*HOW TO* Corsa brake servo setup
PARTS
Take one complete Master cylinder/servo setup from a scrap Corsa. Also get the strengthning plate below it.
http://iainel.co.uk/images/forums/NovaWIP2/463.JPG
FITTING
Position the Corsa plate in the right position, you'll be looking roughly here in the battery tray:
http://iainel.co.uk/images/forums/NovaWIP2/464.JPG
Holesaw or cut a square hole for the assembly to drop through roughly in the right position as so:
http://iainel.co.uk/images/forums/NovaWIP2/470.JPG
http://iainel.co.uk/images/forums/NovaWIP2/465.JPG
You'll find the pedal is far too long, but don't worry yet:
http://iainel.co.uk/images/forums/NovaWIP2/466.JPG
Weld in the tray when you know it's in the right position:
http://iainel.co.uk/images/forums/NovaWIP2/471.JPG
I added drainage grooves and lots of seam sealer to stop water sitting:
http://iainel.co.uk/images/forums/NovaWIP2/744.JPG
As for final mounting, I rotated the assembly to sit like this, as it cleared the scuttle and bonnet better:
http://iainel.co.uk/images/forums/NovaWIP2/718.JPG
http://iainel.co.uk/images/forums/NovaWIP2/721.JPG
PEDAL
Next you'll need to cut/shut the Corsa pedal. I used a Nova pedal:
http://iainel.co.uk/images/forums/NovaWIP2/514.JPG
Welded to a Corsa one:
http://iainel.co.uk/images/forums/NovaWIP2/515.JPG
And braced it both sides with thick plate:
http://iainel.co.uk/images/forums/NovaWIP2/752.JPG
ADDITIONAL BRACING
It's well worth bracing the assembly using an existing Nova pedal setup, as you may find the bulkhead flexes when depressing the pedal hard:
http://iainel.co.uk/images/forums/NovaWIP2/516.JPG
All fitted:
http://iainel.co.uk/images/forums/NovaWIP2/518.JPG
BRAKE LINES
For brake lines, I was making up some custom lines, but consider using the Corsa 4 way distribution block on the bulkhead:
http://iainel.co.uk/images/forums/NovaWIP2/733.JPG