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John Dragon Man's Peugeot 306 Estate 1.9 Turbo Diesel

Introduction

Greetings Everyone!

So i present to you, A car that cost me a grand total of £50!



A Green Peugeot 306 estate with the 1.9 XUD (1905cc) turbo diesel engine.



i bought this car almost 2 weeks ago. it was from one of my brothers work colleagues. it had been in there family for 16 years. the car has never been serviced in this time. just the oil topped up when it needed it and parts replacing for the MOT. its just had a whole complete exhaust fitted to it!.

as you can imagine it was well ready for a good service. first thing was an oil change while i waited for a replacement cam belt kit with water pump as that cam belt was ohh scary! (i'll get a picture of it is that bad)

surprisingly the engine has little blow by which i did expect especially with 150k miles on it. the thing does not even smoke on startup or under load!

the oil was.. not as bad as i expected. it was pretty bad though.
i got a garage to do the cam belt as it was such a pain to get accesses to. for £170 i did not mind that much.

when i got it, it had some really bad electrical faults. the 2 front windows do not work, the radio, clock, central locking, intermittent wiper, rear wiper, multiple speakers, interior light, and loads of other things did not work.
its got a clicky CV joint when turned full lock on the passenger side, the sunroof leaks like crazy, it is also very slow to move and very temperamental.
the only rust it seems to have is around the sun roof. i will have to look into ways of fixing this. one of the methods i though of was to chip out the crusty rust, use some rust converter, paint it using whatever then to fill the holes use expanding foam, cut off level then hollowed down to give me a structure to apply filler to then skim and sand it smooth. the foam is pretty water resistant so should prevent any more rust on the inside. its a bodge as the best way of fixing it is to cut out the bad and weld in new but the car cost me £50 and i think this would work just as well.


well most of the electrical faults have been fixed now. the central locking now works from the remote, the interior light works, the radio and clock are also working now.

i have also been looking into upgrading the headlights to the later clear lens type. the ones it has are pretty weak in terms of light output.



... and i could not help myself could i.



clear lenses mean i can install projector lenses into the original reflectors if i open the headlight up.



my plan is to not use HID or LEDs but keep with the halogens. these projector lenses are bi-xenon meaning they can do dipped beam and high beam. this means that if i install them to the dipped beam reflector i will have effectively 2x high beams per headlight!



i have a YouTube playlist up of the car so i can keep adding videos to it. as i make them, >>see it here<<:



stay tuned!
I like your project, it's a good looking car with classic no-nonsence 90s styling and interior upholstery!

Glad you seem to have saved the engine despite someone's previous efforts to wreck it, I saw your oil change video and it was pretty disgusting... you drained the old oil cold so I'm sure there was / is more grotty sludge on the bottom of the sump. :eek: I'm sure the new oil plus some flush will clear out most of it especially if you drive it hot and hard before the next change. Instead of proprietary flushing compound an alternative is to idle it fast for 15 mins after adding a pint of paraffin or plain diesel fuel... the latter is also a lubricant as well as a solvent.

I quite like the standard wheeltrims though the alloys you were offered would also look great. (y)
 
hmm.. Hmmmmmmmmm...

well i wondered why the seat belt felt loose... turns out after removing some panels...









...
nice.. nice.. guess ill grab the welder then.. hmm.

also this is the sunroof rust:









fun on a bun!

you guys know me, i would not be happy with a good car!
 
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I'm am impressed how upbeat you sound after finding that. 10 out of 10 for +ve attitude .
 
If the rust wasn't visible is covered up by plastic panels or thick paint and the tester didn't spot rust it will pass.
 
Yes, but the MOT tester should've noticed that there was a lot of movement in the seatbelt though.
I agree , dragon man was lucky to get it through MOT , and be skilled enough to fix it .

Scary how some cars pass and my cars get going over by MOT tester with a fine toothed comb!
 
it passed the "tug lock test". there was no movement until i really gave it a good pulling with force. something i always do just to see how things move.. i just managed to snap the few spot welds that held this on to what was left of the car.

kinda having mixed feelings at the moment over this, but it is fixable. its just a pain to make it a permanent fix to cut all the rot out will be damn hard as its travelled along seams.

i guess do what i can, and fill with never ending hot waxyol. (frying element in a bucket filled with waxyol electrically pumped into the offending cavity, then catch what drains out the bottom back into the bucket)
thats pretty much how Fallout was done.
 
well thats the important bit done. it needs painting tomorrow after work (or maybe on my lunch break)













that should be a lot stronger than it was!

im not fussed about how it looks, a bit of a combination of hidden behind plastic panelling and the fact the car cost me £50 leads me to that. im not even going to grind any welds down.

will have to do the dragon man special waxyol trick at some point... just to keep those inner cavities nice and water tight.
 
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another week, or 2..
anyway i turned my attention to the sunroof rust. oh how to get in there and fix it..





after inspecting, shoving one of those mini cameras on a flexi stick into the cavity i found that is was only the skin that was rusting. all of the metal supports were in perfect health.

the best way to fix it would be to cut the top roof skin off.. yeah thats the best way to do it but man... what a job.

i could then also fill it with filler.. hmm it does not really "fill" enough though.

expanding foam.. not theres an idea. i can fill the cavity, and it would give some support to any filler i skimmed over the roof before priming and painting.

so lets get it on..

you ok spidey?


oh.. well that was a little more than i expected..



yeah.. well it should stop the wind whistling through the rust holes now!


give it a day or so, break off any of the "excess" foam. sand it all down smooth, apply a thin layer of filler, sand again, then prime and paint... it will be interesting to see how this goes...
 
ok a little update.. not much has happened. lmao.

for £50 the car has worked flawlessly covering over 2k miles with no issues.

a job i recently done on the car was change the brake pads as they were thin (<1mm!) and fix the intermittent.. intermittent wipe issue

so basically what was happening was that the wipers would park anywhere. i knew the issue would be in the gearbox of the wiper motor so i took it out also finding out that it had been replaced before (by a scrap yard/ebay one)

its in a bit of a tight spot but as soon as you remove the wiper arms (13mm), scuttle(torques screws), and a small triangular brace (3x13mm) the wiper motor is right in the open and comes out with 5x 10mm bolts. (of which one of mine was not even bolted in :D)





so upon getting the motor and mech out i flipped it over and took the back off the gearbox with 4x 7mm bolts. sadly the paper gasket was destroyed but that did not work anyway as it was full of water!
the drain hole in the little recess that the motor sits in was totally blocked so my guess is that over time water got into the gearbox by running down the shaft.

here is what i was greeted with after a little clean up.



just as i suspected. one of the little brush arm contactor thingies has corroded away.

well given it does not snap off i guess i could sand it down a little and solder a new bit to it. after butchering an old relay for a bit of thin flat copper i managed to make the perfect replacement and soldered it on.





perfect!

i took all the gears out of the gearbox, gave the whole thing a good clean out, put some grease in the bottom and put all the gears back greasing each one.

i also cleaned up that copper disk on top of the large gear before adding yet more grease to it and the little arm contactors.

given the paper gasket was all but toast i removed what i could and used some instant gasket to help seal it all together.

stuck it all together, had a bit of fun getting the wipers to stop in the right position as i unbolted the linkages, but soon managed to get them wiping and stopping and automatic wiping.

little thing that bugged me loads but im happy its fixed.

i still need to complete the welding job in the boot. i was naughty and just taped over it all when i took the car in for its MOT. its only a skin and not structural so it may have passed as it was anyway but i have left it all open now so it can help keep it dry and not hold moisture.

the job i will have a go at today is the passenger window not winding up or down. the switch gets power and now lights up, but the window its self does nothing. just hoping that it is the relay that has failed on the motor its self.

oh and for the MOT it needed the bottom wishbone bushes changing which was not that bad of a job and only cost like £8.50 :D

still not used filler on the roof yet, waiting till summer when its more warm.. and dry!

happy with the car! :D
 
Finally built the bi-xenon projector lens headlights! also added a bit of RGB LED strip under the chrome plastic beauty ring that sits around the projector lens. i was able to get a wifi phone app controller to make it do some rather interesting effects!
with the projector lenses being bi-xenon (effectively giving me one light source that can do both high and low beams by moving a flap) i have 2x high beams per headlight. this should be rather good on those dark unlit roads.

heres the 2 lights on the right the "phase 2" (mk2) light, and on the left the modified phase 3 light.


and at night...



For weeks i have been having "flat battery" symptoms when starting the 306. jumping the battery using another car gave the same issues. directly connecting jumper cables to the starter gave the same issues. well thankfully i kept the BX's original dead starter so a week or so ago i stripped that down and freed it up (the brushes were jammed up and some corrosion got around it) its a relatively low miles starter with loads of life left in the brushes.
anyhoo after swapping the starters around, it now starts wonderfully!

also i have managed to finally fibreglass fill all of the holes around the sun roof. i now have no water ingress into the car! no water dripping through the sunroof switch, no wet seats.. no wet carpet! oh what luxury!
i still am yet to sand it all down and smooth it but that will have to wait for a warm dry day when paint wont get rained on. for now i am enjoying the dryness! no clearing windows every morning! its so nice!

the rear window wiper is also working now! after fixing all of the broken wires in the loom.. and it working for a day before failing... it turned out that the relay on the side of the motor (which makes it intermittent wipe and come full on while washing) had some pretty bad dry solder joints. so bad the coil on the relay was unwinding its self! after a few mins of re-winding the coil and soldering it is all working great now.. well its not washing though! need to fix that. its the last electrical gremlin the car has!

had a poor go at window tinting.. sadly it did not go well. i followed youtube videos word for word, using heat guns and everything but i could just not get the tint to "shrink" to the curve of the window.





found a rusty seam in the drivers footwell but i think thats where water has been sitting. the sound proofing under the carpets are still wet so i have things wedged under it to try to give it a bit of an air gap so they can dry out a bit. i should be able to fix the rust easy.

well thats it.. i think.

edit: ohh i have some replacement front fog lights on order too. should help improve the look. i know one has no reflector left!
 
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