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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 14-02-2016, 07:13 PM   #1
gingerscotsman
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1992 Peugeot 405 SRi Restoration

Welcome to my thread detailing the very slow restoration of my Peugeot 405. I have cut and pasted this from various older forums so apologies if its a little disjointed until its up to date.

Car history

The car was purchased in 1999 (iirc) for £1000. It was bought for me by my Grandad and I used it to travel to university. The car was a 1992 Peugeot 405 SRi fitted with the 1.9 litre petrol 8v engine (XU9J2). I graduated in 2001 but sadly by Grandad died on my final day of university. This car therefore is very special to me.


Picture of the car from the original advert

By the time I finished uni the car was a little rough round the edges. It used about 1 litre of oil per week!! This was due to worn valve guides. I had just gained my first job and needed a car to get me reliably to work. I purchased a Nissan Primera and laid the 405 up on my Nanas driveway. We gave the car a last camping trip up the highlands. My ultimate aim for the car was to tinker with it in my own time, do it up and learn some skills relevant to car mechanics than I may one day apply to an older car restoration.


The car in 2001 having just been taken off the road.

Note the Nissan Primera peeking out in the background.

So if the car was taken off the road for repairs in 2001, why are you writing this in 2015?
- I hear you say.

I poked around with the car on and off with the last period of work finishing around 2008. There are a number of reasons it has taken so long to do this but the main ones are available time and lack of adequate facilities. The car was in a driveway at a house 30 miles from my own hence my ability to do an hour or so on the car was very limited. The car became to subject of ridicule with my pals believing that one day I will get round to scrapping it The car means too much to me to scrap, especially after all this time. Plus the chorus of 'I told you so' from many people would be unbearable.

My original reasoning for wanting to keep it still applies. I wish to learn how to do up a car so that I can do something a bit older with some skills I learn on this one. I now however have the advantage of having a double garage available for my work at my new house. I have the challenge of getting the car up here. It presently sits with no rear axle and will be a real pain to move like this. I therefore have the first task of refurbishing and installing a rear axle in order to move the car. For once I have a deadline as my brother (who now owns the house where the car lives - my Nana having died in 2010) is moving home an need the car moved so he can sell the house. I have about 4 weeks. If I don't get it moved it really will be scrapped as home buyers don't tend to like old cars sitting in their new driveways!



Car as it sits presently

Before we get into that however I should bring you up to date with what I have done so far..............

Last edited by gingerscotsman; 23-07-2017 at 03:30 PM. Reason: Photobucket removal
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Old 14-02-2016, 07:20 PM   #2
Willsy309
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Looking forward to seeing the restoration progress. I do have a soft spot for old Peugeots
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Old 14-02-2016, 07:21 PM   #3
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Definitely subscribed to this as I really enjoy threads like this. Have you seen the 306 Rallye restoration thread by Ben W and the 309 GTi restoration too.

Good luck.

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Old 14-02-2016, 07:22 PM   #4
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Before I go on to show the cars current position I thought it worth picking up some previous progress I have made. These are taken from the now defunct mi16.com forum. I did not manage to get the complete record before the data was removed when the website was closed. I have 5 pages though. I'll post these in chronical order.

Post May 31 2007, 11:37 PM
Thought I would share my project with you all.

I have a 1992 Phase 1 405 SRi. I had this car for several years as a daily driver whilst I was at university but it has now been off the road stuck in my Grans driveway for 6 years!

When I took it off the road it burned 1 litre of oil a week. I have since been tinkering away with it on and off with varied success.

Presently I have got the engine running again with a refurbished cylinder head (£70 from ebay!!!). It still has a fault code on it though so I will need to find out which one and rectify it.





As you would expect all the brakes were seized so I have purchased caliper overhaul kits for every corner. I have bead blasted the calipers and painted using black Hammarite. Still got this lot to finish off.

I have had some good results so far and as it is off the road I can spend time getting it back to a reasonable condition.

Anyway, here are some pics. I will post more as I go but its slow progress due to work commitments.



Some lovely green moss growing there!!

Some before and after of caliper bits.




Thought it was starting to look reasonable here again.


I may choose to replace the springs, shocks and some bushes etc at the front depending how they look.

Also toying with the idea of getting the wishbones painted up too.

Will keep you all posted. Having fun doing this though!

Post Jun 2 2007, 01:05 AM

Today I managed to sort the fault code. Turned out I had not plugged the temperature sensor back in, Doh ! The engine is still rough though, will rev of but idle is pretty dire.

Got the front drivers side caliper on today too. Looks great! Should have done this when the car was on the road. Also got the rear drivers side one finished and ready to go back on the car. Sorry for the poor quality pics. Never had my camera today so I had to use the phone.


Caliper ready to go back on.


Caliper back on the car. Looks great! Shame about the rusty spring.

Rear Caliper ready for fitting on my next free day.

Next I have to remove the calipers on the passenger side to get them refurbished. Also got a bottom ball joint to do and the rear hubs to replace. Have to do the hubs as the axle was replaced about 11 months before it went off the road. The new axle did not have ABS hubs and so the car failed its last MOT on the ABS not working. £46 each from GSF, Ouch.

I have lost pages 2, 3 & 4. I will try to reconstruct from memory.

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Old 14-02-2016, 07:23 PM   #5
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Quote:
Originally Posted by Cookies View Post
Definitely subscribed to this as I really enjoy threads like this. Have you seen the 306 Rallye restoration thread by Ben W and the 309 GTi restoration too.

Good luck.

Cooks
Indeed I have. I have been enjoying those threads for a while and thought it about time I put my own up.
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Old 14-02-2016, 07:37 PM   #6
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Quote:
Originally Posted by Willsy309 View Post
Looking forward to seeing the restoration progress. I do have a soft spot for old Peugeots
Sorry willsy I didn't remember your handle off the top of my head earlier when posting lol. If it's any consolation I remembered the car though 😁

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Old 14-02-2016, 07:40 PM   #7
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Posted some time after 2/07/2007

Some general photos of the car.


Some lovely green stuff on car.



My brother had moved the car onto the grass so he could use the drive. Made it really difficult to jack it in the air.


I find this photo arty in an odd sort of way.


More Green Stuff (moss??)

After the previous pictures of the shiny brake callipers on rusty springs and hubs I decided to remove these to restore them. I removed the struts and dismantled them. I don't seem to have many pictures of the strip down but I do have rebuild pics.


Where has the strut gone??


Painted up Wheel Hubs


Front of the Hubs - Cleaned up with a dremel


Sandblasted hub carriers with new bearings and ball joints. Ready for paint.


Masked up


Painting Complete - Awaiting pressing in of hubs


Completed restored hubs


My Nanas dog Ben guarding the parts and looking highly fierce!

I had restored the strut tops also, painting them with silver hammerite. I purchased new springs and dampers and set about rebuilding them.


New bits


Ready for rebuild.


A Spring Compressor was used to compress the springs allowing fitment, with renewed bearings, onto the new strut.


Shiny


Refurbished Strut.

Whilst I was in the arch I also noticed a very sad looking anti roll bar. Out it came for some refurb.


Bolts / Bush seized onto the end. Chopped it off.


Got them out eventually.


No wonder it was stuck. The half height head made it really challenging to get enough torque onto it without the socket or spanner slipping off.


Remains of the holding clamps. Note how worn the rubber is!

Got the anti roll bar powder coated professionally.


This will look great on the car!


Black Hammerite on the Driveshaft.


Strut mount with surface rust.


Strut mount with more surface rust - This time under the underseal.


Inner wing with surface rust.


Attack with this. I should get shares in Hammerite.


Rust Treatment in progress


Rust Treatment in progress


Overcoated with some new paint of the correct colour.

That's everything from the missing blog pages.

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Old 14-02-2016, 08:34 PM   #8
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I had one of these, as a K reg, SRi in red, such great memories of that car
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Old 14-02-2016, 11:46 PM   #9
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Keep it coming! Sub'd 🏻
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Old 15-02-2016, 06:42 PM   #10
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Posted 20 April 2008 - 12:01 PM

I had a busy day yesterday


Suspension back on


More suspension

Got the suspension turrets all waxoyled and then got it all fitted back on. Looks great I think.

Also took this lot


Cleaned awaiting painting 1


Cleaned awaiting painting 2


Cleaned awaiting painting 3


Painted brackets etc.

And fitted it back on. Took this lot off last week when I removed the timing belt. Got the belt back on yesterday and the engine is timed. I way even get to start it today .....

Fingers crossed.

Today's jobs are start it, fit the front brakes and remove the rear brake slider that is seized on.

Posted 20 April 2008 - 10:03 PM

It Runs !!!!!!!

I am very happy today as I tried a start and it ran. Runs reasonably well for a car that has been off the road for 7 years!!!

Today got the brakes rebuilt on the drivers side, wheels on all round, removed rear calliper slider, replaced alternator and tried a start. Needed to put fuel in it. And almost dropped the car with no wheels on! Jacking the car up on grass is not fun

Still, I moved it today, albeit only a few feet back and forward. Cant move it far without brakes!!

Went to put the calliper on the passenger side ad I realised that I have misplaced it. Oops! Think they might be at work.

So next job is brakes. Need to get them rebuilt all round and bled so I can move the thing from the grass to the driveway again.

After that its rear hub replacement and ABS fixing time.

Interestingly whilst I was under the back I saw more rust than I have ever saw on a 405. Will have to get a good look at that later on and sort it out.


Posted 27 April 2008 - 07:40 PM

Nice sunny weekend and I am on night shift testing the generator. It figures.

Still, I got some done today. Not found the missing callipers yet though.

Today I replaced some perished fuel hose. The old one was leaking when the car was running right onto the exhaust manifold


Perished Fuel Hose


New Hose Fitted

Also had a go at fixing the sunroof. This is going to need further work and possibly full replacement. Currently taped shut !!


Sunroof Motor


Gears all gummed up.


Taped Sunroof

Found some old pics of the car when it was on the road. I wonder if I can make it this nice again.


Car Now


Car in 2001 when I took it off the road.

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