Nova 3dr Hatchback Road Rally Car Build Thread

[dionbee]

Hi, My Name's Dion, Been on the forum for a few years under another username and been looking and taking ideas from other build threads until I was ready to have my own!

The Car:
1.2 8v non-sunroof shell,
Was my road car last year, Bought standard and GSi'd the outside and tarted up a bit until I was happy with how it looked. Got bored and Decided I needed a more useable road car (Bought a Passat TDi) and decided to rally the nova.

This is the nova when It was on the road:


How the car was when I got it and chucked my Compomotive Wheels on.


Under the bonnet - OMP strut brace


Rear when fitting new interior


Standard Interior



Painted bumpers, Rear quarters and De-locked boot at the same time

That's how it was until I stopped driving it on the road Last Year..

Any comments etc. Much appreciated.

Dion!

[dionbee]

Here are some parts I have gathered for the car:

Kent Cam Vernier & NVO52 Cam


RFX Group A Wheels in 13"


Boot Pinned with Anodized Black Pins:


Quaife Quick-rack


Bilstein Group A front struts (Including Protec Bumpy tar front and rear springs)


4-2-1 Exhaust Manifold:


Those are some of the parts I have bought, And a few weeks back i Bought a donor car (Rusty ex. Rally car project with a few good bits on it)
Here we are picking it up:


Stripping the White Shell:





Onto the Red one,
This is it before any work starts:


The White shell had a tidy straight SD cage (From what i've Gathered a hockly one) so mocked that in the red shell to see how it fitted, Also tried the seat in place for doorbar and diagonal clearance checking also steering:




Continued....

[dionbee]

Started on the Underside last week, Bought a spit from handling solutions, Best tool I've ever used, Makes the work much easier. Very happy with how clean the shell is if i'm honest. Found one piece of rust on the lower corner of the passenger rear arch but has been since cut out and welded inside and out.




Bought Myself a Harry Hockly Motorsport Chassis Plating Kit, a pair of Topmount strengthening plates and got myself some 'coins' to plate up the circular grommet holes in the floorpan.



Started getting to work on the underseal, Seam welding, fitting the plating kit and Etch priming as I was going along:









Continued....

[dionbee]

So basically that is where I'm at. I'm going back to uni next week so will be a fair few weeks until more beefy progress. I will be carrying on with parts buying and hopefully getting the beam etc. ready to bolt on.

Any comments etc. Are very much appreciated.

Thanks,

Dion!

[peester]

wow. top work. I assume the engine is out whilst its on the spit

[dionbee]

Cheers Mate, Yes The standard 1.2 engine was taken out and sold. The new 1.4 in mid-rebuild. Just standard with new gaskets etc and the Kent cam and vernier.

Dion!

[dionbee]

Back to uni next week so work on the shell will be at a halt for a while so ordered a few new parts today

- Full set of Polycarb Windows in a grey tint from ACW Motorsport Plastics using the PNG Discount!
- FIA Plumbed in fire extinguisher system from Demon Tweeks
- Flat 2mm Polycarb Doorcards (To be flocked at the same time as the dash)
- Alloy doorhandles for the inside (Standard plastic handles fouled the doorbars on the SD cage)

Any ideas and Tips/hints etc. Appreciated.

Dion!

[dionbee]

Bought a Bias Pedal box for the Nova This week (Got it through the post Friday) What are people's opinions on these? Going to be running 236mm Corsa GSi Brakes on the front (Grooved and vented with Ferodo/mintex or similar pads) and Standard drums on the back With EBC Heavy Duty (Black) shoes. Also will be running a Hydraulic handbrake with a bias adjuster inside the car. Do/should I need to be running a Remote Servo for this set up?

Dion!

[jimbob-mcgrew]

nice work DB

what kind of welder do you have ?

could you take a few extra pics of the brakes and calipers for me please mate, when you get round to fitting them

[dionbee]

Cheers mate!

Yeah ofcourse I can. Will be while as I'm back in uni at the mo so just partshunting at the moment. Got the astra GTE calipers on there at the moment, but i felt they were too much of an overkill and kept locking up so going down to 236 with good discs and pads. Should be ample for a little 1400.

[Edit] I'm using my brothers Snap-On Mig. Took a while to get used to, but produces really nice welds once on the correct settings. I'm using 0.8 wire and 'Beergas' and it's been spot on. Wouldnt pay the higher price for argon mix personally as it's not a very large difference. Alsong as the metal is good and clean, you'll be fine!
Dion