505 spark plug extensions
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Thread: 505 spark plug extensions

  1. #1
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    Default 505 spark plug extensions

    What are the recommended options?
    I need to replace or eliminate the spark plug extensions on the 2 litre 505 motor.
    It's running okay, but making suspicious popping/ crackling noises down in the plug tube area!

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    All informed advice appreciated

    Cheers

    John

  2. #2
    1000+ Posts robmac's Avatar
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    Quote Originally Posted by bahay View Post
    What are the recommended options?
    I need to replace or eliminate the spark plug extensions on the 2 litre 505 motor.
    It's running okay, but making suspicious popping/ crackling noises down in the plug tube area!

    All informed advice appreciated

    Cheers

    John
    If you are handy machine up some extenders. Start with some 8 or10 mm (hex or round) brass rod, turn down one end to the shape of a spark plug screwed contact doover (don't need to form a thread) and drill tap the thread to fit the spark plug (I think it is M4 or M5)

    Even if you send it out to a fitting and turning shop it shouldn't cost too much.

    You can the cover the extenders with two layers of heavy duty heatshink tube. (the type with hot melt glue inside).

    FWIW I diced the peugeot caps in top of the plug tubes as well. Toyota 4ag rubber sealing caps fit nicely, seal better and cost a few dollars each.

    505 spark plug extensions-leads.jpg

    I've had no joy long term with spring and bayonet plug tube system. Solid extenders are the way to go, especially with HEI system, IMHO.
    pugnut1 likes this.

  3. #3
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    I have the later type spark plug covers on my 504, and use 505 cover shields which are quite thin. Not sure if they're still available new but come up on EBay sometimes (more likely the French one). I have used cut down early 504 covers as additional shielding (probably not needed).
    The brass extenders were available on 504s from about 1977/1978. I might have some in my stock of spare parts.
    I like the idea of the Toyota covers but haven't been able to find them. They're best on the later heads as they seal out moisture into the tubes.
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    1995 Peugeot 505 GTI executive
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    I bought a set of new extenders from EAI a couple of years ago. I redid the entire high tension side of the distributor as a matter of course.

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    Hi John
    I'm pretty sure I saw these on eBay recently, a quick search will find them.

    Regards
    Neil

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    1000+ Posts robmac's Avatar
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    I've just had a (genius?) idea.

    Get some M4 (approx) bronzing rod.
    Solder (silver solder if you have the gear) a couple brass tits off old spark plugs onto each end of the rod. Insulate with heat shrink.

    Job done without any machining or specialist tools.

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    I've got a set of new plastic insulating sleeves.

    Quote Originally Posted by bahay View Post
    What are the recommended options?
    I need to replace or eliminate the spark plug extensions on the 2 litre 505 motor.
    It's running okay, but making suspicious popping/ crackling noises down in the plug tube area!

    All informed advice appreciated

    Cheers

    John

  8. #8
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    Thank you for all the replies!

    For now I've got a set of rubber caps a la Toyota, and a new set of extensions which should sort the issues for the 505 motored 404.

    The popping crackling noise must be coming from the Piston No 1 or 2 sparkplug area...Funny thing is that it's not misfiring??

    Cheers

    John

  9. #9
    1000+ Posts Beano's Avatar
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    What sort of ignition do you have ? Points and condensor, or a 505 electronic distributor ? If the latter, it can sometimes occur that you have enough spark to power the car smoothly AND crackle....and the engine only misses a little bit.
    My early 505 was popping inside the spark plug tube after I fitted an electronic dizzy. It gives you a big whack if you accidentally get a spark to the finger, too. Actually dangerous, whereas the points-type coil has a lower output and is not so bad.

  10. #10
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    Quote Originally Posted by bahay View Post
    Thank you for all the replies!

    For now I've got a set of rubber caps a la Toyota, and a new set of extensions which should sort the issues for the 505 motored 404.

    The popping crackling noise must be coming from the Piston No 1 or 2 sparkplug area...Funny thing is that it's not misfiring??




    Cheers

    John

    Loose/ stripped spark plug ie not sealing?

  11. #11
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    The car has a Pertronix electronic ignition arrangement, Bosch GT coil.
    All plugs recently installed with clean threads...no sign of stripping...all tightened firmly with a well defined tightening/ stop at the end.

    I think it might be as you say " have enough spark to power the car smoothly AND crackle....and the engine only misses a little bit. "

    Will see what happens when I get the new seals and plug extensions installed.

    Do you think additional shrink fit insulation could calm the crackle ?

    John

    Quote Originally Posted by Beano View Post
    What sort of ignition do you have ? Points and condensor, or a 505 electronic distributor ? If the latter, it can sometimes occur that you have enough spark to power the car smoothly AND crackle....and the engine only misses a little bit.
    My early 505 was popping inside the spark plug tube after I fitted an electronic dizzy. It gives you a big whack if you accidentally get a spark to the finger, too. Actually dangerous, whereas the points-type coil has a lower output and is not so bad.
    Last edited by bahay; 17th August 2014 at 09:48 AM.

  12. #12
    1000+ Posts robmac's Avatar
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    You could try some plastic hose as a test so you don't waste heatshink needlessly.

  13. #13
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    It worked for me briefly. I think it would break down after a while due to heat though. The other stuff if closer to Bakerlight.
    1998 Peugeot 406 D8SV Manual
    1999 Peugeot 406 D8ST Auto
    2002 Peugeot 406 D9SV Manual
    1994 Peuegot 306 N3 Cabriolet Manual
    1994 Peugeot 306 XR N3 Hatch
    1995 Peugeot 505 GTI executive
    1976 Peugeot 504 Sedan - Now sold

    Over 60 Pugs in my time
    Gerry Mullock

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