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309 GTI Goodwood suspension and brake rebuild

Let us know how you getting on with you Peugeot 309, what have you replaced, what are you planning to do, etc

309 GTI Goodwood suspension and brake rebuild

Postby miles1234 » Tue Feb 08, 2011 10:27 pm

My Goodwood is now tucked away in the garage for a lot of work this winter so its ready for some of the shows coming up this summer .
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Rear beam is off and in bits , fuel tank down , luckily the underside is in good nick , only surface corrosion apart from one of the inner sills in the usual spot .
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Re: 309 GTI Goodwood suspension and brake rebuild

Postby miles1234 » Tue Feb 08, 2011 10:30 pm

I have made up some new brake pipes for the rear trailing arms using my new Laser flaring tool , they only took a few minutes to make , very easy to use .
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I will be replacing the brake pipes from the compensators all the way back .
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Re: 309 GTI Goodwood suspension and brake rebuild

Postby Cloverleaf » Tue Feb 08, 2011 11:00 pm

Your brake flaring tool looks much better than mine :) )
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Re: 309 GTI Goodwood suspension and brake rebuild

Postby miles1234 » Wed Feb 09, 2011 11:34 am

I am refurbishing a couple of sets of 1.9 alloys as well this winter . Gives me something to do when the kids are in bed . I am preparing and spraying them in the kitchen :) ) ,with an extractor fan and a couple of dustsheets it makes less mess than you might think .
I was going to have them powder coated professionaly but for 2 sets of 5 including the polished lip for a Goodwood plus the petrol or courier costs its getting toward £400 so i will do them myself and spend the money on the running gear overhaul that i am doing right now .
I have made up a 'lathe' :-$ to spin the wheels while i grind off the kerbing with an angle grinder , it works really well and polishes up the edge a treat with a finer disc on a drill .
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Its a lot of work cleaning the road dirt/oil off 10 rims , then grinding off kerbing , removing all damage with wet and dry , keying the surface with fine wet and dry , 2 coats of primer ,fine rub down , 3 coats paint , polish rim , lacquer .Then comes the nightmare of trying to fit the centre caps without chipping the paint which you have spent all that time getting right .
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Re: 309 GTI Goodwood suspension and brake rebuild

Postby miles1234 » Wed Feb 09, 2011 11:41 am

4 of my Speedline rims i have painted in Pinewood green with a polished lip , i will use these for day to day driving . I have a set of SMR's with Pirellis fitted which i will put on if the car goes near a track .
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Re: 309 GTI Goodwood suspension and brake rebuild

Postby miles1234 » Wed Feb 09, 2011 11:59 am

This 309 has the usual selection of broken or seized bolts , both the screws holding the rear discs to the hub were rounded off .They are M6 x 1.0 mm pitch so I drilled off the head then put a 5mm drill down to clear out the bolt and recut the thread with a tap .
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Re: 309 GTI Goodwood suspension and brake rebuild

Postby miles1234 » Wed Feb 09, 2011 12:08 pm

While cleaning up and checking over the rear brake calipers one of the bleed nipples snapped , these are M7 x 1.00 pitch .I had a tap in this size already but they are available on E-Bay for a few quid .I drilled out the broken steel and was lucky to be able to remove the remaining thread , the aluminium is so soft its easy to ruin the thread . # :-s
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Re: 309 GTI Goodwood suspension and brake rebuild

Postby Lewis205cti » Wed Feb 09, 2011 12:27 pm

The alloys are looking nice. The pinewood green is a nice colour.

I bleed my brakes on the weekend and found the N/S rear had been broken off. Fixed it the same way as you.

Your Goodwood will be looking good at the shows. I'll make sure to park mine away form yours. hahaha
Lewis

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Peugeot 309 GTi Ph2 Black - The daily run about that now gets more spent on it than the CTi turbo project!
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Re: 309 GTI Goodwood suspension and brake rebuild

Postby Cloverleaf » Wed Feb 09, 2011 1:07 pm

By "lathe", do you mean you jack up the car and drive the wheels? :D

My mate did that on his escort to polish the rim of his wheels, only trouble is it's quite a loud thing to do on your drive! =))
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Re: 309 GTI Goodwood suspension and brake rebuild

Postby miles1234 » Wed Feb 09, 2011 10:53 pm

Because i do not have access to a machine shop any more i did consider doing the grinding actualy on the car , but i made up the 'lathe' by mounting a 205 GTI suspension hub to a sturdy wooden box and driving it from a Bosch mains powered drill .I just use 2 wheel bolts to nip down the wheel then spin it fairly slowly .
Ideal for removing the kerbing using an angle grinder with a coarse grit disc . I use a 300 grit velcro backed rubber pad on a drill to polish it up . B-)
I even bolted my rear discs on top of the one on the hub and ground off the wear lip on both sides . :-o
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I am nearly finished with it , if anyone is local and wants to borrow it let me know , the neighbours will wonder what on earth you are doing but the end result is worth it .
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