Offside Inner Front Arch

Posted: 26th March 2017 by asteriskr in 106 Rallye S1 16v
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So I looked at the offside front inner arch and knew that I couldn’t just leave it as it was. It wasn’t just the aesthetics, it looked structurally bad.

OSF Inner Arch

A little love from some 1mm cutting discs and we’re off…

OSF Inner Arch

Ermmm, there’s three layers of metal where the 16v engine mount has been added on when there should only be two.

OSF Inner Arch

That’d be that extra plate that was welded on then…

OSF Inner Arch

I’m seeing daylight through holes that shouldn’t be there and the bit around the grommet hole (particularly below it) is very ropey. Looks like I’ll be doing some more cutting and making a bigger repair patch…

Bonnet and Battery Tray

Posted: 19th March 2017 by asteriskr in 106 Rallye S1 16v
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Bonnet mod is finished:

Bonnet Mod

The other job was tidying up the battery tray which had been chopped and was bent outta shape. This is after I put a big adjustable spanner on it and got it pretty much straight:

Battery Tray

Bit of 1.5mm zintec and some shaping in a vice with a BFH, welded, finished and final shaping and it’s done. Another small job off the list.

Battery Tray

Rallye Progress

Posted: 17th March 2017 by asteriskr in 106 Rallye S1 8v
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All builds have some degree of ‘acquiring parts’ involved. Mine is no exception.

I now have a full exhaust system thanks to Neb’s mate selling this Janspeed 16v manifold and Mark Yates of 106 Parts doing me a stellar deal on a full 2″ Scorpion Pugsport with the motorsport cat. The manifold might be inline for some ceramic coating in the future, but that’s not a priority.

Manifold

I also picked up a pair of Sparco buckets before Christmas and in the New Year sales managed to get a pair of side mounts for them. There’s some decisions to be made about the interior and how the seats are going to me mounted to go back in, but that’s quite low on the priority list and will have to wait. It’s looking like the tunnel being modded as per my S2 and new seat bars going in.

Aside from a few bits of trim, next on the list are polybushes all round and then I can get the front end built back up. After that it’s a rear beam refurb. As always the availability of funds limits progress on the parts front, but the big thing now is time – making forwards progress on the shell is about having some availability to do so.

Seeing as work around the house and garden shedding means the garage workshop now has a bench top work surface I can see and use for the first time in 9 months it’s time to crack on with the car again. So out with the angle grinders and spark up the MIG, let’s get back to it!

As part of fitting Colin Satchell’s strut brace, there’s a need to mod the inner skin on a standard bonnet to clear the brace. The thing is that by the time you do that the end result has weakened the structure and if your effort is anything like mine it will look gash. So I’m working on tidying that up and putting a bit of strength back in.

Roughed out
bonnet Mods

Fabrication in progress
bonnet Mods

bonnet Mods

bonnet Mods

Coilovers Finally Finished

Posted: 27th October 2016 by asteriskr in 106 Rallye S1 16v
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Finally bought some new bits from Baker BM. They’ve tweaked the engine mount design since I bought one of the early ones. Looking forward to getting this fitted, but it needs some work on the car first.

Parts

Parts

To sort out the front struts, I opted for the fixed spherical bearing top mounts:

Parts

I then needed some new 2.25″ coil spring top caps which I drilled out to 12mm.

Parts

Consulted the hive mind over at the MIG-Welding forum and found an amazing new-to-me precision engineers in Liverpool and had the Bilstein B8s machined to lower the shoulder and give more threads for the fixing nut.

Parts

Fitted it all together, so nearly there on these legs now. May look at getting some helper springs. Also need to modify the steering arms on the legs to take Tommy’s rose jointed arms. Bought some rubber gaiters for the rose joints to keep those running smoother for longer.

Parts

Parts

Have done a bit more on the shell, but only putting in 30 minutes here and there.

Patching

Posted: 22nd October 2016 by asteriskr in 106 Rallye S1 16v
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Big hole patch done, will need a little bit of filler before final painting.

Photo

Smaller hole in the inner wing (same side of the car)

Photo

Cut out and replacement made last weekend and welded in tonight.

Photo

Progress is slow at 30 minutes here or there but is moving forward.