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Projects and Restorations Building a car from scratch, restoring your pride and joy, building a track car, or starting a long term project? This is your place to document it.

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Old 02-04-2017, 01:19 PM   #1
VeiRoN
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CitroŽn Saxo VTS Fast Road/Track Day Project

Hi,just wanted to share a list of all the work I've done so far,what you see has already been posted on the Saxo VTS forum of the country of my origin (Italy),though it's pretty quiet these days unfortunately due to the social medias,I've been slowly updating it over the past 2.5 years even though most of the main chassis work (see underside) has only seen substantial progress recently,it's a pretty straightforward progress thread for now,mainly de-rust,paint etc,but I hope it can be of interest in some way.

Obliviously I'm no professional in no way and I learn as I go and test things so please feel free to make any suggestion (main reason for the creation of this thread) good or bad,they're much appreciated.

Last picture before hibernation:



Rear Axle:

Just a note,I've pretty much used all products from Bilt Hamber for the metal,Electrox,Deox-C,Deox-Gel,Hydrate-80 and Dynax S-50.

Out with the old one:







Needed to cut off one of the 4 mounting bolts as it was jammed due to corrosion,an impact would have worked too but didn't have access to that at the time,have one now.



Started disassembling it:



Mild steel washers off the 4 mounting bolts were badly corroded,had someone custom made them in stainless steel to same specs:











Same with the torsion bars offset washers:





These socket off Irwin came in very handy to remove corroded bolts,would recommend them:



Extractor made for the torsion bars:







Pin looks okay on this side,not so much on the other though,see below.





Even though I found the seal had perished badly,not much longer before it wouldn't do his job anymore:



Faulty side,no good:



Used axle from a 1.1,arb still greased nicely:



First and second pin,much better:





Started stripping and de rusting it for new paint,started on the middle the easiest part:







Started working on the trainling arms,made M12 holes for the ARB plate and 6mm grease nipples,3 each arm:





















Deox-C to the rescue:





ARB plate almost finished:





Painted the arms (sorry no pics on them bare out of the Deox):



ARB plate tested fitted:





Mid way trough the Deox process,this was in a bad state:









Splines all clean,look nice (covered in copper grease now):



One part done:



Before and after (again no pics following the Deox apologies,was in the rush to get them clean and painted):



Rubber grommets fitted to prevent dirt inside the trailing arm splines:



Fitted bronze bearings in place of the OEM ones,side to side:





New seals:





Got together a tool to help setting the height of the rear axle:



Cut the outer ring for part upgrade,more on this later:





Axle is ready:



Fitted some PowerFlex:



Painted the rear brake discs shield,electrox first:





Camber kit for the axle,-1.5į from slavesta on 106rallyeforum (this was what the cut ring was for):



Little bit of paint first for the area that will remain exposed:









Assembled:













New rear hubs,after some paint:













Used a nyloc nut instead,grade 10:



80mm studs:







Gaz gold for the rear axle:



Also for the lower gearbox mount and smaller bush from Kam Racing,gave the support a quick paint:









Underside start:







Primed the rear bumper panel for now,still not finished,more later:



Passenger side near where the fuel tank sits,before:







Other side:





Chassis rail driver side,start:



Used Deox-Gel:





Wheel carrier support after Deox,almost ready (no before pics,sorry):







Front mounting pont for the axle:



Driver side,some rust damage present but I wanted to get it cleaned and primed anyway:





Middle part:











Exhuast side,before:



Decided this had to go if I wanted to get everything clean:



Primed:





Rear bench underside,please excuse all the holes from the rear (unused) seat belt plates,mistakes were made,probably should have used a spot weld drill bit instead of normal ones:





Had a start on the front slamp panel for the Pro Comp,it already had (bad) cut holes in it so had to work around that,before:



Started to get it back to bare metal:



Primed:








Passenger side sideskirt,almost ready:











Primed:









Driver side,sadness incoming:



















Floor passenger side has seen some water in the past:









Primed,not finished yet:



Mattig side mirrors,had them painted in the color of the car:









Decided to have a go with carbon fiber wrap (I know):

Before:



After:









Made the garage a bit more comfy,before:

















Made a start at the driver side front arch,feels bad:





Day 1 of many (this is the most recent job and what currently working on,will update as I get more substantial progress done):








Brake System:

Painted the master cylinder as it was looking in poor state due to paint flaking and rust:



Made new brake lines for the front:





Had the sleeves for protection,will have to see if effective:





This is as close as it gets with the steering at full lock,seems to be okay,will do more testing once everything is in place:











Used a rivnut tool to support the lines at the front:









Proportioning valve,trial fitment,6 positions 100% to 60%:





Rear washer custom made for the lines that go to the rear axle trainling arms:



Brake lines for the rear seat that splits and go to each of the rear arms:



Rear bench will get repainted.



Deatil of the flare with kunifer pipe:


Last edited by VeiRoN; 16-07-2017 at 07:06 PM.
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Old 02-04-2017, 01:19 PM   #2
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Got some gold tape for the Pro Comp induction kit,before:









Refitted the manifold with new bolts/studs and gasket:





Retapped the holes as well:



Installed JP4 covers:



Bought a custom badge:



VTR alternator setup,sits lower,easier to adjust and sits farther from the manifold:





Aluminium pulley:





Made up a new earth for the gearbox,same spec as battery negative cable,25mm2 170 amps:





New brakes and discs for the front:









Relocated the fan relays:





106 GTI black pillars in place of the "cream" standard one:





Radiator OEM shield:



Baker BM gr.N gerabox mount:



Only trackday I've taken part in so far at Lydden Hill:


Last edited by VeiRoN; 16-07-2017 at 07:22 PM.
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Old 02-04-2017, 02:33 PM   #3
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Nice work
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Old 02-04-2017, 03:12 PM   #4
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Lovely jubbly, definitely dedicated to your wee saxo.
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Old 02-04-2017, 09:20 PM   #5
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Nice work mate! That rust is all to familiar with me, at least you're using the right products to remove it.

Is Lydden Hill your local track?
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Old 03-04-2017, 08:13 AM   #6
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Thank you,yes Lydden Hill is the local track,I'm in Kent as well.
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Old 03-04-2017, 10:13 AM   #7
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Lovely work, great attention here. I love to see people do things properly!

Good luck for the rest!
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Old 03-04-2017, 04:35 PM   #8
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Quote:
Originally Posted by JMorty View Post
Lovely work, great attention here. I love to see people do things properly!

Good luck for the rest!
Thank you,I appreciate that a lot.

So,gave some attention to the damaged part on the sideskirt,this is how it looked like,I went ahead and made it so possibly a new plate can be welded in,not finished yet I think I'm able to clean it up a little more.

Before and after:





This is how it looked from the interior quarter panel before the Deox gel:



Left it with the Deox for 45 hours,doesn't look like a lot at the bottom from the pictures but it's done a good job so far,covered it again for another application.



The end of the master cylinder was going rusty as it's not protected for some reason so removed the corrosion and gave it a coat with the Electrox:



The tow hook needed some attention as it was rusty,used a flap wheel to strip it taking care not to remove too much good metal,this is as far as I got,now it's being treated by the Deox:





Also continued with the driver side,left it like this from last time,,clearly it will need some large new panels but not a lot I can do about it,this side is the worst (at least visually) and the rot was extended,all I can do for now is get it cleaned and primed,lack of welding skills and tools.







After today so far,few bits that still show some corrosion being treated with the Deox as well (also need to remove the earth to continue further,didn't have a 10mm spanner with me lol)








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Old 03-04-2017, 04:53 PM   #9
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Quote:
Originally Posted by VeiRoN View Post
...didn't have a 10mm spanner with me lol

Always the 10mm you need and never have!
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Old 03-04-2017, 08:18 PM   #10
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Looking good mate! All these cars seem to rust inside out when it comes to the sills, water must just sit in them.

We'll have to organise a track day when both our cars are finished!
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even more rust, feelsbadman, more rust, rust


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