and let layers dry properly but it always look like I let the kids at it with a box of crayons!
    2nd this!!!
  471. Infrequent Poster Joined: Nov 2009 Posts: 122
    #471
    All I can say is WOW!!

    The attention to detail on this build is simply breathtaking and the commitment to cleaning/fixing what bits you have is unreal!

    This has to be hands down on of the greatest project threads I have read.

    I really hope this hits the toad this year as I'd love to see it in the flesh at a show. Keep up the fantastic work and I look forward to many more updates
  472. West Midlands Joined: Nov 2005 Nuneaton (West Mids) Posts: 13835 '64 Volvo V40 R’Design, '89 Ph1 309 GTi, ‘97 Mk1 S
    #472
    Evening all, feels like I've been slacking on the updates this week, however I have been very busy on the old GTi. Thanks very much again for the really positive comments in the meantime.

    I have now started to reassemble the front end, there's still plenty that I want to do and still more that I want to clean up as I go but I'm trying not to get too hung up on it- I do want to get the thing on the road again by the summer so further non essential deep cleaning can continue when I eventually whip the engine out to respray the rest of the engine bay. Makes more sense.

    First up was replacing the old engine mounts. I think you'll all agree that these are well past their best


    These uppers were replaced with new Genuine Peugeot ones. All nuts/bolts/washers were bought from the dealers aswel. The lower as mentioned previously was replaced with a 'group N' stiffer grade rubber bush from BakerBM. The original standard one had a lot of potential for excess movement, I feel the positives of fitting this mount will far outweigh the minor negative of slight increased vibration. Should be minimal with retaining OE upper mounts.

    Next up I dismantled the struts again in order to repaint the top mounts in satin black. They are brand new but in being loose in the bag with the other metal parts they were littered with scratches and chips in the coating. Best to keep thrm well protected, plus these are visible in the engine bay



    Reassembled the strut, fitted it and mated it with the hub assembly for the first time



    Next up I removed the new master cylinder again. The main body of it is electroplated, however the machines surface at the end, and the faces where the brake lines fit are bare metal, they'd started to develop some surface rust. So I cleaned the surfaces back and clear coated them.



    Dug out a new fluid reservoir


    That'll be refitted along with the Brake lines once I've finished painting the bracket from the drivers side. Passenger side de-rusted and painted



    Front calipers arrived back from Bigg Red in Worcester. Blasted and re-coated in the same gold electroplated finish that they would have left the factory with all those years ago.





    Next up, manifold refitted with new gaskets, studs and nuts.



    Then at long last I had some willing assistants to brave the cold with me aswel to get the subframe bolted up into place. Got as far as nipping things into place. Just going through the Haynes manual now to get all the correct torque settings. Shall nip thr bolts up and give everything a clean and carry on with the rebuild. Pics in the meantime....









    Full credit to my friendly parts Genie who managed to locate a full set of new Genuine gear linkages from various locations across Europe


    And to end this update I managed to get hold of a new water outlet (the secondary one, not the one that bolts to the back of the engine block) the existing one looked ok but given the difficulty getting hold of an original type metal one for the block, I bought this new one anyway.



    In swapping them over, the 'SAD' Supplementary Air Device mounts onto the bottom of the outlet. It's well known to be a potential problem point for the idle of 205 and 309's however generally with some routing cleaning to maintain it the problems are often solved. Ideal than to test it whilst oh was off the car. Hooked up a supply to it and was pleased to see that it works perfectly fine



    So it had a thorough clean. Also cleaned and polished up the sensor from the water outlet. I do have a new one but will refit this one for now as it's perfectly good

  473. Saxperience Post Whore Joined: Aug 2008 The wrong carpark Posts: 5152 Xantia 1.9TD
    #473
    This thread makes me wet. Loving it lad. Definately need to see this in person one day
  474. West Midlands Joined: Nov 2005 Nuneaton (West Mids) Posts: 13835 '64 Volvo V40 R’Design, '89 Ph1 309 GTi, ‘97 Mk1 S
    #474
    Aha cheers mate, glad you're enjoying the read :-) I'll keep the updates coming. Shall have another one to post up in a mo
  475. West Midlands Joined: Nov 2005 Nuneaton (West Mids) Posts: 13835 '64 Volvo V40 R’Design, '89 Ph1 309 GTi, ‘97 Mk1 S
    #475
    This morning I've managed to squeeze a couple of hours of progress in.

    My tub of Deox C has arrived, after seeing results that a bloke over on Detailing World had with it on his calipers, and after spending a ridiculous amount of time doing the first hub assembly. I've lobbed the second one in a bucket and we'll see how it gets on over the next 24 hours, and how much time it saves me having to clean it up manually.

    I then moved onto the driveshafts again. They are the original genuine Peugeot driveshafts, however only one of the original CV boots remain as original type. The cars done 90k miles and the shafts still feel good. There is life in them yet, despite the incredibly grubby appearance.

    I forgot to take a pic of the smaller passenger one before I started, however here's a pic of the longer drivers side one







    I hadn't realised how easy these driveshafts are to dismantle until I read the Haynes Manual. So, before I'd got around to reading it I had already begun cleaning up the smaller passenger driveshaft with the intention of painting the exposed metal bits. I've also bought a full set of genuine boots.

    I'd got this far before reading the Haynes Manual



    Essentially once the boot ties are loosened and the boots are pulled away the outer part of the shaft has a small circlip in the end groove (can be seen at the base of the next pic) Giving the end piece a soft tap it slides off. The inner joint simply pulls clear of the housing.

    This'll make it easier to finish cleaning and painting the exposed metal. Thinking I'll stick with a satin black finish as I'd already finished on the outer joint, although I have been tempted with silver with the original appearance just being exposed metal

  476. West Midlands Joined: Nov 2005 Nuneaton (West Mids) Posts: 13835 '64 Volvo V40 R’Design, '89 Ph1 309 GTi, ‘97 Mk1 S
    #476
    Finally got around to starting to clean up the drivers side hub assembly today.

    I wouldn't usually bother doing this update as I've already posted up pics etc after spending hours and hours slaving away on the passenger side one.

    However, this time I took on board recommendations to try Bilt Hamber Deox C, a rust remover that you simply mix with water and leave in a bucket with the part and let it work its magic. Again it's made to only remove rust and won't harm plastic or rubber etc.

    So I mixed some up to the lowest suggested ratio (19:1 for 5% strength) I've had to do absolutely nothing other than give it a rinse off and rub over it with a scotch pad to shift the built up residue. I left it at room temperature for 24 hours so far. Process can be sped up rapidly by heating the solution a bit and/or increasing the strength of the mixture.

    Here's the front/rear before pics of each piece









    And after 24 hours









    I really wish I'd started using this stuff before I spent hours doing the other hub!

    They still need a little more work so I'm just going to leave them for another 24 hours (may aswel) then I can get them finished, coated and reassembled with the new bearing towards the end of the week
  477. West Midlands Joined: Nov 2005 Nuneaton (West Mids) Posts: 13835 '64 Volvo V40 R’Design, '89 Ph1 309 GTi, ‘97 Mk1 S
    #477
    Morning all,

    Been a while since I updated this. I have still been plodding along with it. The last month has had its fair share of frustrations with several things delaying the progress.

    I ended the last update having started to strip down the driveshafts, they are original Peugeot ones and still seem to be fully functional despite looking horrendous.
    My aim was to strip them down, paint the visible metal after getting rid of the surface rust and muck, and fit new genuine CV boots along with the fresh grease that comes with them.

    Started with this






    This is where the frustrations started. I'd already bought the new CV boots. The outer ones were the correct ones, however the inner ones were incorrect. Peugeot listed two part numbers on service box for the XU engine'd models. There's no mention in difference in sizes or age/year of manufacture, so as Sod's law goes I'd bought the wrong one which had a smaller diameter on the largest end which after further digging suits the very early Phase 1's pre 1989 build date. Mine still being a phase 1 with April 1989 build date uses the larger CV joint. So delays there waiting for the correct ones to arrive.

    Eventually, I finished refurbishing the first driveshaft



    I'm still finishing the longer drivers side driveshaft.

    I've also refitted this water outlet with a new sensor & Supplenentary Air Device. All new genuine Peugeot hoses used at either end.



    Next up with parts being refitted left right and centre now there was original bits which just let the side down with their appearance. So I've dug out my Electroplating kit (sourced from GaterosPlating) and set about redoing the plating on some parts. The following were in various states from original plating just starting to weather, to rusty.

    I used electrolysis using a battery charger, two pieces of sacrificial scrap metal and a solution of water and sodium carbonate. Here's how they looked after electrolysis which was about an hour fizzing away



    And all finished. I have had better results in the past but I think the solution and zinc may be getting a bit tired now. Still, they're vastly improved and will last a fair while longer.









    Before


    Almost after, just got to put the mounting clips back on.






    I've also tweaked the front brake lines which I made up, new clips also arrived from Austria.
    (Yes I did get bored a while back and did a tester piece polishing up the cam cover)


    And a couple of pics of the front suspension. I've got all the bits now to refit the calipers etc too so it really shouldn't be long now before its back on all 4 wheels





    That'll do for now, back out to the garage to continue the work.
  478. Saxperience Forum Bum Joined: Mar 2009 Stoke-on-trent Posts: 2640 Mk5 Golf GTTDI Mk2 VTR Project
    #478
    I love reading through your progress threads, always great work, the open top scandal was probably my favourite but all awesome
  479. Established Member Joined: Aug 2009 King's lynn Posts: 2073 Turbocharged vtr
    #479
    Your efforts always amaze me! hats off to you
  480. Established Member Joined: Aug 2012 Posts: 2009 Saxò VTS 16v
    #480
    Amazing work as always,can I ask what tool did you use to flare the brake pipes? All the cheap ones are quite crap,I got a PowerHand one and it works quite well,there's always the "professional" one but it's over a hundred,really don't feel like it's worth my money for now
  481. West Midlands Joined: Nov 2005 Nuneaton (West Mids) Posts: 13835 '64 Volvo V40 R’Design, '89 Ph1 309 GTi, ‘97 Mk1 S
    #481
    Quote:
    Originally Posted by Ben_SaxoForte View Post
    I love reading through your progress threads, always great work, the open top scandal was probably my favourite but all awesome
    Cheers Ben, I did love the old Saxo, great car to start with and get learning since I had absolutely no mechanical knowledge at the beginning of it.

    Quote:
    Originally Posted by VeiRoN View Post
    Amazing work as always,can I ask what tool did you use to flare the brake pipes? All the cheap ones are quite crap,I got a PowerHand one and it works quite well,there's always the "professional" one but it's over a hundred,really don't feel like it's worth my money for now
    I did make the investment of buying one of the more professional type tools. This one always had positive feedback in the reviews that I found. Seems to have done the job nicely so far, the lines havn't seem fluid yet though so I'll reserve final judgement until then :-)

  482. West Midlands Joined: Nov 2005 Nuneaton (West Mids) Posts: 13835 '64 Volvo V40 R’Design, '89 Ph1 309 GTi, ‘97 Mk1 S
    #482
    In between the electroplating much of the last few days have been spent cleaning up the remaining drivers side driveshaft (as pictured above) and wishbone. The Bilt Hamber Deox Gel has done the majority of the work however with a bit of agitation every 30 minutes, cleaning it all off after an hour and reapplying, all of the parts are just about ready for paint.

    The wishbone won't be necessary to return to bare metal in its entirety as the ball joints are not replaceable on these. When they wear it's new wishbone time so most of the original black coating is still good and has survived my scrubbing. With the surface rust gone I can happily repaint the rest.

  483. Established Member Joined: Nov 2011 Newcastle Posts: 1698 Range Rover Sport
    #483
    Have you lacquered the larger areas you've painted? I'm in the middle of painting my interior and dont really want to lacquer as due to the possibility of reaction/ finish of the lacquer ruining the job
  484. West Midlands Joined: Nov 2005 Nuneaton (West Mids) Posts: 13835 '64 Volvo V40 R’Design, '89 Ph1 309 GTi, ‘97 Mk1 S
    #484
    Evenin Deano, yes I have lacquered all of the bits that I've done, little bit more hardy then with 2-3 coats
  485. Established Member Joined: Nov 2011 Newcastle Posts: 1698 Range Rover Sport
    #485
    Thanks man, I thought that would be the case. Guess I'll have to do it too to make it worthwhile and last
  486. West Midlands Joined: Nov 2005 Nuneaton (West Mids) Posts: 13835 '64 Volvo V40 R’Design, '89 Ph1 309 GTi, ‘97 Mk1 S
    #486
    Morning all, time for a bit of an update.

    Finished refurbishing the longer drivers side driveshaft





    Then set about refitting all front suspension, driveshafts and front brake items. Apologies for slightly rubbish pics, it had got dark and the garage lighting isn't favoured by the iPhone.







    I still have plenty of bits to refit but at this point everything was at least fitted and torqued up to be able to put the car back on all 4 wheels for the first time since around last June!
    I will take some better pics outside I've the next few days, in the meantime....



    4 users thanked this post: , , ,
  487. Newbie Joined: Feb 2013 Castelo Branco/Portugal Posts: 1 Citroën Ax 1.4D Citroën Berlingo 2.0 HDi Toyot
    #487
    Top! Good job! 😀
  488. West Midlands Joined: Nov 2005 Nuneaton (West Mids) Posts: 13835 '64 Volvo V40 R’Design, '89 Ph1 309 GTi, ‘97 Mk1 S
    #488
    Evening folks.

    With the front end temporarily back on its wheels I decided to spend today having a bit of a poke around at the back end. As many fellow Peugeot owners will know the rears are typically almost always in need of much more care and attention than the front.

    I havn't found any further holes yet since the earlier bumper bracket one which was repaired. However there's plenty of rust to attend to.






























    Only real pic of improvement for the day is the rear calipers. They don't take too much to clean up atall. They need new slider pin seals and I'll probably strip them and rebuild with new internal seals aswel.

  489. Newbie Joined: Feb 2013 Castelo Branco/Portugal Posts: 1 Citroën Ax 1.4D Citroën Berlingo 2.0 HDi Toyot
    #489
    You will take out the rear axle? It could need bearings and greass...

    Good job
  490. West Midlands Joined: Nov 2005 Nuneaton (West Mids) Posts: 13835 '64 Volvo V40 R’Design, '89 Ph1 309 GTi, ‘97 Mk1 S
    #490
    Quote:
    Originally Posted by Andre21 View Post
    You will take out the rear axle? It could need bearings and greass...

    Good job
    Good evening Andre,

    Yes I will be taking the rear beam/axle off to get it refurbished, I am hoping that it will be ok for a short time to get through an MOT around the end of April though. I'd like to use the car over the summer, and plan to rebuild the axle next winter then when I've saved a few £££ and had a holiday.
  491. West Midlands Joined: Nov 2005 Nuneaton (West Mids) Posts: 13835 '64 Volvo V40 R’Design, '89 Ph1 309 GTi, ‘97 Mk1 S
    #491
    Morning all, bit of an update for you on the last few weeks work.

    Firstly I finished rebuilding my rear calipers, they've been stripped down to each individual piece, new seals throughout along with new pistons and slide pins. I have taken a LOT of pictures sufficient to make a decent guide so I will put that together shortly since the same Bendix calipers have been used for years now on various Peugeots, Citroens and Renaults









    Continuous progress made with rust removal on the rear end, some bits looked terrible on those earlier before pics but it's all coming off easily enough with the help again from Bilt Hamber Deox Gel.

    Before - After a scrub with the wire brush to remove loose rust and flaking paint/coating



    After 24 hours coated with Deox Gel, cling film over the top to prevent it drying out, without it it tends to dry out after 2-3 hours



    After 48 hours. Not bad considering I've only actually put an hour or so of my time into it. Shouldn't take much more to remove the remaining rust deposits.



    Fuel tank also came off so I could inspect the inner sills. These are extremely common for rust on 309's, and I dare say a prone area for newer models that are starting to experience it.
    Despite this looking perfectly sweet and innocent, I am going to strip it back regardless



    I was right to, amazing what is going on under that factory coating



    There is a small hole, but I'm fortunate that I seem to have caught it early. I've seen some owners have to deal with some horrendous rust here



    And so as not to bore you all too much with rust removal pics, just one more show of why I'll continue to rave about Bilt Hambers Deox Gel

    Before


    Almost done after 48 hours



    Other jobs have been to remake the rear brake lines

    These aren't going to satisfy an MOT test





    Using Cupro-Nickel lines with stainless fittings





    It's going to be a long hard slog for the rest of this month finishing the rust remove on the rear end so my next update will probably be in a few weeks when I've got something more meaningful to show again.

    Lastly for this update, I have managed to get my Original Dealer rear plate replicated. Really happy with the results. Side by side there's only marginal difference but without getting very picky with measurements they look fantastic

  492. Saxperience Post Whore Joined: Aug 2008 The wrong carpark Posts: 5152 Xantia 1.9TD
    #492
    Very very nice as always! Might have to get some of that rust remover, mines all solid just browning!

    How did you manage the number plate?
  493. Regular Poster Joined: Nov 2008 Alnwick/Northumberland Posts: 258 Cobalt Blue 106
    #493
    Quote:
    Originally Posted by willsy View Post
    Firstly I finished rebuilding my rear calipers, they've been stripped down to each individual piece, new seals throughout along with new pistons and slide pins. I have taken a LOT of pictures sufficient to make a decent guide so I will put that together shortly since the same Bendix calipers have been used for years now on various Peugeots, Citroens and Renaults
    Straightforward to rebuild or pita? Where did you buy parts for the rebuild?
  494. West Midlands Joined: Nov 2005 Nuneaton (West Mids) Posts: 13835 '64 Volvo V40 R’Design, '89 Ph1 309 GTi, ‘97 Mk1 S
    #494
    Quote:
    Originally Posted by chinkostu View Post
    Very very nice as always! Might have to get some of that rust remover, mines all solid just browning!

    How did you manage the number plate?
    Cheers :-) the rust remover is great, it's even better now that I've discovered that it won't dry out with cling film over the top. Without cling film it drys out and needs removing within 1-3 hours depending on temperature. Obviously means you get through more of it. Whereas with cling film it can be left overnight and will have removed more.

    For the plates I sought the assistance from DMB Graphics. They specialise in Ford stuff but are more than happy to do custom bits. I just sent them several high definition pictures.

    Quote:
    Originally Posted by westwell_22 View Post
    Straightforward to rebuild or pita? Where did you buy parts for the rebuild?
    Very straight forward really, most tricky but is removal and reassembly of the handbrake cable lever. Made up my own tool for that bit but. I got the genuine seal rebuild kit from Peugeot (still available from Citroen too) which strangely included all except 1 seal. So I got the remaining seal, sliders and new Pistons from Bigg Red.

    I will get around to putting the guide together at some point this week I hope
  495. West Midlands Joined: Nov 2005 Nuneaton (West Mids) Posts: 13835 '64 Volvo V40 R’Design, '89 Ph1 309 GTi, ‘97 Mk1 S
    #495
    Minor update

    Removed the rear suspension entirely. At the very least I hoped to check it all over, clean everything up and regrease where necessary. With a bit of luck it would be MOT passable so that I could get some use out of the car over the summer.

    Please excuse the mess


    Got everything stripped down nicely but unfortunately I'm going to have to do the full rear beam refurbishment and rebuild now

    Much wear here, outer bearing has dug itself in quite well


    Other side not so bad but if one needs doing then both pins will be changed.


    Various work around the house is limiting my funds for this at the moment so as things stand it'll be unlikely that I'll get to use it on the road this year. Shall just take my time with it.

    So, I'll get all of the rear suspension bits and rear brake line brackets stripped and electroplated first.. Then bits which were coloured originally will be powder coated in their original colour/finish/closest match possible. I'm aiming for it to be done to as close to factory original as possible.

    Surface rust removal still very much ongoing on the boot floor too. Will post pics when I make some more meaningful progress though.
  496. West Midlands Joined: Nov 2005 Nuneaton (West Mids) Posts: 13835 '64 Volvo V40 R’Design, '89 Ph1 309 GTi, ‘97 Mk1 S
    #496
    Afternoon all, apologies for the lack of updates lately.

    I have been getting the odd bit done which has been mostly dismantling the rest of the rear suspension assembly and gathering some new bits.
    I still need to drop various bits off to be electroplated which are too big to do in my home kit. They'll then go for powdercoating over the top in the original (close as possible) colours.

    The rest of my time, which has been minimal to be fair, has been spent doing the rust removal on the rear end.
    After having a good poke and a prod (see before pics on the previous page) I was finding that the surface rust was starting to creep under bits of the factory stone chip finish which from simply looking at the stone chip looked in perfectly good order.

    So as with the rest of the work so far there's just no point in doing things by halves or settling for a temporary job of rust treatment.
    I've decided to completely strip it back to back metal. I figured out that Nitromors does a nice enough job of softening and loosening the factory stone chip and compromised original galvanised costing underneath it. Then it's been the lengthy job of applying Bilt Hamber Deox Gel to get rid of the surface rust. I'm not a believer in the rust converter type products so it's got to be rust free metal.

    Here's how things are looking anyway



    I've got further with the passenger side here


    Almost caught up


    It's going to take me a good while longer but it's got to be worth it in the long run
  497. West Midlands Joined: Nov 2005 Nuneaton (West Mids) Posts: 13835 '64 Volvo V40 R’Design, '89 Ph1 309 GTi, ‘97 Mk1 S
    #497
    Just a couple to show how long this is taking

    This is another 2 hours work since the last set of pics. Doesn't seem like much difference



  498. West Midlands Joined: Nov 2005 Nuneaton (West Mids) Posts: 13835 '64 Volvo V40 R’Design, '89 Ph1 309 GTi, ‘97 Mk1 S
    #498
    Another days work on this section. Maybe one more day and this bit will be rust free













    After this bit is rust free I'll give it a couple of good coats of Bilt Hamber Electrox zinc primer. Then I'll get the bit above the fuel tank stripped back. It's taking so long to do these sections that I need to get a coating on it before moving on to the next so that it's more manageable

    Once the entire rear end is done then I'll reapply some fresh stone chip in one go.
  499. Established Member Joined: Jan 2013 Portsmouth Posts: 1335 1997 Mk1 VTS
    #499
    Bloody hell that stuff is good!!
  500. West Midlands Joined: Nov 2005 Nuneaton (West Mids) Posts: 13835 '64 Volvo V40 R’Design, '89 Ph1 309 GTi, ‘97 Mk1 S
    #500
    Hey all, finally a bit more of an update for you.

    At long last I've conquered the worst looking bit of the 309's rear end.



    I'm pretty confident that I can't possibly have got it any more rust free.

    So before it has chance to think about rusting again I've given it 3 liberal coats of Bilt Hamber Electrox. Given the time it's taking between sections I'll do this on each of them then give the lot a final coating before moving on to the stone chip.









    Next task is to conquer the sections either side which are a little tricky to say the least.

    Passenger side underway



    Drivers side so far untouched

    1 user thanked this post:
  501. Established Member Joined: Dec 2007 Redcar, Middlesbrough Posts: 2285 16v Rallye S2
    #501
    Right Willsy Its been July since the last update

    I'm gagging for an update I've followed it since the beginning. we're due an update surely ?
  502. West Midlands Joined: Nov 2005 Nuneaton (West Mids) Posts: 13835 '64 Volvo V40 R’Design, '89 Ph1 309 GTi, ‘97 Mk1 S
    #502
    Evening Rob,

    Yes there is some slight progress on this (I'll collate it over the weekend and get it posted up- currently in Italy but returning home tomorrow)

    Progress has been slow partly due to the weather being too good. The Deox gel needs at least 30 minutes really to do its thing removing the rust on the rear. The problem that I've had is that the garage does get very warm in Summer even with the doors open which has meant that the gel is drying out within 15/30 minutes.

    I have however bought another project to tinker with over the last few months



    Rest assured the 309 progress shall continue with some pace this week. Feeling fresh and ready for some more onslaught to tackle the 309
  503. Established Member Joined: Dec 2007 Redcar, Middlesbrough Posts: 2285 16v Rallye S2
    #503
    Looking forward to it buddy!
  504. Established Member Joined: Dec 2007 Redcar, Middlesbrough Posts: 2285 16v Rallye S2
    #504
    I've been waiting over a month now bud!

    no pressure
  505. Established Member Joined: Aug 2012 Posts: 2009 Saxò VTS 16v
    #505
    LOL

    yeah 458 chacs
  506. Saxperience Post Whore Joined: Mar 2009 Uppingham, Rutland Posts: 9569 mk1 JP4'd VTR, '16 Fabia Monte Carlo
    #506
    Dammit I was all excited
  507. Established Member Joined: Dec 2007 Redcar, Middlesbrough Posts: 2285 16v Rallye S2
    #507
    still waiting!
  508. West Midlands Joined: Nov 2005 Nuneaton (West Mids) Posts: 13835 '64 Volvo V40 R’Design, '89 Ph1 309 GTi, ‘97 Mk1 S
    #508
    Good evening everyone, and a belated Happy New Year.
    Apologies for the lack of any update during the latter part of 2016, generally there wasn't any. I'd bought another project to occupy me for a couple of the hotter summer months whilst it was too hot and impractical to continue with the rust removal on the 309 rear end (too hot, gel dries out too quickly) however that projects been a pain in the ass, and sapped a lot of time.

    Anyway I've restarted on the 309 from where I left off. From the previous update I was beginning to tidy up the passenger side of the boot floor.



    One thing that's become increasingly apparent is that originality with the factory stone chip really isn't feesable to get hung up on with this restoration. The truth of it is that the old finish is failing and so is the original galvanazed coat underneath. Anyone who thinks they have a mint 309 underneath would be sadly disappointed. There's bits that I'd cleaned which looked in good order but in cleaning back the boot floor most of it has been removed, for the greater good.

    These bits for example all appeared to be unbroken clean factory stone chipped areas. After some digging I've unearthed some welding requirement. This is a common area either side of the fuel tank which, from some horrors that I have seen, I think this has been captured VERY early

    Passenger side

    Looks harmless??


    Needs attention


    The worse, drivers side



    Those areas can be sorted soon. In the meantime I'm focusing on the areas which are obstructed for access if the rear suspension was fitted.

    Back into this area









    Another example of 'what lurks beneath' the right hand side here was coated in some lovely factory stone chip just minutes before this pic



    So on with the Bilt Hamber Deox Gel again



    This really is a painfully slow process. It's so tight in these box sections that no substantial tools can fit in to aide the process, I'm also of the frame of mind that I don't want to remove good material unnecessarily in the process; these areas look like they could/would be a real pain to have to replace any with new material.

    This really is my working tool box at the moment. A scribe set for picking at loose rust. Deox gel and a small rotary tool size wire cup and wire wheel to use on the drill where it'll fit



    So working in cycles my next day commenced with 3 hours worth of scratching at loose surface rust with the scribe set and screwdrivers. That followed with 2 hours worth of Deox Gel working its magic whilst I did some housework to pass the time.

    This is the same area as above after the first application of gel









    I've then spent another 2-3 hours scraping again at some of the stubborn areas and picking at some of the pitted bits with the scribe. This is as far as I got yesterday













    There's still plenty more hours of work to go into the rear end. Bare with me, I'll get onto more exciting stuff at some point hopefully :-)
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  509. West Midlands Joined: Nov 2005 Nuneaton (West Mids) Posts: 13835 '64 Volvo V40 R’Design, '89 Ph1 309 GTi, ‘97 Mk1 S
    #509
    Over the next few days I have a dent guy booked for Friday so I'm hoping he can get all of the small car park dents out of the rear quarters so they're up to scratch. That'll then enable me to fully fit the interior as much of it has been loose fit for ages in anticipation that access is going to be needed behind the doorcards etc at some point.

    More rust removal pics of course

    And I'll take some pictures of all elements of the car, just as an 'as it stands' gallery to start 2017.
  510. Regular Poster Joined: Feb 2016 manchester Posts: 256
    #510
    Sounds torture doing all that rust removal! Fair play for sticking at it.
  511. Established Member Joined: Dec 2007 Redcar, Middlesbrough Posts: 2285 16v Rallye S2
    #511
    http://i0.kym-cdn.com/entries/icons/...77/so_good.png
  512. North West Joined: Apr 2009 Warrington, Cheshire Posts: 5733 PH2 Peugeot 106 "race" car - Currently in pieces
    #512
    Almost 12 months have gone by... Any progress?
  513. West Midlands Joined: Nov 2005 Nuneaton (West Mids) Posts: 13835 '64 Volvo V40 R’Design, '89 Ph1 309 GTi, ‘97 Mk1 S
    #513
    Afternoon all, apologies for being slow on the updates. There have been a couple on Detailing World, but here’s a copy/paste of the latest ones for you

    ..............................


    Apologies for the lack of any update during the latter part of 2016, generally there wasn't any. I'd bought another project to occupy me for a couple of the hotter summer months whilst it was too hot and impractical to continue with the rust removal on the 309 rear end (too hot, gel dries out too quickly) however that projects been a pain in the ass, and sapped a lot of time.

    Anyway I've restarted on the 309 from where I left off. From the previous update I was beginning to tidy up the passenger side of the boot floor.



    One thing that's become increasingly apparent is that originality with the factory stone chip really isn't feesable to get hung up on with this restoration. The truth of it is that the old finish is failing and so is the original galvanazed coat underneath. Anyone who thinks they have a mint 309 underneath would be sadly disappointed. There's bits that I'd cleaned which looked in good order but in cleaning back the boot floor most of it has been removed, for the greater good.

    These bits for example all appeared to be unbroken clean factory stone chipped areas. After some digging I've unearthed some welding requirement. This is a common area either side of the fuel tank which, from some horrors that I have seen, I think this has been captured VERY early

    Passenger side

    Looks harmless??


    Needs attention


    The worse, drivers side



    Those areas can be sorted soon. In the meantime I'm focusing on the areas which are obstructed for access if the rear suspension was fitted.

    Back into this area









    Another example of 'what lurks beneath' the right hand side here was coated in some lovely factory stone chip just minutes before this pic



    So on with the Bilt Hamber Deox Gel again



    This really is a painfully slow process. It's so tight in these box sections that no substantial tools can fit in to aide the process, I'm also of the frame of mind that I don't want to remove good material unnecessarily in the process; these areas look like they could/would be a real pain to have to replace any with new material.

    This really is my working tool box at the moment. A scribe set for picking at loose rust. Deox gel and a small rotary tool size wire cup and wire wheel to use on the drill where it'll fit



    So working in cycles my next day commenced with 3 hours worth of scratching at loose surface rust with the scribe set and screwdrivers. That followed with 2 hours worth of Deox Gel working its magic whilst I did some housework to pass the time.

    This is the same area as above after the first application of gel









    I've then spent another 2-3 hours scraping again at some of the stubborn areas and picking at some of the pitted bits with the scribe. This is as far as I got yesterday













    There's still plenty more hours of work to go into the rear end. Bare with me, I'll get onto more exciting stuff at some point hopefully :-)


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  514. West Midlands Joined: Nov 2005 Nuneaton (West Mids) Posts: 13835 '64 Volvo V40 R’Design, '89 Ph1 309 GTi, ‘97 Mk1 S
    #514
    Afternoon folks, apologies for the delay in a meaningful update. Busy year so far but with most of my non car related ‘to do’ list being conquered it’s time to get upto date on here, and prepare for some more graft.

    First up is a quick catchup of the rear end rust removal progress. As I left off from the last update, I was working on a bit of the boot floor box section. It is a bit finicky on these old Pugs.

    Last update you were left with this pic...



    Well I progressed a bit and managed to get some of the box section back to bare metal, treated any pitted bits (just to make sure all the rust was sorted) with Bilt Hamber Hydrate80, then gave a liberal few coats of Zinc rich Bilt Hamber Electrox over the top.

    That should keep it in decent order for a good while. I didn’t get much done on the boot floor area. It’s so time consuming at this stage id decided that it would best to do small sections at once to get it coated ASAP rather than having larger areas of metal bare for a prolonged period.

    Here’s where I got to





    Once I’ve done all the donkey work here it’ll be easier to do the stone chip over coating in more or less one sitting I hope.

    At this point I’d had enough of lying down under the car so opted to move onto the next task for a bit.

    Next update following shortly - rear suspension rebuild



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  515. West Midlands Joined: Nov 2005 Nuneaton (West Mids) Posts: 13835 '64 Volvo V40 R’Design, '89 Ph1 309 GTi, ‘97 Mk1 S
    #515
    Next up then, rear suspension time.

    Having removed the rear beam assembly from the car there was no way that it would be going back on in the same condition.



    Que a complete strip down



    It’s just as well that I did strip it down as a common item of wear found on 205/309s (or indeed many Peugeot’s/Citroen’s of the same era using a Torsion bar setup) is the bearings, when they get so tired and dry they tend to collapse and just eat their way into the shafts causing excess play, camber and inevitably an MOT fail & a big fat repair bill

    The left shaft here being particularly bad where the outer bearing sits



    Trailing arms were completely stripped down. Both the main shafts and the hub pins are to be replaced



    Removing the old bearings from the main suspension tube was next. Outer ones have no easy way of removal so to begin the inner race was easily flicked out with a screwdriver as it it was obliterated anyway, then that just left the outer casing to shift.

    Many guides online seem to suggest bludgeoning it with an old screwdriver so that it collapses in on itself and will simply come out.
    I felt that there was less control with that method and more chance of leaving some damage on the tube itself. Therefore with a dremmel and mini grinding disk I carefully cut through the bearing outer casing until a hairline crack appeared. Then it was easy with a light tap to crack the casing and pull it out with ease





    The inner bearing was easy enough to remove as it’s situated some way inside the main tube. Inserting one of those old worn shafts which were now pressed out of the trailing arms are useful in that their diameter is small enough to sit against the bearing then with a piece of wood tap the bearing out through the tube (not the best description unfortunately, but equally impossible to take a pic of)

    Next up was to clean the splined areas of the tube and the trailing arms where the torsion bars sit in. Again handy dremmel and mini wire wheel attachment works wonders





    Then it was off for blasting, zinc under coat and powder coat for most of the parts

    I gathered together other bits which were originally zinc plated and sent those off to ElectroplateUK too




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  516. West Midlands Joined: Nov 2005 Nuneaton (West Mids) Posts: 13835 '64 Volvo V40 R’Design, '89 Ph1 309 GTi, ‘97 Mk1 S
    #516
    Gradually parts then started arriving back from being powder coated.

    First up was the torsion bars. I wanted as close a match as possible to the original deeper (red oxide?) shade



    The eagle eyed or those with a Pug/Cit background may have noticed that the bars are originally are marked with a yellow ring. One bar has 1 ring, the other has two. I don’t know if there’s any difference other than as a drivers/passenger marking about it, however continuing with the attention to detail I measured the rings and their positions before sending them for powder coat, and replicated them upon return



    The next bit is where the dampers sit in and is a link between the main tube and the rear mounting bushes. The factory finish for these I couldn’t find anywhere to replicate as it’s like a zinc leaf finish (again I haven’t got a clue how to describe it otherwise) anyway best I could do was a light grey metallic. The silver looked a bit cheap



    Trailing arms finished in satin black and reassembled next with new shafts & pins



    The main tube also satin black at the ends with a JCB yellow centre tube. It looks bright in this pic due to the flash but the darker JCB yellow is much closer to the original appearance.



    In order to refit the inner bearings to the tube I needed something a bit less archaic. I decided to use the wooden handle of an old gardening tool and used a hole cutter to create some pvc discs to fit on the end which were tough enough to tap the bearing in, yet wouldn’t damage it



    Bearing sat on top



    The other brackets and bits and bobs also returned from ElectroplateUK



    And then I started to fit it all together. I’ll setup the height when it’s back on the car but for now it’s sitting pretty in the corner of the garage














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  517. West Midlands Joined: Nov 2005 Nuneaton (West Mids) Posts: 13835 '64 Volvo V40 R’Design, '89 Ph1 309 GTi, ‘97 Mk1 S
    #517
    Morning all,

    Last minor update whilst I’m still on holiday. (Although it has still taken many hours to do accurately)

    One of my jobs to do is to ‘adapt’ the two new genuine front wings that I have in order be the correct spec. A daunting task considering there are no GTI ones left, and it took long enough to find a matching pair of wings from an earlier model. From memory my Parts Genie Craig only found one other genuine wing in Europe and that was a Phase 2...

    Whilst the shape of the wing itself remained the same throughout production of the 309, there were three notable differences between model years, and with spec.

    1) There was an entirely plain wing with no side repeater

    2) There was a slightly later Phase 1 which did have a side repeater implemented which was located just in front of the door mirror, but slightly lower around the height of the top of the wheel arch


    3) Then the phase 2 wing changed again with the side repeater moving further down as seen below


    So my first job was to use a template drawing (as handily added to the Haynes manual) and cut this shape into my two new wings



    Using a few select drill bits and various dremmel attachments I dived in. I spent a LOT of time ensuring that my template was good, and that it was accurately placed







    Next up, being a GTI meant that I’d have a further three holes to drill on the lower part of the wing where the GTI’s side trim fits in.

    Again plenty of measuring was required








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  518. Saxperience Forum Bum Joined: Dec 2012 Perth Posts: 3665 Peugeot 106 1.1 Turbo Peugeot 106 1.5D Turbo Peuge
    #518
    Excellent

    A bit more involved than drilling a poverty spec S1 106 wing to take Rallye arches! Which I'm not looking forward to.
  519. Infrequent Poster Joined: Mar 2018 Wirral Posts: 151 106 GTI - 106 GTI shell - New 106 Rallye shell
    #519
    loving the attention to detail great restoration work so far.....just out of curiosity, roughly how much was it for all the brackets and bolts to be electroplated ? did they take long to be done? . Im looking to have a few things done myself.
  520. West Midlands Joined: Nov 2005 Nuneaton (West Mids) Posts: 13835 '64 Volvo V40 R’Design, '89 Ph1 309 GTi, ‘97 Mk1 S
    #520
    Quote:
    Originally Posted by karl_mh View Post
    loving the attention to detail great restoration work so far.....just out of curiosity, roughly how much was it for all the brackets and bolts to be electroplated ? did they take long to be done? . Im looking to have a few things done myself.


    Cheers Karl for everything in the picture it was £40 turnaround time within a week. ElectroplateUK were great. They don’t deal with postage (but they’re happy enough to box up and stick a label on) so I had to arrange my own courier both ways which was no problem


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  521. Newbie Joined: Jul 2018 Posts: 3
    #521
    Need and update!

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