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[car_restoration] Matts Standard 1.9 Lazer


100 replies to this topic

#1
m@ttc

m@ttc
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  • Location:Rowley Regis, Westmidlands
ok so i thought id get round and start a topic since i have done quite a bit on the car now and i cannot see me finishing soon. what started as a quick overall to get the car back on the road has seen the car off the road for the past 2 years, in that time i have done :-

complete rear beam refurbish new bearings, seals, trailing arms etc painted to look pretty
ditch the 16 inch alloys and refurb some original 1.9 alloys (rattle can's in shed) which have come up really good
4 new tyres, falken ziex ze912, (seem to get good fedback on the furum)
head gasket changed for an oe one, cam belt changed and water pump, valve tappets shimmed, headbolts new, new seal on cam cover came in kit with headgasket also in kit inlet manifold gaskets, exhaust manifold gasket, and valve stem seals
valves re-ground to the cylinder head
big bore zorst put in bin and a new back box from the stealers (imported from france for me) new exhaust rubers
new engine mounts from auto five
new dizzy, leads, ignition amp, vacume advance, spark plugs
coil and tacy relay changed for known good ones
exhaust manifold weldeld in usual spot the surface ground back the sittng face level
new oil n water/ ecu temp sensors
dash lights changed blown bulbs
alternator belt
original clarion stereo off ebay wired in
injectors refurbed by mad professor
exhaust gasket between maifold and down pipe new spings and bolts fitted
new gear selecter rods from stealers and lever ball on subframe
sad tested working fine
changed fuse board

theres probably a lot more but thats all i can think of for now

so now im at a stage where i had a problem with the starter not engaging properly with the fly wheel after checking all the common problems that normal occur with this and getting nowhere, i decided to drop the box to see what was going on which has seemed to escalade into another mountain of jobs to get through, see i seem to think whilst its off i might as well:-

refresh the front suspention
drive shafts
crank shaft seals
fix broken stud in gear box housing for the oil filter mounting
get a new oil filter housing thingy (thanks marksorrento205)
fix the brocken stud in the block for the gearbox mounting (only held on with 3 bolts)
refurb brake calipers with new piping etc

then ithink to myself whist it stripped this much i might as well get the engine out and sort out some of the rust issues in the bay ive had a decent shell in the shed for a while, just a base model from the scrap yard

so the engine bays al stripped and ive started to do something with the rust whilst doing every thing else at the same time so ill stop rambling heres some random pics

http://i1034.photobu...ct/P1010392.jpg
http://i1034.photobu...ct/P1010012.jpg
http://i1034.photobu...ct/P1010432.jpg
http://i1034.photobu...ct/P1010512.jpg
http://i1034.photobu...ct/P1010407.jpg
http://i1034.photobu...ct/P1010406.jpg
http://i1034.photobu...ct/P1000414.jpg
http://i1034.photobu...ct/P1020043.jpg
http://i1034.photobu...ct/P1000969.jpg
http://i1034.photobu...ct/P1000965.jpg

there's loads more but there on the laptop and its got a virus :ph34r: ill sort em later if you like or put em in an album and post the link

ok so this is what ive been upto today

here she is
http://i1034.photobu...ct/P1020093.jpg
drivers headlight panel removed no need to have gone poking with a screw driver on this one, funny thing is the part number stickers on the back how does paper last longer than steel? :blink:
http://i1034.photobu...ct/P1020113.jpg
http://i1034.photobu...ct/P1020118.jpg
think ive gotta remove a bit more still
http://i1034.photobu...ct/P1020114.jpg
drilled off back mud guard panel
http://i1034.photobu...ct/P1020117.jpg
drilled off good panel from doner
http://i1034.photobu...ct/P1020119.jpg
removed seam sealer from this area dunno why just had a gut fealing too, glad i did found this
http://i1034.photobu...ct/P1020116.jpg

ok first question can any body tell me exactly what the different layers of material are in this image in order i want to try and recreate it when i come to it
http://i1034.photobu...ct/P1020120.jpg
the first coat on the bare metal seams to be two differnt colors here
http://i1034.photobu...ct/P1020121.jpg

Edited by m@ttc, 09 September 2012 - 07:18 PM.


#2
vtifan

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looks a good base mate,love the colour,if you are going to do it do it right,looks like you are doing a proper job on her :)

#3
m@ttc

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  • Location:Rowley Regis, Westmidlands
little update. been cutting out some rust in the bay, im gonna do the right hand side first then tackle the left heres the pics.
http://i1034.photobu...ct/P1020131.jpg
had to remove the engine mount to get this bit out
http://i1034.photobu...ct/P1020128.jpg
little rust between the panels on the engine mount wouldn't have known it was there, if i hadn't of taken it off.
http://i1034.photobu...ct/P1020124.jpg
http://i1034.photobu...ct/P1020125.jpg
ive been using a draper type dremmel thing to get to hard to reach places/precision grinding :lol:
http://i1034.photobu...ct/P1020122.jpg
thing is the cutting disks are really weak gone through 10 on 2 inch of grinding, need to see if i can get stronger disk's from some where.
the red paint in the pictures is some holts top coat, i dunno if this is ok to use? just wanted to protect the bare metal until i get back to it.
also need to do something with this but not sure what yet
http://i1034.photobu...ct/P1020129.jpg
dont know wether to cut it out and put a better strut piece in? seems a bit advanced for me dont want the front wheels out or anything, probably just grind it back and paint.

thats pretty much it so far although ive done some welding on the gear box ,i dont get chance to play in the bay in the week. So in the week this week i plan on tarting up the brake servo so hope fully that will be nice and shiney next week, i only plan on removing the rust and hammerite it, hope it looks ok when im done.

Edited by m@ttc, 16 September 2012 - 07:42 PM.


#4
m@ttc

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ok little update, managed to get some reinforced cutting disks for the dremmel something like 2.50 for 20 disks there great for awkward areas dont get much cutting out of little disks thou. 1 disk does this much
Attached File  1348286868805.jpg   15.96KB   1 downloads
also got some mini steel wheels for it great for removing rust in between panels
also managed to paint the brake servo
Attached File  1348205887417.jpg   12.53KB   4 downloads
decided against black and try to match its original colour, i went for ral 6003 olive green

well the engine bay looks the same as last time, the welder i had planed to use i brought off ebay, just isn't up to the job so iv'e ordered a new one, so im waiting for that to arrive at the moment
in the meantime ive been cutting metal of the bits in the shed
Attached File  1348919167251.jpg   20.48KB   0 downloads shell from scrap yardAttached File  1348919195428.jpg   17.64KB   3 downloads
rusty bits and not so rusty bits
Attached File  1348921445103.jpg   21.01KB   5 downloads
also been shopping and brought this
Attached File  1349006432286.jpg   13.77KB   5 downloads

thats it for the body so far, as the cars outside and the nights are drawing in this may have to wait a bit or be a little slower progressing as id have liked. There's lots of other things to be getting on with on this car so ill still be busy over winter months

got my oil filter housing off marksorronto welded, then with the gearbox the mounting hole was fubard so i drilled and tapped in some ally althread and welded it in place. then had the suface's machined level
Attached File  1347874516963.jpg   18.4KB   5 downloads
checking flatness with eng blue
Attached File  1348472326988.jpg   17.6KB   2 downloads
all i need now are the 7mm pins that mount it to the gearbox

thats it for now, i need to get a new window wiper mech and suspention mounts bearings and rubbers mine look like this
wiper mech (a little worn out)Attached File  1348459330549.jpg   9.56KB   4 downloads
and these bits hopefully they all come in the kit

Attached Files



#5
Tom Fenton

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The suspension top mount kit usually comes only with the rubber donut and the bearing. You have to re use all the other bits. I have blasted mine and then had them plated to make them look nice rather than the usual crusty finish.

#6
m@ttc

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The suspension top mount kit usually comes only with the rubber donut and the bearing. You have to re use all the other bits. I have blasted mine and then had them plated to make them look nice rather than the usual crusty finish.

I've thought I may have to take this route. What finish did y
ou have them plated Tom?

#7
cybernck

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Is that a genuine headlights panel?

#8
m@ttc

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Is that a genuine headlights panel?

no its not :( i brought it from imperial automotive, hoping it'll be an hadriens panel but turned out to be rhibo??
Attached File  1348732802578.jpg   13.19KB   1 downloads
each individual pressed panel look great but the assembly of them isn't looks like it might need a little tweeking to fit properly but we'll see

#9
cybernck

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Oh well. How much was it and do they have inner wing panels too? Sorry for the slight off topic :).

#10
GLPoomobile

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The suspension top mount kit usually comes only with the rubber donut and the bearing. You have to re use all the other bits.


Peugeot used to do a complete kit with everything. Dunno if they still do as I've not been on Servicebox for about 2 years. Probably NFP by now :(

#11
Tom Fenton

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Certainly worth looking to see if the Peugeot kit is still. Available, I must admit I didn't look at that option.
I had my bits done in yellow passivate as I think it looks smart, one thing I struggled to find was info on what finish the visible strut top bits would have been from new? Certainly looking at the concours and show and shine cars at Pugfest there were some in silver plating, some painted silver some painted black.

Here's a pic of my bits, with the other stuff I had done at the same time. I still need to have some spring top pans done.
Posted Image

#12
m@ttc

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Oh well. How much was it and do they have inner wing panels too? Sorry for the slight off topic :).

it was £107.81, it dont look like they have inner wing panels but they have front wing panels £70.49 heres the link
http://www.crashrepa...panels?_ts=1870

#13
m@ttc

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the kits are still available from peugeot, the large kit includes a spring but they show NFP for the spring seperate, but does come with the bearings which i need. The smaller kit dont come with the bearings and it dont show you if you can buy the bearings seperatly :( . Im gonna give them a ring next week and see what i can get. Spring top pans dont come in any kit and they dont appear to have an part number, but im gonna see if i can get the place next door to my works to hot dip galv them for me :)

#14
Tom Fenton

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You can buy a decent SKF kit which comes with the bearing and the rubber donut.

#15
m@ttc

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You can buy a decent SKF kit which comes with the bearing and the rubber donut.

cool where can i get this magical item?? :)

#16
Tom Fenton

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Truth be told I got mine second hand/unused from Craig on here, I am sure he can advise where to source.

#17
m@ttc

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ok , update time ive been shopping at peugeot brought two new top mount kits

 

Attached File  IMG_20121216_103701.jpg   49.66KB   8 downloads

doesn't come with a spring but does come with a galvenised top pan, so no need to get my old one done now  :)

 

also brought new wiper mech kit

Attached File  IMG_20121214_161445.jpg   32.74KB   8 downloads

 

ive started to refresh the sub frame some pics

Attached File  1353521111226.jpg   15.05KB   5 downloads

this took ages to get this clean, high pressure steam cleaner, hot jet wash, sand blasted, rust treated and wire wheel'd until i was happy with it.

 

etch primed

Attached File  1353569506309.jpg   12.56KB   1 downloads

 

and painted, I decided to use hammerite smooth out the tin, i used a paint roller and put two too three coats on, and a last coat of the same paint out of a spray can and im quite happy with the result.

Attached File  1354290737377.jpg   17.25KB   0 downloads

 

some blasted parts

Attached File  IMG_20121205_172509.jpg   32.96KB   2 downloads

 

some gold parts again hammerite gold smooth spray can paint

Attached File  IMG_20121214_163057.jpg   35.72KB   2 downloads

dunno if i should have done the heat sheild in that paint? But its done now i wonder if a coat of clear VHT on top might help?

 

ive stripped the rack down to change the internal bush, but since doing this i have learnt the bush is different in pas racks and are not available to buy seperately :(

heres the bush

Attached File  1353085004412.jpg   13.12KB   2 downloads

ive decided to make one myself, i got the plain bearing for 92p and gonna turn a new housing on a lathe at work, also ive made a tool so i can press the ends over after to keep the bush in place, thats the plan anyway :lol:

 


Edited by m@ttc, 16 December 2012 - 11:19 AM.


#18
m@ttc

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update continued.....

 

ive been tarting up the gear box

 

Attached File  1350104578994.jpg   20.77KB   0 downloads

 

its had a new 

clutch housing plug (pt no 212143)

gear box breather (forgot pt no)

primary shaft seal and guide bush (210535)

yellow bushes (217514 + 217622)

 

ive removed and painted the end cover there was a little surface rust inside which is now gone so im glad i done that, reasealed the diff housing with rtv silicon as that had a little leak on it. And a little bit of welding to one of the mounting holes as it had split the casing. and a bloody good clean as it was filthy :lol:

Attached File  IMG_20121216_193627.jpg   45.21KB   0 downloads

 

i think thats all i can do without stripping it, it was fine before so im not going to bother.

 

ive changed the lower engine mount bush too

Attached File  1353410404266.jpg   13.45KB   0 downloads

this is the best method to remove i find a lot less toxic and quicker than burning it out.

 

new bush fitted (pt no 180904)

Attached File  IMG_20121214_113120.jpg   27.91KB   0 downloads

 

this is the only eng mount not availble from auto five so i got it from pug

 

have auto five stopped trading??? i wanted loads more stuff from them so its a shame if they have. :(

 

 



#19
cybernck

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Yes, it seems they have.



#20
dcc

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I just hammer the bush out - a firm tap does the trick.





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