Peugeot 403 wagon restoration
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Thread: Peugeot 403 wagon restoration

  1. #1
    Fellow Frogger! PCOATES505's Avatar
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    Default Peugeot 403 wagon restoration

    I bought a 1960 wagon in 2005. This was to be a major restoration project.
    The wagon had sat in a shed for 27 years before I got it, it didn't have a lot of rust, but had suffered quite a lot of damage when it was used as a paddock basher, before it was parked.
    The front spring was broken in 4 places, the shockers were stuffed and the tyres had rubbed on the guard arches and wore through the arch, the front vallance had taken a battering as well.
    Peugeot 403 wagon restoration-000_3161.jpg Peugeot 403 wagon restoration-000_3162.jpg

    The sill panels were rusted out

    Peugeot 403 wagon restoration-000_2770.jpg

    but the rest of the body was reasonably solid.

    Peugeot 403 wagon restoration-dads-pics-016.jpg Peugeot 403 wagon restoration-dads-pics-026.jpg

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    Last edited by PCOATES505; 7th August 2011 at 11:31 PM.

    I am gunna get another 403 on the road........one day

  2. #2
    Fellow Frogger! PCOATES505's Avatar
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    Default Making life easier

    I stripped the front panels off then decided to build a rotisserie to make the rust repairs easier.


    Peugeot 403 wagon restoration-000_2652.jpg Peugeot 403 wagon restoration-000_2855.jpg

    A bit of rust in the front sub-frame
    Peugeot 403 wagon restoration-000_2768.jpg

    The engine bay looked a mess
    Peugeot 403 wagon restoration-000_2653.jpg

    The body was covered in sign writing, which was very hard to get off

    Peugeot 403 wagon restoration-100_0622.jpg

    And the roof was covered in surface rust as well as sign writing.

    Peugeot 403 wagon restoration-403-wagon-004.jpg


    cheers Pete
    Attached Thumbnails Attached Thumbnails Peugeot 403 wagon restoration-403-wagon-001.jpg  
    Last edited by PCOATES505; 4th August 2011 at 09:32 PM.

    I am gunna get another 403 on the road........one day

  3. #3
    Fellow Frogger! PCOATES505's Avatar
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    Default The work begins

    I started work on repairing the inner sills, and a hole in the floor above the jack point.

    Peugeot 403 wagon restoration-403-wagon-repairs-001.jpg Peugeot 403 wagon restoration-403-wagon-repairs-002.jpg Peugeot 403 wagon restoration-403-wagon-repairs-003.jpg



    Peugeot 403 wagon restoration-100_0232.jpg Peugeot 403 wagon restoration-100_0234.jpg

    During the rust repair process I discovered damage to the top of the transmission tunnel. Someone had decided to fit a floor shift, so they attacked the tunnel with an axe, then gave up on the floorshift idea. The bolts for the gearbox mount had also broken out of the floor, so a few repairs were needed here as well.

    Then body deadened the whole underside.

    Peugeot 403 wagon restoration-000_2856.jpg

    cheers Pete
    Last edited by PCOATES505; 7th August 2011 at 11:32 AM.

    I am gunna get another 403 on the road........one day

  4. #4
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    Default Yes! Pete's on the job again

    Pete,

    Great to see you on the restoration road once again. Keep it up!

    friday403

  5. #5
    Fellow Frogger! PCOATES505's Avatar
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    Default Never off it

    Quote Originally Posted by friday403 View Post
    Pete,

    Great to see you on the restoration road once again. Keep it up!

    friday403
    Hi Chris

    This one has been on the back burner for a while, been held up by 3 years of drought and no money and some health problems, but it is under way again.

    cheers Pete

    I am gunna get another 403 on the road........one day

  6. #6
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    This is great Pete. A fine beginning. I'm specially excited by your Rotisserie device as I'm wanting to build one for my 49 model 203 when I get to it.
    Do you have any more pics of how that thing works or how you built it?

    Are you using a Mig ?

    How was the body deadener applied? Brush/spray etc.? Are you using a rust converter under this? What kind?

    Hope you don't mind all the questions.

    Keep it coming, please.

    Cheers,
    Dan

  7. #7
    con
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    Default 404 wagon

    Great start Peter; this will keep you off the streets for a while!


    best wishes

    con...
    Last edited by con; 4th August 2011 at 10:59 PM.

  8. #8
    Fellow Frogger! PCOATES505's Avatar
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    Quote Originally Posted by luthier View Post
    This is great Pete. A fine beginning. I'm specially excited by your Rotisserie device as I'm wanting to build one for my 49 model 203 when I get to it.
    Do you have any more pics of how that thing works or how you built it?

    Are you using a Mig ?

    How was the body deadener applied? Brush/spray etc.? Are you using a rust converter under this? What kind?

    Hope you don't mind all the questions.

    Keep it coming, please.

    Cheers,
    Dan
    Hi Dan,
    Welding is done with a Mig.
    Bare metal was treated with RS1 (phosphoric acid) rust convertor other areas were wire brushed and thoroughly washed before body deadener (Wurth body deadener) was applied with a body deadener gun.
    The rotisserie was fairly simple, a frame on the front that fitted to the bumper mounts, with a brace that bolted to the sub-frame where the cross member mounted. The rear frame also attached to the bumper mounts, but with braces that went down each side to the jack points. Each frame had a piece of pipe that fitted through the triangle stand. I used a small chain block to help rotate the body.
    I will take some photos of the various bits and post at a later date.

    cheers Pete

    I am gunna get another 403 on the road........one day

  9. #9
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    Default Fill in jobs

    In between bursts of body work I reconditioned the mechanicals.
    The motor was a bit sad.

    Peugeot 403 wagon restoration-000_2654.jpg

    So it got a full rebuild, Crank grind, new main and big end bearings, piston liner kit, Cam grind with refaced followers, full engine balance. The original head had 7 cracks so I bought another and had it re-coed with new valves and hard seats, had some corrosion welded and the head surfaced.
    New water pump, reco starter and an alternator.

    Peugeot 403 wagon restoration-000_3031.jpg Peugeot 403 wagon restoration-000_3032.jpg

    I am gunna get another 403 on the road........one day

  10. #10
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    Default more body work

    The sill covers were badly rusted.

    Peugeot 403 wagon restoration-000_2769.jpg

    So I made new ones and used the original end pieces

    Peugeot 403 wagon restoration-000_3197.jpg

    Peugeot 403 wagon restoration-000_3198.jpg

    Peugeot 403 wagon restoration-000_3199.jpg

    Peugeot 403 wagon restoration-000_3204.jpg
    Last edited by PCOATES505; 5th August 2011 at 12:40 AM.

    I am gunna get another 403 on the road........one day

  11. #11
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    Default Rear Axle

    After removing the complete rear end from the wagon, I removed the springs from the axle and dismantled the springs, then sanded the individual leaves to remove the rust, ground flat the areas where the leaves had lapped into each other, then treated all the leaves with rust killer (RS1) and painted all the leaves with POR 15. Springs were then re-assmebled and fitted with new shackle bushes.
    Rear Axle
    The axle tubes were removed and new bearings and seals were fitted, the diff was checked over, the housings cleaned and re-painted then re-assembled.


    Peugeot 403 wagon restoration-dads-pics-008.jpg
    Last edited by PCOATES505; 5th August 2011 at 03:41 PM.

    I am gunna get another 403 on the road........one day

  12. #12
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    Default Front end and Brakes

    Apart from the broken spring the front end wasn't too bad. The front spring got the same treatment as the rear ones. The cross member was sand blasted and painted with POR 15, the king pin assemblies, brake drums and back plates were done as well. New wheel bearings and seals were fitted.
    The steering rack got a refurbish with new rack eye bushes, new gaiters and reco tie rod ends.

    The brakes were in a sorry state, no linings left and the rivets had scored the drums. I managed to re-use 2 of the drums, but had to find replacements for the other two. The drums were machined and new linings fitted. All the wheel cylinders and the master cylinder were stainless steel sleeved and new rubbers and boots fitted. The rear handbrake cables were totally stuffed, no covering and the cables were seized solid. I had to get new ones made.
    Cost to overhaul the brakes was $700, ouch

    cheers Pete

    I am gunna get another 403 on the road........one day

  13. #13
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    Default Body work

    After finishing the rust repairs and applying body deadener, the whole underside was undercoated and painted.

    Peugeot 403 wagon restoration-000_3165.jpg Peugeot 403 wagon restoration-000_3166.jpg


    The engine bay was cleaned, new body deadener applied and it was undercoated and painted as well.


    Peugeot 403 wagon restoration-000_3158.jpg

    I am gunna get another 403 on the road........one day

  14. #14
    Fellow Frogger! PCOATES505's Avatar
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    Default Dash

    While the dashboard was out it got dismantled, sand blasted, painted, upholstered and reassembled.

    Peugeot 403 wagon restoration-000_3030.jpg Peugeot 403 wagon restoration-100_0225.jpg

    I am gunna get another 403 on the road........one day

  15. #15
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    Default Some assembly required

    I was lucky that I had replacement panels for the front of the wagon, the panels were inside a car that I rescued from the tip. The panels were in mint condition.

    Peugeot 403 wagon restoration-000_3129.jpg


    So the car has a good as new front valance and two mudgaurds


    Peugeot 403 wagon restoration-100_0018.jpg

    I am gunna get another 403 on the road........one day

  16. #16
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    Default Times change

    It was about this stage that the drought hit hard, times were uncertain, there was a possibility that I might not have a job and would have to move house, it became necessary to get the wagon mobile, so I refitted all the mechanicals, fortunately everything had been reconditioned.

    Front end going in
    Peugeot 403 wagon restoration-100_0021.jpg Peugeot 403 wagon restoration-100_0213.jpg

    rear end in
    Peugeot 403 wagon restoration-100_0211.jpg

    motor and gearbox in
    Peugeot 403 wagon restoration-100_0207.jpg

    Fortunately I kept my job and survived 3 years of drought and low income, but very little got done on the wagon during this time.
    cheers Pete

    I am gunna get another 403 on the road........one day

  17. #17
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    ....just a little feedback so you know we're watching and waiting for the next installment - loving your work^^^

    Cheers
    Chris
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  18. #18
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    Default Work during the drought

    One job I could do without financial cost was removing the old paint. The quarter panels weren't to bad, I just scraped the paint off with a razor blade and got back to the original primer, but the roof was another story. It was covered in surface rust, like measles, and was as tough as. It took 2 full days with an orbital sander with 60 grit paper to get it back to bare metal.

    Peugeot 403 wagon restoration-403-wagon-010.jpg Peugeot 403 wagon restoration-403-wagon-014.jpg
    Last edited by PCOATES505; 5th August 2011 at 09:28 PM.

    I am gunna get another 403 on the road........one day

  19. #19
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    You set very high standards, Pete! Great job and a very enjoyable read.

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    Totally inspiring Pete.
    I just have to mention scotchbrite sanding pads here. It's probably gone past the point where you'll need them, but they beat sanding pads hands down.
    Alpine put me onto them, saying they should be used on a polisher, but I got the ones that go on a 5" angle grinder and without the guard they are a bit diabolical, but remove paint real quick[flesh even quicker of course]. They even take metal if you haven't got a light touch. I like that because where there's rust you just need that extra grit.
    I used about 6 discs to completely strip the 203.
    I bought them from Blackwoods for $14 each. They are purple, made by 3M.

  21. #21
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    Default Interior clean up

    The interior was pretty grubby

    Peugeot 403 wagon restoration-100_0191.jpg

    so it got a clean up, floors were rust treated and body deadened.

    Peugeot 403 wagon restoration-100_0210.jpg

    Then I applied alumimium backed bitumen panels to the floor and more body deadener over the top.

    Peugeot 403 wagon restoration-100_0263.jpg Peugeot 403 wagon restoration-100_0261.jpg

    I am gunna get another 403 on the road........one day

  22. #22
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    Brilliant .... If only you could describe the incredible amount of effort and time that's gone into this. I saw and episode of "Pimp you ride" last week. The quality of the work they do is staggering. Little wonder people have no idea the time and effort involved in restoring a car. Seriously 2seconds was devoted to the rebuilt ... "here it is in primer, lets see what the colour is like" ................... They skipped about 200hours of rust removal and bodywork prep ... skipping over it in 2seconds.

    little wonder people post stupid questions on those american bodywork boards.

    seeya,
    Shane L.
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  23. #23
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    Default Panel beating

    wagon is currently at a panel beaters getting some dents removed (they were well beyond my capabilities). It had accident damage to the passenger side rear quarter which had been poorly repaired, a nasty crease through the drivers side rear guard arch and a dent in the roof

    Peugeot 403 wagon restoration-wagon-panels-004.jpg

    Peugeot 403 wagon restoration-panel-beating-003.jpg Peugeot 403 wagon restoration-panel-beating-004.jpg Peugeot 403 wagon restoration-repairs-002.jpg


    and now it looks like this

    Peugeot 403 wagon restoration-403-wagon-repairs-004.jpg Peugeot 403 wagon restoration-panel-beating-001.jpg


    now I wait until it comes home again.
    cheers Pete
    Last edited by PCOATES505; 7th August 2011 at 11:22 AM.

    I am gunna get another 403 on the road........one day

  24. #24
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    Quote Originally Posted by PCOATES505 View Post
    The interior was pretty grubby

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    so it got a clean up, floors were rust treated and body deadened.

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    Then I applied alumimium backed bitumen panels to the floor and more body deadener over the top.

    Click image for larger version. 

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    Hope you kicked the cat's arse for strolling across your handiwork. My guess is it's a ten year old ginger tom? (I was an injun tracker in a former life).



    Mike.
    Started out with nothing, still got most of it left.

  25. #25
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    Default You are right

    Quote Originally Posted by DoubleChevron View Post
    Brilliant .... If only you could describe the incredible amount of effort and time that's gone into this. I saw and episode of "Pimp you ride" last week. The quality of the work they do is staggering. Little wonder people have no idea the time and effort involved in restoring a car. ............. They skipped about 200hours of rust removal and bodywork prep ... skipping over it in 2seconds.

    seeya,
    Shane L.
    A lot of hours have gone into this project, it has been going for so long I tend to forget, but some of the detail I have missed :-
    Repairs to the front jack points and bumper mounts, they were bent up so far that I couldn't get the new front panel on. Rust in the sub-frame beneath the battery was repaired at the same time.

    Rust in the rear pan and sub-frame behind it that the tow bar was mounted on.

    Frames for mounting seats from a 405, beacause the wagon seat mounting is flat and the 405 floor is sloped, frames that are 40mm high at the front are needed to get the seat on the correct angle to give support under your legs. I have since rebuilt these frames, they weren't high enough at the front and the seat was too far forward.
    Peugeot 403 wagon restoration-100_0228.jpg

    Doors repaired and being prepared for painting.

    Peugeot 403 wagon restoration-403-wagon-016.jpg Peugeot 403 wagon restoration-403-wagon-017.jpg

    Mountings welded into the base of the B pillar to fit inertia reel seat belts.

    Dismantling the brakes, the wheel cylinders and shoe adjusters were seized, the shoes had gouged into the drums and left masive ridges, it took 6 hours /wheel to get the drums off.

    I have no idea how many hours I have spent, 500 would be a conservative estimate ( I work slowly these days). The cost of the project has been spread over 6 years so has not been a financial burden,, some of the major costs are :-

    Engine rebuild $2000
    Brakes $750
    Paint , body deadener etc. $1000
    Bearings and seals for gearbox, wheels, axles etc. $300+
    Seals and channels for doors and windows $700
    Upholstery $500 so far probably another $500 to go
    Panel beaters repairs to doors and rear quarters $600 "cheap"

    Iwill do the math for you $5850

    And it still looks like a heap of shit

    but one day!!!!!!!!

    cheers Pete
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    I am gunna get another 403 on the road........one day

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