Canadian 404C restoration

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Re: Canadian 404C restoration

Berichtdoor Mike Tippett » 28 dec 2019, 08:34

A bit of light work after Christmas:

1) wired up the extra interior light so it is a map light only (independent of the ceiling light)...may decide to change that later so it works with the doors too.

2) mounted the electric screen washer pump behind the steering column and got some new tubing to fit, as well as a new ABS T-fitting.  Installed a one way valve so it won't drain back when not in use.

3) developed a wiring diagram to connect the Swedish market two speed rotary wiper switch, which also has a push function to operate the screen washer.  The first owner fitted two speed wipers when the car was a few years old but I didn't like the rocker switch he used.

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Next I will tackle wiring up the switch or install the driver's door upholstery panel.  Perhaps rubber brake lines.  May even attempt the rear window installation if I get ambitious enough.
1966 Peugeot 404 Coupé Injection 4598609 in restoration 2017-20
2006 smart BRABUS Canada 1 cdi cabriolet
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Re: Canadian 404C restoration

Berichtdoor Mike Tippett » 29 dec 2019, 06:27

On Saturday the driver's door panel got mounted. You might think it's a 10 minute job, but it's not. The replica upper door panel is for a Cabriolet and required a whole lot of modification to fit.

Afbeelding
1966 Peugeot 404 Coupé Injection 4598609 in restoration 2017-20
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Re: Canadian 404C restoration

Berichtdoor Mike Tippett » 29 dec 2019, 10:48

Afbeelding

Both sill plates are mounted with the OE plastic rivets.
1966 Peugeot 404 Coupé Injection 4598609 in restoration 2017-20
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Re: Canadian 404C restoration

Berichtdoor Mike Tippett » 30 dec 2019, 08:04

Stainless steel rear exhaust mounted with original Peugeot OE belts/hangers:

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And the middle section is mounted too, held in place temporarily with a zap strap:

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Flexible hose between floor and torque tube mounted to my homemade brake lines:

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Right front brake hose mounted (the end is capped):

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And left front (you can see the cap on the end in this photo):

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Left front side bumper mount added. The cage nut had flown the coop many years ago and so getting the long bolt started into the nut I was hanging onto with a dab of butyl was a bit of a challenge but it worked better than my attempt with magnets!

Afbeelding

Afbeelding
1966 Peugeot 404 Coupé Injection 4598609 in restoration 2017-20
2006 smart BRABUS Canada 1 cdi cabriolet
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Re: Canadian 404C restoration

Berichtdoor Mike Tippett » 20 jan 2020, 07:20

Afbeelding

Windshield is in. It's a laminated screen as all cars sold in Canada and the USA have had to be equipped with since the 1950s. The brand of the screen is F&F, and it's called "Safety Plate" on the tiny etching. Locally made in the sixties or seventies, which is amazing as so few Coupés were sold in Canada (none in USA) and the shape is different than the Cabriolet. There is a safety test decal on the screen from January 1973 so I expect the original broke between 1967 and 1972.
1966 Peugeot 404 Coupé Injection 4598609 in restoration 2017-20
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Re: Canadian 404C restoration

Berichtdoor Mike Tippett » 26 feb 2020, 07:22

Afbeelding

Today I got my 18 cleaned and tested injectors back from Nottingham Diesel Services Ltd.

The 6 NOS:
2 x DL0 20D - release at 37 bar, good jet, no drips
3 x DL0 20D - release at 35 bar, good jet, no drips
1 x DL0 20B - release at 33 bar, good jet, no drips

The 4 originals from my car's engine:
1 x DL0 20B - release at 29 bar, good jet, no drips
3 x DL0 20B - release at 27 bar, good jet, no drips

Random spare injectors:
3 x DL0 20B - release at 30-32 bar, good jet, small drip but OK
3 x DL0 20B - release at 22-25 bar, jet OK, but drips under residual pressure that could make cold and warm starting a problem.

2 x DL0 20B - defective

I'm going to use 4 x NOS injectors (DL0 20D).
1966 Peugeot 404 Coupé Injection 4598609 in restoration 2017-20
2006 smart BRABUS Canada 1 cdi cabriolet
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Re: Canadian 404C restoration

Berichtdoor Mike Tippett » 11 apr 2020, 04:16

Afbeelding

As you may recall, before Christmas I put the rear window in but there were a couple of issues: the lower stainless steel trim piece was perfectly straight and the glass is slightly curved, so it was constantly trying to pop the clips out.  And so it did, once the glass was in.

After pulling the trim off I realized that the problem was also that the replica clips were about 2mm shorter than the originals and so didn't penetrate far enough inside the seal's rubber slot to engage with the small channel at the end where the hooked bit goes.  So each of the 30 clips had to be adjusted carefully by hand to match the depth of the 16 remaining originals, which were cadmium plated a couple of years ago.  In doing this - they're made of spring steel - 5 of the 30 snapped but 25 survived. 

I then mounted them to the SS trim along with the 16 originals and so far it's holding well enough.  Actually the rubber seal relies upon the window aperture to keep it tight.  So during installation I'm going to have to ensure the helpers push hard on each clip as I pull the rubber seal through to the inside of the car to make sure the seal clamps the clip in the right position (fully inserted).
1966 Peugeot 404 Coupé Injection 4598609 in restoration 2017-20
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Re: Canadian 404C restoration

Berichtdoor Mike Tippett » 12 apr 2020, 23:31

Today, with the able help of my two daughters I remounted the rear window of the 404 Coupé with no problem at all, and the modified clips are working perfectly.

Took 5 minutes to install and this time I started from the bottom of the seal and finished at the top. I used a smaller gauge nylon cord to do the lip service (!) this time and it worked beautifully.

YES!!

Afbeelding
1966 Peugeot 404 Coupé Injection 4598609 in restoration 2017-20
2006 smart BRABUS Canada 1 cdi cabriolet
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Re: Canadian 404C restoration

Berichtdoor Mike Tippett » 13 apr 2020, 02:35

Rear parcel shelf and leather rear bench installed. For the moment there will be no speakers, because my 1981 Blaupunkts are dead.

Afbeelding
1966 Peugeot 404 Coupé Injection 4598609 in restoration 2017-20
2006 smart BRABUS Canada 1 cdi cabriolet
2008 Mercedes-Benz B 200 5 speed
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Re: Canadian 404C restoration

Berichtdoor Mike Tippett » 15 apr 2020, 06:33

And today, the naughty....err....dirty bits....

Removal of crankshaft, camshaft, pistons, liners...

Summary: 

- Crankshaft journals looks more or less OK: 0.3 mm should do.
- The upper (compression, I presume) rings were broken on all 4 pistons (!!)
- Lifters and peak of the cams on cylinder 4 were heavily worn (oddly, the other were OK)
- Sleeves were not too rusty in the water jacket area and the block where the seals mate is perfect.
- There was a lot of very thick sediment deposited in the lower sides of cylinders 1 and 2, especially by the block drain hole on #1.

I have new pistons, sleeves etc; however I could use a new cam or maybe get a regrind.  Need new lifters of course.

AfbeeldingAfbeeldingAfbeeldingAfbeeldingAfbeelding
1966 Peugeot 404 Coupé Injection 4598609 in restoration 2017-20
2006 smart BRABUS Canada 1 cdi cabriolet
2008 Mercedes-Benz B 200 5 speed
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Re: Canadian 404C restoration

Berichtdoor Mike Tippett » 19 apr 2020, 04:45

The engine is totally apart now, as noted. The cam has bad wear so I am trying to source a new one from Le Club 404's stock. The new head and piston/sleeve kit are in the two cardboard boxes.
Afbeelding

Today, after cleaning off the engine block and moving it to where you see it above, I made 10 spacers for the carpet snaps. These space the carpet appropriately for the thickness of the undelay, so they're not puckered.
Afbeelding

Original Peugeot clips used for the visible ones. The rest are virtually the same.
Afbeelding
1966 Peugeot 404 Coupé Injection 4598609 in restoration 2017-20
2006 smart BRABUS Canada 1 cdi cabriolet
2008 Mercedes-Benz B 200 5 speed
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Re: Canadian 404C restoration

Berichtdoor Brownie » 19 apr 2020, 11:46

Good work! A solid restauration with attention to detail. Must be a hard job to restore a Peugeot in Canada.
403 Break Diesel 1960
204 Cabiolet 1968
104 GL6 Benetton 1978
604 GTI Automatique 1985
305 Select 1985
505 V6 Automatique 1986
505 V6 Automatique 1987
505 GTI Fam Dangel 1989
505 SW8 Automatique 1991
206 XS 1.6 SW Automatique 2005
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Re: Canadian 404C restoration

Berichtdoor Mike Tippett » 19 apr 2020, 18:30

Thanks, the spare parts are a little harder in some cases to find, although with others such as body panels, there are sometimes still examples here from the olden days! In other respects it's similar to restoration everywhere: bring lots of money, and then some more. ;)
1966 Peugeot 404 Coupé Injection 4598609 in restoration 2017-20
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Re: Canadian 404C restoration

Berichtdoor Mike Tippett » 20 apr 2020, 05:49

The underlay for the rear transmission tunnel was installed along with the carpet, the rear floor carpets.... and then the passenger seat.
Afbeelding

My wife Sandy tried out the seat for height and comfort.
Afbeelding
1966 Peugeot 404 Coupé Injection 4598609 in restoration 2017-20
2006 smart BRABUS Canada 1 cdi cabriolet
2008 Mercedes-Benz B 200 5 speed
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Re: Canadian 404C restoration

Berichtdoor Mike Tippett » 26 apr 2020, 05:34

Drilled 3 holes in the panels to mount the new carpet in the front driver's side.  The fourth hole was already there above the accelerator pedal.  

Afbeelding

Also mounted the new speedometer cable and the accelerator cable.  The driver's seat was a bit of a bear to install because the captive bolts in the bodyshell were not long enough to penetrate the new (thicker) seat runners and so I had to knock it out and put a bolt and (blind) nut inside one.  

Afbeelding

The interior is now done apart from the transmission tunnel, which is still naked because I have to install the C3 gearbox and its Nardi floor shifter before final trimming. That'll be a while then.

Afbeelding
1966 Peugeot 404 Coupé Injection 4598609 in restoration 2017-20
2006 smart BRABUS Canada 1 cdi cabriolet
2008 Mercedes-Benz B 200 5 speed
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Re: Canadian 404C restoration

Berichtdoor Mike Tippett » 04 mei 2020, 07:25

Mounted the glovebox on Saturday. It is a drawer under the dashboard under the Pininfarina badge. I have the Italian F.I.S.T. key for its lock!

Afbeelding

Sunday I cleaned and sorted all my nuts and bolts into the proper sizes.
1966 Peugeot 404 Coupé Injection 4598609 in restoration 2017-20
2006 smart BRABUS Canada 1 cdi cabriolet
2008 Mercedes-Benz B 200 5 speed
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Re: Canadian 404C restoration

Berichtdoor Mike Tippett » 08 mei 2020, 05:34

Saturday I'm going to rebuild the AEG/KF fuel lift pump with a kit supplied by my buddy Peter van Deukeren from NL.

The tiny bearings:
Afbeelding

The shaft seal:
Afbeelding

The kit:
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My two AEG PLF 5 pumps:
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And today, because I couldn't find the original clips for the dash pad, I made these out of 1mm thick spare rocker panel/sill material. They now have to be covered with a thin layer of black vinyl. They join the top of the soft dashboard pad with the soft A-pillar trims. Each one has been shaped by hand to fit each side very well.

Afbeelding
1966 Peugeot 404 Coupé Injection 4598609 in restoration 2017-20
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Re: Canadian 404C restoration

Berichtdoor Mike Tippett » 10 mei 2020, 22:03

Dashboard clips covered with vinyl.

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Passenger side:
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Driver's side.
Afbeelding

It was a pretty decent effort, I am pleased with the result.
1966 Peugeot 404 Coupé Injection 4598609 in restoration 2017-20
2006 smart BRABUS Canada 1 cdi cabriolet
2008 Mercedes-Benz B 200 5 speed
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Re: Canadian 404C restoration

Berichtdoor Mike Tippett » 19 mei 2020, 06:12

Dismantling of the AEG/KF fuel lift pump.

A little bit of electrical tape over the motor's drive pinion facilitated the armature's extraction from the pump body without in any way damaging the original grease seal, which is still supple. So I will leave it in place and use the same technique to re-insert the pinion through this seal.
Afbeelding

The freed armature.
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Making up some different sized slotted washers in the garage made short work of extracting the tiny drive pinion and nearly as tiny bearings.
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Armature mounted on a drill in a vise so I could polish the commutator/slip ring with fine emery cloth.
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Comparison between the armature of my car (4598609) on the right and that of a scrapped Canadian Cabriolet (6800519) on the left. 4598609 has done 83,000 miles. I bought the entire drivetrain from 6800519 in 1982, and at least the electric motor seems to show the traces of more like 200.000 miles...
Afbeelding
1966 Peugeot 404 Coupé Injection 4598609 in restoration 2017-20
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Re: Canadian 404C restoration

Berichtdoor Mike Tippett » 25 mei 2020, 04:38

Today I pressed the new bearings onto the motor shaft with a vise and then the pinion gear after it was inserted into and through the grease seal in the underside of the motor mounting plate. Checked the length of the original brushes: 6 mm and 9 mm....too short, so I looked in my spare parts stock and found two new or nearly new ones, both 12 mm long. Then the motor was tested and it was SO smooth!

Afbeelding

Next task: the hydraulic part of the pump, which sits below the electrical part.
1966 Peugeot 404 Coupé Injection 4598609 in restoration 2017-20
2006 smart BRABUS Canada 1 cdi cabriolet
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Re: Canadian 404C restoration

Berichtdoor Mike Tippett » 26 mei 2020, 02:58

Today I reassembled the hydraulic part of the AEG/KF PLF5A fuel lift pump.

Bad surprise: despite the excellent condition of the electrical part of the original pump that equipped my car, the same could not be said of the hydraulic part. The idler pinion inside the pump chamber was seized to its shaft! The last time I ran the engine was about 2005 so the seizure occurred after that....I presume after I disassembled the car in 2016. Also, the lower plate that covers the pump chamber has a regulation valve that is supposed to be removed and checked during a rebuild like this and it too was seized! Anyway, all was not lost...

...because I have a spare lift pump from a car I used to own in 1981-1985 and its hydraulic portion was perfect. All it needed was a thorough cleaning.
Afbeelding

Cleaning nearly done and the last bits about to go back together....
Afbeelding

And it's together. I did another dry run test with it all assembled and it sounded good. I should try a pump test, I suppose, though I have no reason to think it won't pump.
Afbeelding
1966 Peugeot 404 Coupé Injection 4598609 in restoration 2017-20
2006 smart BRABUS Canada 1 cdi cabriolet
2008 Mercedes-Benz B 200 5 speed
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Re: Canadian 404C restoration

Berichtdoor Mike Tippett » 14 jun 2020, 04:20

Last weekend I repainted the rearview mirror body and reassembled and mounted it.  Harry was giving me a hard time over not yet having done that!  Quite rightly!

Afbeelding



Second time doing the driver's door panel.  The window winder was not happy staying in place and that was down to the padding under the vinyl being too thick next to the embellisher.  I also had to remount the lower part of the vinyl in order to slightly recontour the lower edge to better fit. And finally, the screws under the armrest were mounted.

AfbeeldingAfbeelding

I got new lifters and timing chain tensioner from Alveas in France, and two sets of NGK BP7ES from Rock Auto.

Afbeelding
1966 Peugeot 404 Coupé Injection 4598609 in restoration 2017-20
2006 smart BRABUS Canada 1 cdi cabriolet
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Re: Canadian 404C restoration

Berichtdoor Mike Tippett » 02 jul 2020, 07:43

Seat belts mounted
Afbeelding

High temperature paint on the brake shoes - rear linings need to be changed
Afbeelding

Whipped the brush holder out of the the SEV-Motorola alternator - dirty inside
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Brush holder before cleaning
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clean slip rings
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Remounting. (the bolts holding the brush holder in are 1/8 inch, which is neither nor 5.5 mm. American parts!
Afbeelding
1966 Peugeot 404 Coupé Injection 4598609 in restoration 2017-20
2006 smart BRABUS Canada 1 cdi cabriolet
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