Peugeot 103 "3rd Eye" mod

I've getting a borekit for the Peugeot 103 engine but it's the old kind, definitely pre-1975. I've also been informed that to fully accomodate my kit I'll need to incise a 3rd transfer port into my transfer case. After much searching of the forums I haven't been able to find any information on the technique. Has anyone performed this technique?

Re: Peugeot 103 "3rd Eye" mod

Hmmm malossi... cases.. email me.:)

Re: Peugeot 103 "3rd Eye" mod

Yeah Freddie suggested I get new cases but I seriously don't want to go splitting my engine in half. Not only do I lack the tools to split them, but I also lack the time to do so (and the money as well). I'd rather just carefully cut here and there. Thanks for the offer Ed.

Re: Peugeot 103 "3rd Eye" mod

if you can't split the case, and you don't feel comfortable putting a new case together. 1977 can put a case together for you and ship it to you. It will cost a bit more, but that's less than trying yourself, breaking it, and having to try again.

Re: Peugeot 103 "3rd Eye" mod

If you are wanting to dremel in a third transfer into your cases but are unwilling to do a proper job at if (splitting the cases), this kitting thing might just not what you should be doing at the moment till you have the time to do it right!

Re: Peugeot 103 "3rd Eye" mod

Well, so I figured, I _do_ enjoy being thorough most of the times. Thing is, this time, I'm not all that interested in reaping the full benefits of the kit...just looking for a little extra grunt to push a heavy dude a little harder. I've already a plan in mind involving a hand file and some putty and will do it safely...wouldn't be the tenth time I did a successful port job with a hand file. I had only hoped someone on this forum has attempted the job by hand w/o splitting the cases, we got lots of techiies on this forum.

Thank you both for your suggestions.

Re: Peugeot 103 "3rd Eye" mod

I just took a look at a stock bottom end. While I haven't added a transfer without splitting the cases it should be doable if you plug it up well.

With that said, you won't have a lot of clearance with the crank in there. It will take a long time to hog out that much aluminum with a file. This isn't just opening a port, it's creating a new one out of solid metal. It will probably be a long and arduous process with the small amount of travel you'll be able to get with your file.

I'm not saying you shouldn't do it. Hand tools are always preferable over power tools.

Re: Peugeot 103 "3rd Eye" mod

@Rocky

Yeppers I accidentally found a thread discussing the technique and you're absolutely right, a TON of material needs to be removed there and it will take me a while with my hand file. I won't be able to just ramp this port into the "3rd eye" will I?

Re: Peugeot 103 "3rd Eye" mod

Save yourself the headache and just buy the after market cases...

Re: Peugeot 103 "3rd Eye" mod

this is the really good case for it

1243626053_picture_082.jpg

Re: Peugeot 103 "3rd Eye" mod

Or pick up a rotary tool (Dremel), split the case, spend an afternoon on it and you'll be all set.

Re: Peugeot 103 "3rd Eye" mod

split the case...trying to mod the case without splitting and with a handfile is not the proper way or the easier way.

You wouldn't rebuild a car engine while it was still in the car with a screwdriver.

That would be doing it incorrectly with the wrong tool.

Do it proper or not at all.

once you get metal file shavings in those case bearings your bottom end it toast without splitting.

do it right the first time

https://www.mopedarmy.com/forums/discuss/read.php?f=7&i=126652&t=126626

https://www.mopedarmy.com/forums/discuss/read.php?f=7&i=126570&t=126482

Re: Peugeot 103 "3rd Eye" mod

Forgive my stubbornness (and outright laziness) on the issue, I know what I need to do...just trying to cut some corners here and maybe save some cash. I hope you don't mind but I'll be consulting each of you from time to time about this build, I won't fail.

@Fred, I'll email you about a case-splitting tool and other parts.

Re: Peugeot 103 "3rd Eye" mod

bump

Re: Peugeot 103 "3rd Eye" mod

Case splitting tool = blow torch ..... Super easy

Re: Peugeot 103 "3rd Eye" mod

split the case you will spend as much or more time doing it your way and wont be as sweet that case is super easy to split

Re: Peugeot 103 "3rd Eye" mod

Yerp, done and done. The case came off the frame and was completely apart in 45min...piece of cake.

Re: Peugeot 103 "3rd Eye" mod

haha, I was also going to try to talk you into doing it right.

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