My Black 1.6 8v Xsi aka Huwwy

[curl666]

Thought I would get a blog on the go, just to show you what I'm up to!

Bit about me:

Name - James
Age - 19

In my 2nd year studying photography at university. University life rocks, student loan basically funds the car, travel and drink habit. Since being at university I've hitch hiked to Morocco from Swansea, flew to the Isle of Wight for Lunch, Reading festival, spray painted parts of the Berlin Wall, snowboarding in Austria....on and on and on

More Importantly on to the car:

Spec as I bought the car end of Jan 08

1995 M reg 1.6 Xsi in black
116K Miles on it
Tax and Mot'd

Mods

Stainless Steel 4-2-1 Manifold (no idea what make??)
Custom powerflow duplex exhaust - basically 2 twin exhausts
Sparco Upper Strut Brace
K+N Induction Kit
Show Cage
15in TSW alloys - two tone silver/black - think they are called Volcano's
Headlight Eyebrows
RGM front spoiler
Lexus Lights
Tinted Windows
Richbrook Steering Wheel, handbrake, gearknob and gaitors

The car ran well and drove home from Oxford to Cardiff, its a bit chavved up for my liking but will be getting rid of the front spoiler, headlight eyebrows, lexus lights ASAP

Will give it a good clean, inside and out and polish when i get chance!

http://www.pistonheads.com/sales/images/350111-1.jpg
http://www.pistonheads.com/sales/images/350111-2.jpg

UPDATED

Removed the following:
Lexus Lights
Front splitter
Lexus Lights
Smoked Side Repeatershttp://i43.photobucket.com/albums/e387/curl666/Xsi002.jpg
http://i43.photobucket.com/albums/e387/curl666/Xsi001.jpg

UPDATED

Interior of the car, was stripped, all cleaned and washed, and put it all back in!

Engine Bay was in a bit of a mess, and the major factor was the Rocker Cover, this was removed, sanded back to bare metal and re-painted silver.

Before

http://i43.photobucket.com/albums/e387/curl666/enginebay.jpg

After

http://i43.photobucket.com/albums/e387/curl666/rockersilver.jpg

Updated

Serviced the car with new oil, spark plugs, cleaned air filter etc
6x9's speakers on parcel shelf removed
Amplifier and a load of wiring removedRemoving the wiring took alot longer than i had thought, the wiring was run under the carpet, and fixed below the runner on drivers door, which meant carpet and seats had to be removed. On the plus side i did find some spare change !
Oil catch tankBought an oil catch tank of ebay £35, some 16mm hose, intend to get some Samco 90 degree bend tubing off the Rocker Cover, but this will do for now.

http://i43.photobucket.com/albums/e387/curl666/oil-tank.jpg

Updated

Battery tray was rocking, turned out to be 1 of the securing bolts missing. Old bolt drilled out, and whilst I had the chance, I rust treated and painted up the area and tray!

http://i43.photobucket.com/albums/e387/curl666/batt001.jpg

http://i43.photobucket.com/albums/e387/curl666/batt002.jpg
Updated

Set about replacing the lower water hose, as I noticed a bodge repair job with it being held together with a plastic bag and cable ties!

* removed thermostat from housing, to allow me to flush engine
* engine and radiator flushed
* re-fitted and sealed thermostat
*Lower Hose removed, and in doing so snapped the water inlet adaptor
*working from underneath the car, fitted new water inlet adaptor, requires alot of patience
* fitted hose at lower radiator
*fitted hose at inlet
*connect the lot back up
*re-filled system with water and anti freeze

Quite pleased with the skills im picking up, and confidence with working on the car, with no other experience!

Also fitted ECU Cover, and new shiney radiator cap

Pic below shows old parts and the new bits, water inlet was split in 3!

http://i43.photobucket.com/albums/e387/curl666/pipe.jpg

Updated

On starting the car for the first time since fitting new lower water hose, water hose seems to be doing the trick, but noticed a stream of oil pissing out the engine.

Source of the problem believed to be headgasket

Parts ordered:

New Headgasket set
New Headbolts
New Water Pump
New Belts

Replacing the headgasket has taken alot longer than I first expected but I'm still enjoying working on the car!

I've had a few set backs, the weather has been a royal pain with the car being outside, long delivery times on parts, few rounded bolts that needed introducing to MR Angle Grinder, and a water pump that was introduced to my dad and Mr Chisel, Mr Drill, Mr Mallet not Timmy!

Progress Pics - Head Removed

http://www.106rallyeforum.com/gallery/data//505/0011.jpg
http://www.106rallyeforum.com/gallery/data//505/0022.jpg
http://www.106rallyeforum.com/gallery/data//505/0041.jpg

Head Cleaned up

http://www.106rallyeforum.com/gallery/data//500/tn_DSC_4748.jpg

All my new parts - head set, bolts, water pump, belts etc

http://www.106rallyeforum.com/gallery/data//500/tn_DSC_4745.jpg

Water Pump - New and Old

Haynes Manual "Undo both securing bolts, and slide pump out" YEAH RIGHT!!!!

http://www.106rallyeforum.com/gallery/data//500/tn_DSC_4750.jpg

Whilst the rain has kept me from working on the car, I decided to paint up some of the parts I had removed, radiator fan, alternator belt pulley, the head was also given a lick of black paint.

http://www.106rallyeforum.com/gallery/data//500/tn_DSC_4743.jpg

Yesterday I set about painting the oil sump, as I'm currently awaiting parts from what must be the slowest Peugeot Dealer in the country!

http://www.106rallyeforum.com/gallery/data//500/tn_DSC_4762.jpg
http://www.106rallyeforum.com/gallery/data//500/tn_DSC_4771.jpg

Updates

I've bought the following "toys" over the last month or so, upgrading the xsi if you like. Most parts are still awaiting fitting!

S1 Rallye 22mm Front ARB
Saxo 24mm Rear ARB
Ventura Uprated Lowering Springs
Spax PSX Front Dampers
Peugeot 406 Brake Calipers
Corbeau Forza Bucket Seats and subframes
Formula Power Blue HT leads
OMP Lower Brace
Drivers Side Door and trim clips

Which brings me to up to date to where I am today, headgasket is on the go, drivers door removal on going.

Give the head a lick of paint:

Head Painted up Black

http://www.106rallyeforum.com/gallery/data//500/head2.jpg

My intentions for the car

I intend to strip the car of all un-needed weight, just turn it into a faster road/track car, underneath of car to be cleaned and repainted, inside of car to be painted. Just general improvements!

When i get a bit of £££ i will look into a different induction kit, some S2 Rallye Steels, and would like to get some more power from the 8v with possibly preformance cam, and bike carbs. But also being lured to the darkside that is 16v's

[JonB]

looks sweet but imo that exhaust is awful

[curl666]

cough cough its for sale on the forum cough cough

Picking up a new magnex decat system, single 3in inward rolled tip, on the weekend.

[chompy]

good work! nice un-bastardising :cool:

[Seph]

Great rescue project, loving the attention to detail, get a better filter on there and youl see a massive difference.

[James]

:D i was hoping you were going to save it lol! should be sweet when its finished mate

[JonB]

cough cough its for sale on the forum cough cough

Picking up a new magnex decat system, single 3in inward rolled tip, on the weekend.


thank god for that lol sweet choice on exhaust too :)

[curl666]

good work! nice un-bastardising

Nice term :) Yep I want to keep it looking as standard as possible, I think they are a cool looking car to start with. Just clean Huwwy up as best I can, considering ripping all the window tints off too!

Great rescue project, loving the attention to detail, get a better filter on there and youl see a massive difference.

Yeah the filter is probably not doing me any favours, it looks fairly old too! Considering getting a BMC CDA but they carry a hefty price tag, and with the plans of bike carbs/throttle bodies in the future, it would become redundant.

Might just pick up a cheap BMC copy for time being, or a simota style induction kit!

i was hoping you were going to save it lol! should be sweet when its finished mate

Project Save the Xsi is go! :D

thank god for that lol sweet choice on exhaust too

Thanks! I picked it up off ebay, seems to be what Im after, single exit with decat! Think of the weight saving now with that 4 exhaust setup removed!

Exhaust use to belong to Mr C Gibson off here, so its got some Rallye history :)

[curl666]

UPDATES

Bought a set of Corbeau Forza Sports on ebay, £90 for 2!

They are 2nd hand, but fella only had them in his car for 2 months before selling the car. They are in as new condition! Really happy with them :)

http://i43.photobucket.com/albums/e387/curl666/seats.jpg

[aidy]

i fucking knew and a i mean KNEW i shouldnt have opened this thread! i miss my black xsi SOOOOOOOOOOOo much that i almost have a tear in my eye reading about yours!

[curl666]

i fucking knew and a i mean KNEW i shouldnt have opened this thread! i miss my black xsi SOOOOOOOOOOOo much that i almost have a tear in my eye reading about yours!

How long ago did you sell it?

Is there a blog lurking about on here about it? Dont see that many black ones!

[James]

James are you in Glyntaff art collage? or was? im sure i remember your white s1 , i had a quiksilver at the time on various wheels as i kept gettin bored of em vts wheels , gti6 wheels black speedlines and vtr rims

[curl666]

Yeah I'm in glyntaff Art college!

What course are you studying?

My White 106, had white VTR wheels, and random door stack decals...RIP!

The only other James, I know/seen around there, has to be around 6ft with a surfer style image/haircut! :rolleyes:

[Mattyboy]

Haynes Manual "Undo both securing bolts, and slide pump out" YEAH RIGHT!!!!

http://www.106rallyeforum.com/gallery/data//500/tn_DSC_4750.jpg



Lol, looks like the one in my Charged block when i removed it! :p

Good blog and good progress! :cool:

[James]

Yeah I'm in glyntaff Art college!

What course are you studying?

My White 106, had white VTR wheels, and random door stack decals...RIP!

The only other James, I know/seen around there, has to be around 6ft with a surfer style image/haircut! :rolleyes:


im not there no more mate finished last year lol

[curl666]

Updates

Finally got the Xsi running again, very pleased to say i change the head gasket, belt, water pump etc all on my own :rolleyes: Picking up lots of new skills, just from getting in there and doing it, then asking the forum when it goes wrong :o

Progress

* Head painted black
* 10mm Formula Power Blue HT leads
* Heat wrapped raceland manifold
* Magnex Single 3in tailpipe Decat exhaust fitted
* New door fitted
* Minilites on a 106 :)

http://www.106rallyeforum.com/gallery/data//500/bay2.jpg
http://www.106rallyeforum.com/gallery/data//500/bay.jpg

Also a photo of my new wheels, awaiting fitment :)

http://i6.ebayimg.com/03/i/000/e5/6c/2289_1.JPG


Busy with uni work currently, but cant wait for the summer months, have buckets seats etc ready to go :)

[Seph]

Great rescue project the bay is looking really tidy now.

One bit of constructive criticism, get yourslef a better inudction kit, all that filter is doing is sucking hot air in.

[Quiksilver_TR]

Bay looking nice and tidy.

Wheels will be different!

[curl666]

Great rescue project the bay is looking really tidy now.

One bit of constructive criticism, get yourslef a better inudction kit, all that filter is doing is sucking hot air in.

Thanks yep car is getting to look much better now :)

As for the constructive crit - R6 bike carbs - summer project :) :p

[Seph]

Now your talking!

[curl666]

Updates

Spent the best part of the day fiddling with the xsi.

Power washed all 4 wheel arches, just to inspect for summer plans to paint/underseal. Passenger rear arch needs some attention, the rest did not look too bad!

Got the TSW's off cleaned those up ready to sell, and most importantly I trial fitted one of the minilite style alloys!

The wheels went on without any trouble, was a bit afraid that the centre of the alloy would need to be made larger. But they went on nicely, although I require some spacers, as on the rear they sit quite close to the inside arch, and on the front they are close to the strut!

The wheels are 14in x6JJ - didnt think the 6JJ meant anything different but on measuring they are near enough 7in wide??? Made in Austrailia? 5.6kg each :)

Few pics just to give you a rough idea

http://www.106rallyeforum.com/gallery/data//500/minilites003.jpg

http://www.106rallyeforum.com/gallery/data//500/minilites002.jpg

http://www.106rallyeforum.com/gallery/data//500/minilites001.jpg

Spacers and tyres next!

I also stripped most of the rear interior and if i get chance tomorrow will carry on with that, and fit the bucket seats!

[106_Andy]

did you tackle that headgasket with like no prior mechnical knowledge?

Thats some big respect from me if you did, was it hard, thinking about doing mine just not sure what or how badly i can **** it up...

[curl666]

106_Andy Re: My Black 1.6 8v Xsi aka Huwwy
did you tackle that headgasket with like no prior mechnical knowledge?

Thats some big respect from me if you did, was it hard, thinking about doing mine just not sure what or how badly i can **** it up...

Yeah i done the head gasket all on my own, with just the use of the haynes manual, and some cracking advice/help over on 106rallye.co.uk

I wouldn't say its tooo difficult, you just have to be confident in doing something, which you have never done before.

I labeled up every single pipe, switch, object, that had to be removed with some masking tape and wrote a quick description of where it went back on.

Also bought some boxes, with lots of lil compartments in which i place all the bolts etc and labeled them up, so for example one box for "cambelt cover bolts"

I had a few delays with ordering parts, rounded bolts, and a bastard water pump, plus i done it outside which meant i could only work on it when it was dry. So it did seem to take some time.

But now i've done it and if i had all the parts again, i would be confident i could do it in an day!

[curl666]

Well i've been hacked off with uni recently, so been working on the car as a stress cure :)


Stripped the car of all un-needed weight

Swapped my xsi interior for 2 bucket seats and harnesses

fitted the bucket seats

trial fit of the minilites with tyres


http://www.106rallyeforum.com/gallery/data//500/interior_stripped.jpg
http://www.106rallyeforum.com/gallery/data//500/interior_stripped2.jpg

On removal of the drivers seat and carpet, i found the front mounting panel to be damaged :(
So theres another job I have to do :) I have tidied it up a bit, but will still probably be picked up on MOT for insecure seat etc

http://www.106rallyeforum.com/gallery/data//500/interior_stripped3.jpg

The bucket seats are Corbeau Forza Sports, similar to the ones i purchased not so long ago, except these ones are FIA approved! The harnesses are Sparco 3 points.

http://www.106rallyeforum.com/gallery/data//500/buckets1.jpg

http://www.106rallyeforum.com/gallery/data//500/buckets2.jpg

http://www.106rallyeforum.com/gallery/data//500/buckets3.jpg

Minilites are 6J x 14in wrapped with Yoko A539's 185/50/14 - tyres set me back £240 including fitting, new valves and balanced up.

http://www.106rallyeforum.com/gallery/data//500/minilitesxsi.jpg

The minilites looked a lil lost with the car being at standard ride height and the low profile tyres, but it is probably exaggerated in the photo as the car is still jacked up!

Finish uni in the next 2 weeks or so for the summer holidays so plan to lower the car then, and get the wheels on!

which means the TSW volcanoes will be up for sale if anyone is interested

o and for you photographers out there, please excuse my dap exposures, and the extreme wide angle lens :)

[James]

looks sweet mate , soz i didnt beep the other day was in a world of my own didnt notice u waved lol , ive been meaning to stop but i only ever see u working on it when im on my way to work lol

[curl666]

Yeah i see your car nearly everyday day :)

Even recognise the exhaust note, and know that if i pop my head out of the window i will see your nana. Usually involves you slamming it across the estate! :D

Busy with uni work this week, but then break up for the summer, so will be playing with the xsi most of the time. Feel free to chat but one day, i will hear the note of your exhaust coming, start the xsi, and just as you pop over the brow of the hill im going to floor it across the estate!

[V6Jules]

them minilites look MINT :D

[James]

Yeah i see your car nearly everyday day :)

Even recognise the exhaust note, and know that if i pop my head out of the window i will see your nana. Usually involves you slamming it across the estate! :D

Busy with uni work this week, but then break up for the summer, so will be playing with the xsi most of the time. Feel free to chat but one day, i will hear the note of your exhaust coming, start the xsi, and just as you pop over the brow of the hill im going to floor it across the estate!

haha lol i cant help it heavy foot and that estate asks for it lol!

you better get that 8v breathing well then to catch me;) lol

[curl666]

haha lol i cant help it heavy foot and that estate asks for it lol!

you better get that 8v breathing well then to catch me;) lol

Hopefully bike carb it over the summer months :)

[James]

will be looking forward to that mate!! they sound amazing

[curl666]

Updates

Took the XSi for its first MOT since I have had it, and well like i expected it failed...



Registration Plate Lamps not working
Front position lamps incorrect colour (blue)
Nearside side repeater not working
Nearside rear fuel system component insecure
Offside front inner arch suspension component mounting excessively corroded
Both front lower ball joints
Exhaust emissions



So I have a lil more than I had expected to get on with, but there we go, I still love the lil bastard!

Only major jobs for me to do are some welding in the front arch and the 2 ball joints. I imagine the front had rusted, because when I got it there was no inner arch liner so it was thick with mud.

I have decided to completely strip the front suspension off the xsi, as this gives me the chance to fit my uprated shocks and springs, clean and paint the inner arches, replace any bushes with uprated items and will be easier to weld up the area needing attention.

http://www.106rallyeforum.com/gallery/data//500/frontsuspension.jpg

Drivers side inner arch - rusted area needs to be cut out and replaced

http://www.106rallyeforum.com/gallery/data//500/driversarch.jpg

Passenger Side arch before cleaning

http://www.106rallyeforum.com/gallery/data//500/passarch.jpg

Passenger Side Arch - cleaned, surface rust taken back to bare metal, all rust treated, and primed ready for gloss black top coat.

http://www.106rallyeforum.com/gallery/data//500/passarchnew.jpg

Primed all the way in and around the arch, right up into the suspension turret. Plan to replace the brakes and go for braided lines hence why I didnt mind getting a lil paint on them!

The XSi looked the best ever on the way to the MOT, now its a lil rough. But slowly getting there!

[Seph]

Absolutely fantastic work this mate.

Great little resurrection.

[mellowyellow]

Great stuff

Love those Minilite wheels :D

[JonB]

looks sweet as pal

but tut tut not checking the lights ;)

[curl666]

Thanks for the comments guys...

As for not checking the lights, completely forgot about the rear number plate ones, and set about changing the bulbs, cleaning up the connections, but still nothing working!

Decided to remove the rear bumper to find where the wiring entered the car, I have the connection from the lights, but there is nothing on the inside of the car for it to connect to! Weird!!!

[Steffrallye]

looks good lad, need to get on with my rust work really lol

[Andy XSi]

Loving the minilights hats off to ya

[curl666]

Updates

Well i finally made some progress, after a mixture of shit weather and a throat infection keeping me in doors!

Wishbones Rebuilt



Cleaned and painted - Black
New Ball joints
New Polyrace Middle Wishbone bushes
New Solid Rear wishbone mounts



http://www.106rallyeforum.com/gallery/data//500/wishbones.jpg

Struts rebuilt



Cleaned and painted - Slate Grey
Spax PSX Shocks
New Bump Stops
-35mm Ventura Springs (come with bilstein kit)
New droplinks



http://www.106rallyeforum.com/gallery/data//500/struts.jpg

The passenger inner arch has been painted gloss black, happy with the finish, hopefully prolong the life of my XSi shell! I have partially fitted the passenger side wishbone and strut, but on hold as I believe my driveshaft is knackered and I found my ball joint pinch bolts to be bent!

Other parts ready to be fitted:



22mm S1 Rallye ARB with Powerflex Bushes
CAT for MOT :)
SRD fibreglass bonnet
Bonnet Pins
Minilites
OMP steering wheel
OMP lower Strut Brace



http://www.106rallyeforum.com/gallery/data//500/pins.jpg

I spotted these R6 bike carbs on ebay, and couldn't resist they look in very good condition. So decided to start my Bike Carb'd PH4 newmans build :) Picked them up for £54!

Aim to do as much of it as I possibly can including attempting to make my own inlet manifold, just a learning experience.

Bought from RR member - h0wudo1n

http://i14.ebayimg.com/07/i/000/fd/9b/05bf_1.JPG

TAX runs up end of July so must get it MOT'd ASAP!

[JonB]

coming on nicely bud same bottom arms as me ;)

[curl666]

coming on nicely bud same bottom arms as me ;)

Thanks!

Have you got you bottom arms fitted to the car yet? If so did you notice an improvement?

[JonB]

not yet, i still havent fitted my engine yet :o

drove my mates car when they were fitted and they felt really good :D

[curl666]

Here goes:

I had been waiting a week for a set of spacers to show up so I could fit the minilites, only to receive a phone call saying they had been lost in the post. I needed a set of wheels ASAP and spotted a set of Fondmetal alloys on ebay.

The description of the wheels was limited to say the least "Fondmetal Alloys - RARE - 4 tyres", with no clue as to what car they fitted.

I stuck a bid in of £51 thinking id take the risk as they were 4 stud, went away for the weekend and come back to an invoice from the seller saying I had won them for £46. Only after the auction I found out they were removed from a Pug 205.

Well my dad kindly offered to pick them up whilst I was working today, and I believe they are an EXTREME BARGAIN! They are in very good condition, with only 1 mark worth mentioning, they come with 4 nearly new tyres, and appear to be in the original polished metal finish.

LOVE EBAY SOMETIMES!

http://www.106rallyeforum.com/gallery/data//500/fondmetal4000.jpg

http://www.106rallyeforum.com/gallery/data//500/fondmetalLIP.jpg

http://www.106rallyeforum.com/gallery/data//500/fondmetallogo.jpg

The camera flash makes them shine a lil more than in the flesh, but they just need a good metal polish and not a bad set of wheels as a spare set :)

When i rake some cash together, I will get them refurbished either standard white or gold

Wheels - 15in 7J
Tyres 195/50/15


Got the wheels cleaned up and fitted this afternoon:

They are sitting perfectly, look awesome in the flesh!

http://www.106rallyeforum.com/gallery/data//500/fond004.jpg

http://www.106rallyeforum.com/gallery/data//500/fond003.jpg

http://www.106rallyeforum.com/gallery/data//500/fond002.jpg

http://www.106rallyeforum.com/gallery/data//500/Fond001.jpg

[Kemixx]

Wow! That was a right bargain!

[chiddy0407]

sell them to me! now!

i love them, how can they be a second set of wheels? lol

[Loz]

Wow they look awesome!

[curl666]

How much would you pay for them Chiddy?

Seen your car recently in PFC mag, looked good!

[chiddy0407]

well, i know what you paid, so a fiver more lol

[curl666]

I finally got around to spraying my new rocker cover, after I over tightened the silver one and damaged it. The new one had been fitted to the car for some time in primer, and has been on the to do list for a while.

So yesterday I decided to strip it back to bare metal, primer, colour and a coat of clear. Quite pleased with how it turned out, although I fooked up the clear and have some runs on the back n front edge.

http://www.106rallyeforum.com/gallery/data//500/rocker2.jpg

http://www.106rallyeforum.com/gallery/data//500/rocker.jpg

[JonB]

looks sweet shame the ht leads arent red tho

[curl666]

Thought it was about time I got on with the XSi, I've been back in uni/out getting smashed the past few weeks and with it being cheaper to use the train the XSi has just been sitting there...

Today I finally got around to chopping the dash up, was quite shocked how much weight came off it!

Started a few jobs ready to get the gearbox off, which will be on Saturday now.

http://www.106rallyeforum.com/gallery/data//500/DSC_7080.jpg

http://www.106rallyeforum.com/gallery/data//500/DSC_7076.jpg

http://www.106rallyeforum.com/gallery/data//500/DSC_7085.jpg

Slowly collecting the parts up required for bike carb n cam project, but I've decided to get it as light as possible, with uprated brakes and suspension before i search for more power.

[qwerty]

If you wanna sell the wheels let me know!

Car looks spigging awesome! Brilliant progress and Kudos to you for tackling stuff yourself.

Picking my S2 XS up soon and decided to try and do as much work as possible myself. Even bought a bus pass for when it all goes wrong!

[Marshall]

those rims are sweeeeeeeet

[Stealth106]

looking good mate.....glad its all coming together....

personally would lose the saxo spoiler off the rear think will give it the more mint look you seem to be going for ;)

[Stiney106XT]

This is awesome progress mate! Makes me wanna go get mine finished. Love how it's all done on a students budget too.

[jamesDpug106]

i want those wheels :(

[curl666]

Thanks for the comments guys :)

I'm undecided as to remove the saxo spoiler, i quite like the way it looks, but I think the previous owner must have had it professionally sprayed at 1st, then has tried to spray over some scratches or damage, as there is a small patch which looks like its been sprayed in the dark :)

[Stiney106XT]

lol, mines being resprayed as we speak! I really want to get mine lowered with a sports exhaust and 4-2-1 manifold, just waiting on pay day now. What have you got planned next for your lil beast?

[Stiney106XT]

Where did you get those HT leads from? As I'm after an upgrade for mine.

[curl666]

Hey,

Plans for the next few weeks:

Spray interior black
Fit carbon door cards
Remove as much weight as possible


I have a few parts laying about, need to get the decat back on, set of Koni rear shocks and a fibreglass bonnet ready to fit.

Bought the HT leads from a guy on the rallye register, they are made by Formula Power. £35

[curl666]

Updates

Spent about an hour cleaning my new set of Rallye steels, before fitting them to the XSi. The wheels set me back £64 off Kiwi inc centre caps and 16bolts using a 20% ebay voucher :) Also mr Bowya picked them up £10 :)

Cant complain, 4 decent tyres, wheels cleaned up nicely, caps and bolts!

http://www.106rallyeforum.com/gallery/data//500/tn_DSCF0151.jpg

http://www.106rallyeforum.com/gallery/data//500/tn_DSCF0153.jpg

http://www.106rallyeforum.com/gallery/data//500/tn_DSCF0156.jpg

http://www.106rallyeforum.com/gallery/data//500/tn_DSCF0159.jpg

Also took a photo of the suspension and wheel arches which i refurbed but did not get a photograph of :

http://www.106rallyeforum.com/gallery/data//500/tn_DSCF0147.jpg

The fondmetals are currently sitting in the garage, I plan on having a go at refurbishing them using various drill attachments and metal polishes. If funds allow I will take them to a professional.

[10six]

look well an well done on tackling all this work yourself will be shweet when the car is finished

[str18]

really good thread going mate! some great progress and work! can I ask where you got those HT leads and how much you paid for them?

[curl666]

really good thread going mate! some great progress and work! can I ask where you got those HT leads and how much you paid for them?


Thanks guys :)

The HT Leads were purchased from a member off the Rallye register. They cost me £35.

They are made by Formula Power, who I would imagine you will find if you google.

[curl666]

Please add a huge key mark to that last photo, after some prick decided to key my car front to back :(

[curl666]

Updates

I picked up a 5th rallye steel which was in major need of a refurb, to use as my spare wheel which will be bolted down in the boot. £10 for the steelie on a budget refurb :)

* Drill & Wire Brush to clean wheel
* Various grades of wet n dry
* Kurust treatment
* High Build Primer
* Awaiting gloss white top coat

To save me paying a tyre shop to remove the tyre, i took to it with a knife, turned out alot harder than i thought with all the steel banding inside the tyre but saved a few £££ :D

http://www.106rallyeforum.com/gallery/data//500/steelie2.jpg
http://www.106rallyeforum.com/gallery/data//500/Steelie.jpg

(apologies for poor quality, but its not the most interesting topic anyway)

Received my GRP N engine mounts, so I have those ready to fit :)

And also found another black XSi breaking for spares and got a good deal on the following parts, which will be kept for spares but fitting the drivers wing and door this week :)

* Front and Rear Bumper
* Drivers n Passenger Doors
* Drivers front wing
* Xsi spoiler
* Black Xsi petrol cap

£100 :)

I plan on cutting up the bumpers to get out some Kg's

[chiddy0407]

cut a tyre off to save cash, legend

[curl666]

chiddy0407 Re: My Black 1.6 8v Xsi aka Huwwy
cut a tyre off to save cash, legend

Yeah, tyre shop is just across the road too if you remember :)

Started off with a plaster board knife, which I would recommend, until I got to the steel wires inside the tyre. So I took an angle grinder to a tyre :rolleyes:

[curl666]

After spotting a set of fibreglass bucket seats on ebay for a good price, I put the Corbeau's and subframes up for sale. I put a few quid towards these new lightweight babies:

http://i11.ebayimg.com/07/i/001/03/90/05c0_1.JPG

Weigh in at 3kg a seat :)

Yes I aim to make public transport more comfortable than my car! :)

[Matt_R]

Just had a read of it all, nice progress!
Really need to get started on mine.

Love the fondmetals and the idea of cutting bumpers to save weight!!

Keep up the nice work!

[curl666]

http://www.106rallyeforum.com/gallery/data//500/paint.jpg

Today I sanded down the primer, cleaned and de-greased the areas I'm painting, and got busy with a rattle can or 2. Doesnt look too bad, although hoping I can get a more glossy finish, as it is drying matt.

I will sand down any imperfections tomorrow, maybe another coat, and then I can refit the interior loom and dash.

[Andy XSi]

If you spray on lacquer you will get a really nice wet look shiny finish, and will also protect the paint

[Crooksey]

I remember doing this to mine.

My snot was red for ages.

[curl666]

Front and Rear Bumper Diet :)

Another job off the to do list, removed both front and rear bumpers and chopped out all the un-needed plastics behind. Every lil gram helps :)

Got quite a bit of weight out of the front bumper, it feels lighter. Theres 2 metal plates behind the bumper for the fog lights, so they are out. Also trial fitted my rallye vents, now I have cut out all behind ready to fit them.

http://www.106rallyeforum.com/gallery/data//500/lightweight_bumper4.jpg

http://www.106rallyeforum.com/gallery/data//500/lightweight_bumper2.jpg

[alanandlexie]

ooh - what have ya done with the fogs?

My drivers side arch has the exact same rust spot, must be curse of the french eh!

[curl666]

ooh - what have ya done with the fogs?

My drivers side arch has the exact same rust spot, must be curse of the french eh!

Sold the fog lights a while ago!

Yeah it seems like the water/dirt gets soaked into the bulkhead sound deadening material. Its just sitting there over time all wet, so its bound to rust.

Teaching myself to weld, so I can fix her up myself next time without having to pay someone else.

[106nath]

great progress, loving this blog u must have some big confidence in those jobs u have undertaken m8 well done

[curl666]

http://www.kamracing.co.uk/images/AB105P182.jpg

Took the plunge and ordered an OMP 10 point bolt in. Will be nice once its arrived.

[curl666]

Pick n Mix engine removed:

Have a fair bit of uni work on the go, so have to balance the xsi with uni work and a job. Decided to whip the 8v out today ready for the new engine. Which I should be picking up on the weekend.

I took the engine apart bit by bit, just to make it as light as possible to drop out. So removed starter, alternator, head, loom ecu etc etc, then with help of a friend I lowered the bottom end onto a car crawler and wheeled the engine out through a gap in the drivers wheel arch :)

http://www.106rallyeforum.com/gallery/data//500/engine_bay.jpg

[DanMac]

fair play mate. major respect for taking all that on by yourself. good luck with the project. looks awesome!

[curl666]

Ebay strikes again...

Sadly the engine I was going to buy turned out to have a slipped timing belt, so I needed an engine and needed it quickly. Time for a bit of ebay action.

http://i20.ebayimg.com/05/i/001/25/7f/df05_1.JPG

Complete GTi/Vts engine with 70,000 miles includes the following:

Full engine and all associated parts.

Gearbox

Drive shafts

Front suspension struts complete with disks and calipers

Wiring loom (still attached to engine all wires that need to be connected to car labeled)

Full interior wiring loom

Fuel tank and fuel pump

Unlocked Ecu

Down pipe

Price less than £300 :)

Plus I've sold the xsi head, raceland, ht leads for £150. So far the conversion has cost <£150 when taking into account selling the 8v bits. :)

I couldn't take the ebay suspense!

[Bullock106xsi]

good buy mate hope the engine is all in working order! love this progress blog

[Crooksey]

Great buy, all though I am always wary of deals like that, hope it turns out allright for you.

Plus cant belive you went 16v, the engine you were going to buy of me has now been rebuilt and ready to drop into my XSi, its a monster.

[curl666]

Great buy, all though I am always wary of deals like that, hope it turns out allright for you.

Plus cant belive you went 16v, the engine you were going to buy of me has now been rebuilt and ready to drop into my XSi, its a monster.

Yeah it does seem like a very good deal, got it on ebay.

I have talked to the seller numerous times, as he had everything for sale previously on ebay but another auction. The guy runs a scrap yard. He seemed a decent guy and offered to fit and get it up and running, so he must be confident about the engine.

Yeah I was against the 16v's and even bought a spare XSi head to build up. But with the setup costs on the rollers, it worked out around the same as a GTi conversion. So I thought id opt for the gti lump, as I had found one locally. The only nice 8v id found was 200+ miles away in kent

[curl666]

Started degreasing the engine bay ready for some rust removal and a DIY spray job. I got a bit bored of that, so had a go at fitting the fibreglass bonnet.

http://www.106rallyeforum.com/gallery/data//500/fibreglass_bonnet.jpg

Its sitting on there nicely, just need to fiddle to get it at the correct height etc and then job done. :D

[Bullock106xsi]

cant wait to see the finished article mate its coming along nicely. found much rust in the engine bay?

[curl666]

cant wait to see the finished article mate its coming along nicely. found much rust in the engine bay?

There is no major rust, so should just be able to grind down to bare metal and a lick of paint etc. Just so much damn uni work on the go, not much time to spend on it!

[Bullock106xsi]

There is no major rust, so should just be able to grind down to bare metal and a lick of paint etc. Just so much damn uni work on the go, not much time to spend on it!

mate i know the feeling. i want to get some work done on mine but its my daily runner and used for work. thinking about getting a shed to run into the ground while mine gets some proper work done on it. good to hear theres no major rust either.

[curl666]

Mini Update:

Removed most of the gubbins up front, inc headlights, radiator, bumper etc, ready for easier access for 16v conversion. Also continued cleaning the engine bay down ready to respray.

Found the ride height rather amusing with it back on 4 wheels and no engine :)

http://www.106rallyeforum.com/gallery/data//500/ride_height_.jpg

Poor lil xsi - 16v conversion underway

http://www.106rallyeforum.com/gallery/data//500/poor_xsi.jpg