Siert
Posted a lot
Posts: 1,104
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Nov 15, 2009 12:01:58 GMT
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I thought I'd start a thread here on my 309 as I guess the way things are turning out it somehow fits here better all the time... So I bought it shortly after I moved to Finland as a standard 309 1.6 on a carburator with 300.000km (thats 187k miles) on the clock and I think the tires were the only reasonable thing about it The steering and suspension were particularly awful. Early jobs outside my home included: Rebuilding the steering rack, replacing wishbone bushes with new standard ones, replacing radiator with one from a Citroën BX, replacing brake master cilinder, and so on... Then I saw this Autoslalom movie from 2007 on youtube: I google'd what kind of event this was and found that it was being organized the week after that. So I signed up. A good idea with non-working rear suspension (seized axle) and no idea whatsoever about any form of motorsports. But it was fun. Desperately trying to improve the car as much as I could without a workshop I got myself into trouble: A bolt holding the hub carrier to the shock broke. To cut a long story short, through the autoslalom people I got in touch with the students car club on our campus (I'm a postgraduate student myself) and they helped me out. So now I was a car club member, which opened new possibilities... In the workshop I continued; first I binned the carpet that was completely soaked in rainwater, I fixed some rust on the sills, and most importantly rebuild a rear axle, my own one was beyond repair. Got the settings all wrong... (yes, that's wrong in my book) Got some 309 GTi lowering springs and second hand 306 Break shocks (a car 1.5 times the weight of mine). Happy with this ride height As it needed to go faster I added stripes :-) Put some 14" 205 rims on it. I find it much easier to improve the car than to improve my driving :-) The most recent improvement has been a 22mm rear anti-roll bar instead of the 16mm that I was running (standard 14mm) which has finally made it possible to keep the throttle on while cornering And this is as it stands now, the really crappy engine has finally been removed. This 1.6 GTi engine will replace it. Its essentially the same engine as the original one, only its all alloy and has different cam&crank etc... It spend some time in a 405 on a carburattor hence the mechanical fuel pump. I'm probably also going to get it running on my old carburettor first. I bought the engine without the injection system, but have now stripped everything I need from a BX 1.6 GTi (yes they had those in Finland). The Bosch L-jettronic isn't very complicated but it will still be quite a job to do all the wiring.
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Last Edit: May 5, 2013 13:58:59 GMT by Siert
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Nov 15, 2009 14:13:01 GMT
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Nice car, i've allways liked the 309. You don't see many 1.6 ones here though, infact i think i've only seen one before.
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Earth Rocker
Part of things
Among the living.....Just!!!
Posts: 215
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Nov 15, 2009 18:35:10 GMT
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OOOOOOOO, what the deal with the Saab, (SORRY I'LL GET MY COAT.)
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Nov 15, 2009 18:41:44 GMT
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Hallo Siert, I am jealous of you doing motorsport....
Look forward to the rest of the progress.
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Siert
Posted a lot
Posts: 1,104
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Nov 15, 2009 18:49:21 GMT
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OOOOOOOO, what the deal with the Saab, (SORRY I'LL GET MY COAT.) Haha, I was expecting somebody to ask about that... No need to get your coat, variety is what's so great about this forum! If I remember/understood it correctly the engine that just came out is a standard 8valve 2 litre (?) engine. It looks damn good on Aero rims even though it has different colour doors etcera. The car failed its inspection because of rust something like 2 years ago. It was still used during the two trackdays a year our carclub organizes. On the last trackday it ran on very bad tires, but it really flies in a straight line even with that old engine. We drove with 3 cars without anybody being noticebly faster on a lap for something like 5 laps in a row it was such fun especially as they were so different but yet so close on a lap (mine doesn't go in a straight line, but it goes around corners). - Saab - Swift GTi - Me with the 309 It's now getting a Turbo engine... and even though I'm also upgrading my engine I think that it means I will just be biting his dust in the future ;-) Here's a movie of our trackday featuring both cars!
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Last Edit: Nov 15, 2009 18:49:57 GMT by Siert
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Earth Rocker
Part of things
Among the living.....Just!!!
Posts: 215
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Nov 15, 2009 18:57:08 GMT
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Thanks, that video is mint, look on the Porsche driver face would be priceless to see an old Saab 900 on his tail, good cars, had mine a few years now.
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Siert
Posted a lot
Posts: 1,104
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Nov 15, 2009 19:07:24 GMT
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That white Porsche GT3 is extremely fast, but with a sensible driver. Nobody feels like getting in his way anyway. I think what you see there is the Saab just went aside to let the Porsche pass.
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Siert
Posted a lot
Posts: 1,104
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Nov 24, 2009 16:58:16 GMT
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Well the "new" engine and gearbox are in and for now they work well! ;D So now I have an all-alloy 1.6 GTi engine that for the moment is running on the carburettor I took of my old engine. It was all together pretty straightforward. All the unexpected surprises had to do with the gearbox which had different control- and clutch levers on so they had to be swapped over from the old box. The pin holding the old clutch lever and fork in place was stuck, and as it was difficult to work on as long as it was still fitted to the old box we decided to remove it as one piece and then take the pin out on a press or vice. So my friend took the honour of carefully removing it from the old cast iron box with that special tool he carries on his shoulder Which did the trick ;-) The biggest gearbox related surpise came when I finally had the engine running though. I sat in the car, pushed the gearlever to left-forward, released the clutch and... went backwards As I knew that Peugeot made so called BE1 and BE3 gearboxes which share the same casing, but not the same pattern I did realize immediately what had happened... It by the way has nothing to do with the different levers and clutch forks as it seems both types of levers were used on both types of boxes. It's a bit problematic as my gearlever doesn't have the release mechanism to engage reverse which I now find is really VERY convenient when reverse is left of first. It's kind of hard to find first now, and changing back from third to second also required some practice as the gearlever can go further left as second gear is... So I've got to get that sorted. After that: Fuel injection
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luckygti
Posted a lot
I need to try harder!
Posts: 4,912
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Nov 24, 2009 22:27:51 GMT
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Love it, I used to have a really nice 309 Gti a long time ago which had to go cos I ran out of money to keep it going! I think that's why I bought my 205! I think I'll eventually carb the 1.6 engine when I get round to it! Need to get the 1.9 that replaced it sorted first!! How did you find the rear axle rebuild? I keep putting it off (and the lowering) cos I is scared of mucking something up!
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Carlos
Part of things
Posts: 551
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Nice little project. Reminds me of my old 309 SRi (1.6i engine from 205 GTi) from a long time ago and I miss that car very much. Never seen another for sale - if it was I'd have it!
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Carl -------------------------------- 1992 Peugeot 205 GTi 2.0 16v 2004 Volvo V50 T5 --------------------------------
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Siert
Posted a lot
Posts: 1,104
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Nov 25, 2009 16:52:36 GMT
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How did you find the rear axle rebuild? I keep putting it off (and the lowering) cos I is scared of mucking something up! It's not an easy job, but it's not exactly the hardest job in the world either, and its quite pleasant that you can work on the axle away from the car. It's one of those jobs that takes time because you have to figure out how its best to do things, and how they exactly works. It took me something like two and a half weeks of weekends and a couple of nights to do. I think if I were to do a second one I'd be much faster. As my car had been used for a long time with serious axle problems it didn't have any bearing left on the trailing arm pin and thus it had started to grind out the tube so it was beyond repair. I bought a second axle and rebuild that, using the best trailing arm pin from each axle. I think I've read on an English forum that they cost 70 Pounds new, and if you've been driving to long with squeeking noises and severe handling problems then you'll need one or two of those. So rebuilding early saves money. The whole job does cost some money, with all the bearings involved and maybe some paint, and some new mounting rubbers. I think I spend about 170 Euro's. It's deffo worth it though, not only does it make the car handle much better it's also really nice to know that you can set the ride height or change torsion bars without to much hassle because everything is nice and clean. Is used the rear beam refurb guide on 205gtidrivers: www.205gtidrivers.com/articles.php?data=b-rearbeamrefurbIf you don't want to do it yourself there's a guy on 309ownersclub who I think is well worth recommending: www.309ownersclub.com/Community/viewtopic.php?f=5&t=4715I've only seen his work on pictures but he seems to have an extremely high standard with everything he does. I did buy some stuff from him a couple of times and he's a pleasant guy to trade with as well.
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Siert
Posted a lot
Posts: 1,104
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Well, yesterday was a day of sudden mojo changes. To cut a long story short: Carburettor failed last week before Christmas, so the already planned injection system had to be installed. It's an LE-jetronic so not very complicated. I'm doing all the wiring from scratch using cheap unprotected connectors (which I will seal later) in places where I think they're convenient. I had a big wiring mess finished just before my Christmas holidays. I was pretty convinced that it wasn't going to work straight away, and that it would have many random problems once it did. Also, I had all of the holidays to make the problems worse in my mind. Putting the car back into the workshop on Thursday the first thing I had to do was mount a fuel pump. Looking under the car I found some rust that I didn't know about, and also the rust I did know about has taken the shape of holes now, so I wasn't happy... Nothing really shocking, but it seemed like I'd be better of taking the car out of traffic to do the job properly and buying a reliable working car for winter use (which is not very sensible at all, as I can do without a car so having only hobby cars is fine). So I went out to buy a very Skoda Felicia Combi yesterday but we got a phonecall while on or way that somebody had showed up at the sellers house and given the guy the asking price. I went back to browsing car ads and even opened a topic here on Rover 600s... Here's the not to serious rust, actually the worst rust is around the front windscreen which is so loose in the rubber you can move it around by hand (and obviously leaks a lot). Well finally at somepoint in the afternoon I managed to convince myself to finish a temporary fuel setup. So, I hung the old BX pump under the car using tie wraps. Then I connected it to the inlet manifold with old fuel pipe from the BX and old hydraulics hoses of the GS. The pump's wires conveniently went through the rust hole in the floor as you can see on the previous picture. The setup looked like this when I first turned the key: And surprisingly enough, it fired... well, at least it sounded like it was going to. After closing some holes that were keeping air from flowing through the air flow meter it ran ;D ;D ;D Result, and big mojo boost! So I connected all the vacuum hoses and tried again, and it started immediately and started to idle nicely ;D Somewere late at night I decided it was all to nice not to test drive. As you can see I don't yet have space for the air flow meter, so I took the bonnet off and tie wrapped everything together, leading to this setup: These pictures were taking after the 2 minute test drive which took place at midnight on slippery roads, and it seemed to perform brilliantly!!!! If you look closely you may see some steam on the picture as I accidently mounted the cap on the thermostat housing badly so once the system came on pressure it threw some coolant out. But it works ;D ;D ;D ;D ;D
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jo0lz
Part of things
FucT FiAT
Posts: 321
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Jan 16, 2010 23:35:06 GMT
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LoVe iT MaD.....fancy taking it for a test drive looking like that.... ;D
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Siert
Posted a lot
Posts: 1,104
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Jan 24, 2010 20:45:13 GMT
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Some black tape has changed the appearance of the engine bay Even though Peugeot fitted this 1.6 multipoint injection engine to 309's themselves I have some fabrication to do to get it all to work. The reason is that I took all the parts of a Citroën BX, and there are differences. 309 injection models have their fuel pump in the tank, on the BX the fuel pump is outside the tank. I'll use the BX pump as I don't have a 309 injection tank (I had one scrapped couple of months back ) As high pressure fuel pumps aren't great at pumping fuel trough empty lines I wanted it to sit about level with the bottom of the fuel tank so that the fuel will flow to the pump easily. On the BX it also sits at that height approximately, but it's mounted behind the rear axle. As the 309 axle takes much more space the floor is way to high behind the tank. Also, it would be very hard to route a pipe from behind the tank to the engine as the tank is sqeezed in between the sills. So, I wanted the pump in front of the tank, but of there's no space there either. As I had to fix some small rust holes in the floor anyway, I though I made as well change the design a bit (By the amount of seam sealer and the lack of a picture without it you can guess how bad my welding is) The pump now hangs in its original mounting rubber of the BX, and the fuel filter will go in the other hole. I've also made a setup for the air filter, but I'll have to change that again as it's ridulous. The air filter became the lowest part of the car as well as the mudguard for all the dirt coming off the left front wheel... I find that it is really hard to fabricate things. Trying to do these really simple things and getting messy results has made the respect I have for the great fabricators on this forum even bigger. Fixing cars is easy. Fabricating is hard. But it'll work! ;D
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Siert
Posted a lot
Posts: 1,104
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Feb 28, 2010 20:36:23 GMT
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As I wrote in my last post I had made a mount for the AFM and airfilter a couple of weaks back, but it just didn't work the way I planned. I build it badly and the airfilter ended up being the single lowest part on the car So I got back to it last weekend. The plan was still more or less the same: - I don't want to use the original Peugeot setup, as I don't have the parts, and its not a great design with the air filter behind the engine anyway. - I don't want to move the battery to the boot as the cables are expensive. - I would like to have cold air intake, but without taking the headlight off. So, "the only way was down". Silicon tube is expensive so I went out to the DIY store and after having a look around came back with a piece of PVC pipe in the exact right size for my intake duct The airfilter is also fitted to the AFM using some PVC plumbing parts. The black bar that sticks out in front of the gearbox of the previous picture was version 2 of my AFM mount, but I found that the radiator didn't fit if I put it like that. So, I modified it, modified it again, and modified it once more until I came up with a bracket that fits the AFM between gearbox and radiator. Then I welded a shield to the right side of the airfilter, which is mainly for preventing hot air to flow from the radiator into the airfilter. A second shield is bolted to nuts welded on the first shield and the car, this one hopefully keeps the dirt coming from the left front wheel away from the air filter. Some orange paint to the right hand side shield, as more orange parts equals more power ;D Air is coming in through a hole I cut next to the radiator Which is exactly where on a GTi model the foglight would have been mounted. I still need to open this further and tidy it. Steel and rubber on concrete, (c) Siert 2010 It may not be the best solution imaginable (I shouldn't attempt river crossings with it ) but I'm really happy because in the end it turned out how I had it in mind.
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Siert
Posted a lot
Posts: 1,104
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Apr 15, 2010 20:30:56 GMT
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I've been doing a lot of work to this in the last couple of weeks. After welding all the small rust holes I found earlier shut I thought I was done with it. I ordered orange brake lines from www.brake-lines.co.uk/ the same place where Matt Jones ordered his pink ones. One of the lines in the set of 4 they send me had the wrong connectors on it, but I e-mailed them and they send me a new one for free. When I wanted to install the brake lines to the rear I decided to drop the rear axle to get better acccess after which I was just pulling and pushing a bit around some "surface rust". This of course resulted in a hole in one the bars the axle attaches to... So I went from... To opening the floor to reveal the original rust hole, in the metal bar at the point where the spare wheel carrier attached to it. After which I cut away half of the bar, and opened up the floor also on the other half of the bar to inspect it. Folded a new half-a-bar from sheet metal and welded it in. The worse your access to something is the harder this welding thing becomes And after closing the floor it looked like this I'm still learning to weld but I must say I'm pretty pleased with myself for getting this done! By the Finnish law the easiest way to get the engine swap approved is by showing that Peugeot themselves also build a 309 with these specifications. On Tuesday a Peugeot Dealer got me the name of the right person to call at the Finnish Peugeot importer. I called the guy and he understood exactly what I was talking about and made me a certificate and posted it the same day! Tomorrow I'll take my car for the "modification" inspection, as well as the normal yearly inspection. I have to pass it to make my deadline. As on Sunday the first autoslalom event of the season takes place; The extremely useful practice day.
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Apr 16, 2010 15:37:43 GMT
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Very nice work mate. When's the next event?
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Siert
Posted a lot
Posts: 1,104
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Apr 16, 2010 15:43:27 GMT
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This passed the inspection today! Both the lowering and the engine swap are now mentioned on the license papers.
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Siert
Posted a lot
Posts: 1,104
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Apr 18, 2010 14:55:27 GMT
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So it passed its inspection on Friday, but it was leaking gearbox oil. I spend all Friday night changing the driveshaft seals which fixed, or so I thought. I somehow decided that I could spend my Saturday racing it down an improvised drag strip on a small airport with some French car clubs rather than checking whether everything was actually working properly before my "important" autoslalom training event today. On my third and fastest 1/4 mile run (17.5 seconds) I lost a lot of gearbox oil... Unfortunately I had no other choice but to drive the 80 miles home slowly with little oil in the box, which resulted in knocking noises from the differential about 10 miles before I got home. After filling it up with 85W140 (!) it still leaked and knocked. I decided to go to nearby autoslalom event today anyway, knowing that I would probably blow it up. I just really wanted to have a chance to test the rest of the car. After two laps I started leaving an oil trail and so I had to stop. I then fetched my GS... with which to the spectator's amusement I did another 5 laps Fastest lap out of 2 on wet asphalt with the 309 was 1:34, fastest lap out of 5 on as good as dry asphalt with the GS was 1:39 Somebody made really nice pictures of the GS racing, once I get them I'll post them in its own thread.
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Siert
Posted a lot
Posts: 1,104
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May 15, 2010 20:17:04 GMT
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Well after breaking my gearbox I started inquiring about a Peugeot 405 that had been standing at our car club with a properly broken engine for a while. I took its engine and gearbox out, removed the gearbox from the engine and had everything else scrapped. Then I took my engine out on Saturday, and swapped the gearbox and put it back in on Sunday. Unfortunately all wasn't good as the engine didn't run even though it had fuel and sparks. It turned out that there where lots of relatively small problems like a broken temperature sensor wire, crankcase ventilation blocked, etc... I still seem to have some vacuum leaks, but the car made it to its next event; a trackday on the Ahvenisto racetrack in Hämeenlinnä (Finland). The car worked great and I was really happy with my best lap time (approx. 1:52). The first actual competition event in the autoslalom season is next weekend. I'm looking forward to it!
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