1.6 8v T project

[mikec123]

Hi my name is Mike i recently decided to take my 1.6 T out and stitch weld my engine bay and re-spray it! I recently had it rolling roaded at stealth motorsport at 190.9 bhp and 184.5 lb ft. I am also going to fit upgraded engine mounts, strengthening kit, lightened flywheel, paddle clutch center plate and a limited slip diff!
http://i275.photobucket.com/albums/jj320/mikec1234567/100_0520.jpg?t=1217268034

http://i275.photobucket.com/albums/jj320/mikec1234567/100_0519.jpg?t=1217268876



http://i275.photobucket.com/albums/jj320/mikec1234567/Intercooler.jpg?t=1217268212
http://i275.photobucket.com/albums/jj320/mikec1234567/100_0619.jpg?t=1217269206
Took drive shafts out!
http://i275.photobucket.com/albums/jj320/mikec1234567/100_0617.jpg?t=1217269149
http://i275.photobucket.com/albums/jj320/mikec1234567/100_0611.jpg?t=1217268942
Took my rad and intercooler and all pipes for the intercooler off

http://i275.photobucket.com/albums/jj320/mikec1234567/100_0612.jpg?t=1217269028
http://i275.photobucket.com/albums/jj320/mikec1234567/100_060pol.jpg?t=1217268302
Found this nasty suprise hiding behind my headlight!!

I have got the engine and gear box out pics to follow!

[7ova]

good luck with your project mate :thumb:

[Mike]

Good stuff Mike, Scott was telling me about this car before, quite some power figure!!

Is it a T2 that you use?? What kinda boost pressure do you run mate?

[General Baxter]

why does this ring a bell?
http://www.pngclub.com/images/car_images/2953big.jpg

[Riggy]

yes welcome mike , scott does love your car lol , needs to finish his though haha , glad to hear your goin back to std kit aswell :thumb:

[mikec123]

Got my engine and gearbox out saturday with the help of my dad! Then yesterday me and scott took the brake servo and most of the bulkhead sound deadening off!
http://i275.photobucket.com/albums/jj320/mikec1234567/100_0660.jpg?t=1217345428

[mikec123]

It is a Garrett T2 running 12 psi! and that pic posted by Baxter is my car before the turbo conversion!

[NovaNeil]

My old Turbo Conversion :D Glad its still going strong Mike! Look forward to following its progress.

Neil

[scott.parker]

More pics dude...

Tell you what that sound deadening didnt half wiegh a **** load more then it looks! The break servo almost beat mike (stubern ****er wanted to stay on that flange!) so i got my hands dirty lol

Riggy for some reason i like to rip things off others cars, and work on theres rather then mine! lol

[mikec123]

Pic of engine outhttp://i275.photobucket.com/albums/jj320/mikec1234567/100_0659.jpg?t=1217440926

[mikec123]

http://i275.photobucket.com/albums/jj320/mikec1234567/100_0621.jpg?t=1217442044

[wilson_sri]

Nice to see another 1.6T mate! Whats the spec of the engine? Impressive power!

[iluvnovas_02]

hi mate good luck wi the project i have a few questions 4 u wat engine is it and wat turbo kit did u get and wat pistons did u use

[wizzy]

great car mate

[craig green]

Nice to see another 1.6T mate! Whats the spec of the engine? Impressive power!

Courtenay conversion with adapted DTA management if its as Neil had it. CS15 head too.
I was close to buying the original silver GSi it came from but had mine converted instead.

Nice to see the engine still lives. :thumb:

[mikec123]

Yep it is alot of Neil's old parts minus the aquamist, oilcooler and head! I have standard pistons but have a spacer plate to make the right compression! I'm hoping to get the engine to 200bhp just another 9bhp to go! Thanks for all your comments! Cleaned the brake servo up tonight pics to follow!:)

[1.6 8v turbo nova]

nice to see another 1.6t, ive got one that will be on road soon, and im also aiming for the 200bhp mark :) ive got the spacer plate bodge too, one of my pistons overheated and cracked.

[craig green]

The only issues I had with mine & HG issues were because the injectors were badly in need of a clean. Get that done to minimise any poor atomisation issues.

[Steve]

Nice project mate, really good power as well from the small block, surprised at the amount of torque it makes as well.

Will be good to see it all finished and what it does on the rollers again. :thumb:

[mikec123]

Pic of brake servo off the bulkhead!





http://i275.photobucket.com/albums/jj320/mikec1234567/100_0661.jpg?t=1217608777

[mikec123]

Took it apart ready for prep and spray!




http://i275.photobucket.com/albums/jj320/mikec1234567/100_0662.jpg?t=1217608991

[mikec123]

Started stripping the seam sealer in the engine bay off today, will put pics up tomorrow!

[Riggy]

good progress fella :thumb:

[DW-Nova]

Nice little car there mate, good to see that your starting a little overhaul, will probably be turboing my 1.4, what is the 1.6 turbo like to drive? how dose it compare to a redtop performance wise?

[mikec123]

The 1.6T is good to drive, but sometimes if im just driving along nice and steady and the boost kicks in it just goes flying down the road, because its a small turbo there is virtually no lag! As for comparing it to an XE, power wise a standard XE has less power! 1.4 T sounds interesting! 8v or 16v? What turbo are you thinking of using?:thumb:

[scott.parker]

Nice little car there mate, good to see that your starting a little overhaul, will probably be turboing my 1.4, what is the 1.6 turbo like to drive? how dose it compare to a redtop performance wise?

Ive drove mikes car,and compared to my old xe nova it was loads faster and much more nibble,easyer to drive,much more fun..but stick tb's on the xe and then your talking :D

[DW-Nova]

Will be making a 1.4 8v turbo with a renault 5 carb and whatever turbo i fancy as i work at a breakers yard i've kinda got a free choice, what turbo are you using on yours? I will be positioning the turbo where the exhaust back box would usually be.

[mikec123]

Spent abit of money today bought some paint for spraying my servo and other little bits!



http://i275.photobucket.com/albums/jj320/mikec1234567/100_0663.jpg?t=1218117907

[mikec123]

Cleaned my servo, then masked it up and got a piece of timber and drilled a 38mm hole in it to hold it upright for spraying!



Primer


http://i275.photobucket.com/albums/jj320/mikec1234567/Brakeservoinprimer.jpg?t=1218118143http://i275.photobucket.com/albums/jj320/mikec1234567/brakeservosprayed.jpg?t=1218118235Topcoat

[mikec123]

Started to clean the seams up in the engine bay ready for welding next weekend

http://i275.photobucket.com/albums/jj320/mikec1234567/enginebayseams.jpg?t=1218209467
http://i275.photobucket.com/albums/jj320/mikec1234567/seamaroundturrett2.jpg?t=1218209432

http://i275.photobucket.com/albums/jj320/mikec1234567/Seamarroundturrett.jpg?t=1218209384

http://i275.photobucket.com/albums/jj320/mikec1234567/Seam.jpg?t=1218209261

[craig green]

Don't forget the chassis leg to bulkhead joins in the bay & under the wheelarch.

[mikec123]

Yep cleaned them up today! got all the seams back to bare metal pics to follow tomorrow!

[DW-Nova]

What gbox and drive shafts are you using with your 1.6 turbo? just curious as i cant see the standard items lasting long and i'm thinking of what to use on mine, also sorry if you've said already but what is the spec of the engine internals on your engine?

[mikec123]

I have a F13 gearbox and standard drive shafts ive not had an trouble with them yet!As for my engine internals its all standard set up just got the courtaney spacer plate in between two head gaskets to achieve the right compression!:thumb:

[craig green]

I was running 170bhp (13psi) on the std box, clutch & shafts with no issues at all.
GM build large safety margins into their engines & transmissions. Unlike french hot hatches.

[mikec123]

I ve got abit further with my project i have removed the front wings and cleaned more of the seams up a



http://i275.photobucket.com/albums/jj320/mikec1234567/100_0683.jpg?t=1219180397



http://i275.photobucket.com/albums/jj320/mikec1234567/innerarch.jpg?t=1219180497

[mikec123]

Started cleaning up my seams and i noticed a dodgy bit by the turret a so i cleaned it up and have made a 3mm steel plate

http://i275.photobucket.com/albums/jj320/mikec1234567/innerturret.jpg?t=1219180614

[mikec123]

3mm plate


http://i275.photobucket.com/albums/jj320/mikec1234567/100_0686.jpg?t=1219180899

[mikec123]

Polybushes came from rallydesign bargin!



http://i275.photobucket.com/albums/jj320/mikec1234567/polybushes.jpg?t=1219181201

[scott.parker]

Started cleaning up my seams and i noticed a dodgy bit by the turret a so i cleaned it up and have made a 3mm steel plate

http://i275.photobucket.com/albums/jj320/mikec1234567/innerturret.jpg?t=1219180614

lol that spot weld almost had me beat,but i got it in the end! :thumb:

[mikec123]

it was abit tricky. Got my tie bars off today after work and took the top part of the front panel off! Also my chassis plating kit and my engine mounts turned up from chris astley 3 weeks after ordering them. Pics tomorrow of all my progress!!:D :D

[twistysnovagte]

top work and progress there mate,very impressive spec, and 200 bhp shouldnt realy be a problem for you.should be a nice sight when it all goes back in!

[mikec123]

not had a good day today my friend doing my welding managed to set fire to part of the loom and the fuse box and dash so ive bined the dash but iam after a new loom and fuse box, if anybody can help me could they let me know!!! cheers :wtf:

[DAN-F]

nice mototr mate
how thick is the spacer for lowering compression?

[mikec123]

I think its a 2mm spacer i can't remember it was while ago but i bought it from courtenay!

Pic of my engine mounts from Chris Astley

http://i275.photobucket.com/albums/jj320/mikec1234567/Enginemounts.jpg?t=1220029267

[mikec123]

Pic of tiebars ready to be cleaned up and re-sprayed and new bushes to go on
http://i275.photobucket.com/albums/jj320/mikec1234567/Tiebars.jpg?t=1220029454


Intercooler brackets sprayed up
http://i275.photobucket.com/albums/jj320/mikec1234567/interbrackets.jpg?t=1220029506

[mikec123]

Did more work to the car today took it to my mates work for welding! Pics of the penertration marks from the inner wing to bulkhead on the drivers side

http://i275.photobucket.com/albums/jj320/mikec1234567/Weldsdriversside.jpg?t=1220111188


Passenger side

http://i275.photobucket.com/albums/jj320/mikec1234567/Weldspassengerside.jpg?t=1220111253

Pic of the front panel in place and all the engine bay welds!

http://i275.photobucket.com/albums/jj320/mikec1234567/Frontpanelinplace.jpg?t=1220111490

Decided to place the wings on the car to see whether the front panel was in place!

http://i275.photobucket.com/albums/jj320/mikec1234567/Frontpanelwithwingsinplace.jpg?t=1220111608

http://i275.photobucket.com/albums/jj320/mikec1234567/Frontpanelandwing.jpg?t=1220111668

[scott.parker]

Nice one dude shame about the fire, dont forget to do the ones under the rack..

[mikec123]

Yeah done those dude!:thumb:

[*Dave*]

lovin this one thinkin about doin turbo conversion on my gsi but dont want to mess it up. lol

ill prob get it wrong.

great!

[mikec123]

Chris Astley chasis plating kit! Getting them welded on this weekend!

http://i275.photobucket.com/albums/jj320/mikec1234567/Platingkit.jpg?t=1220464884

[mikec123]

Done abit more on the car i cut out the rusty parts from behind the front panel!

Drivers side before

http://i275.photobucket.com/albums/jj320/mikec1234567/driverssidebefore.jpg?t=1220646725

After

http://i275.photobucket.com/albums/jj320/mikec1234567/Driversafter.jpg?t=1220646784

Passenger side

http://i275.photobucket.com/albums/jj320/mikec1234567/Passengerbefore.jpg?t=1220647035


After
http://i275.photobucket.com/albums/jj320/mikec1234567/Passengerafter.jpg?t=1220646934

[Novaboi_1991]

looking good mate, you know what your doing :) , im gonna mod my nova to the max, like ur idea's

[burgo]

looking good mate, you know what your doing :) , im gonna mod my nova to the max, like ur idea'slmfao

[mikec123]

Did abit more to the car made a 3mm steel plate to go behind the passenger side turret

http://i275.photobucket.com/albums/jj320/mikec1234567/PIC_0670.jpg?t=1222030027

[mikec123]

Passenger side outer chassis rail plate welded on and primered!

http://i275.photobucket.com/albums/jj320/mikec1234567/PIC_0672.jpg?t=1222030339

[mikec123]

Me on the right and my very helpful friend Si because if it wasnt for him holding down the car it would have floated away:D

http://i275.photobucket.com/albums/jj320/mikec1234567/PIC_0669.jpg?t=1222030522

[Rickyb]

looking good matey :thumb:

[nova_nath]

lookin good keep it up

[mikec123]

welded the plate i cut to go behind the passenger side turrett

http://i275.photobucket.com/albums/jj320/mikec1234567/platebehindturrett.jpg?t=1224100359

I stripped the underseal off my passenger side splash guard and found a nice big hole, better get the welder out again

http://i275.photobucket.com/albums/jj320/mikec1234567/splashguardds.jpg?t=1224100418

Ive decided to fill the seams along the top of inner wings i used metalik filler

http://i275.photobucket.com/albums/jj320/mikec1234567/filledseam.jpg?t=1224100545


Primered up drivers side with zinc primer!

http://i275.photobucket.com/albums/jj320/mikec1234567/driversinnerwingprimer.jpg?t=1224100643

[Mike]

Looking good Mike, admire your enthusiasm TBH mate! Im a lazy mofo, id have just got my hands on a donor shell again lol

[mikec123]

Cheers buddy i wanted to keep the shell because its an orignal silk violet gsi otherwise i would have re-shelled:D

[scott.parker]

Humm, dude i didnt think the wing would come out as good as that to be fair, looks pretty good, will have to come dig in soon (pending tomo's out come)

Scott

[craig green]

What's metallic filler?

Fair play for fixing up a shell beyond its prime though, I did it with mine & its a lot of work.

[Steve]

Its like ordinary body filler but it contains metal, so is supposed to be alot better.

[mikec123]

yeah it is alot of work but it will be worth it in the end! I thought i would go for the metalik filler over normal P38 because there wasnt much price difference and like steve said it contains metal!:thumb:

[mikec123]

Engine bay in primer

http://i275.photobucket.com/albums/jj320/mikec1234567/enginebayprimer.jpg?t=1225045978


http://i275.photobucket.com/albums/jj320/mikec1234567/driversprimer.jpg?t=1225045849


http://i275.photobucket.com/albums/jj320/mikec1234567/Passangerprimer.jpg?t=1225045902

[krobinson]

Good work on the shell, just make sure you seal the inner arches well because water can get under that filler in the bay.

Keith

[mikec123]

Cheers buddy will do:thumb:

[scott.parker]

Good good,getting there, cant wait to spray the bay!

Scott

[mikec123]

Not working this week so thought i would do abit on the car. I cut out the rusty bits on my passanger's side splash guard.

http://i275.photobucket.com/albums/jj320/mikec1234567/splashcut.jpg?t=1225300629


Then i made a template from hardboard.

http://i275.photobucket.com/albums/jj320/mikec1234567/splashtemp1.jpg?t=1225300714

Template offered up into place.

http://i275.photobucket.com/albums/jj320/mikec1234567/splashtemp2.jpg?t=1225300773

Then i made the metal plate from 3mm steel bending and shaping it into position, then i put a couple of G clamps on it to hold it in place ready for welding this weekend.

http://i275.photobucket.com/albums/jj320/mikec1234567/splash1.jpg?t=1225300987

http://i275.photobucket.com/albums/jj320/mikec1234567/splash2.jpg?t=1225301043

[scott.parker]

Humm..dude might be worth diggin out some more of that grotty bit behind it first, i'll come looks'y tomo.

Scott

[mikec123]

yeah cleaned up behind there just not a pic of it

[scott.parker]

yeah cleaned up behind there just not a pic of it

Taddar!! as if like magic!


http://img201.imageshack.us/img201/6169/30102008630yj3.jpg

So i went round today to see how Mike was getting on, an while there gave him a had with a few things, lent him my thoughts on some ideas etc.

Mike was busy outside on the car sorting the inner wing splash gards, so i got busy inside removing loads of acoustic sound deadening (why someone would go to the hassle of getting rid of the GM stuff then cover it with this **** i don't know) but i do know it's thiner and more sticky to take of then GM stuff

Inner wings/splash gard before cutting..

http://img171.imageshack.us/img171/7028/30102008631ra1.jpg

Mike busy grinding off chunks!

http://img171.imageshack.us/img171/1262/30102008633xc7.jpg

http://img201.imageshack.us/img201/4614/30102008634iq8.jpg

Wallah!

http://img201.imageshack.us/img201/3894/30102008635mv9.jpg

http://img201.imageshack.us/img201/7201/30102008637rv9.jpg

http://img201.imageshack.us/img201/5458/30102008636tm9.jpg

Random bay pic!

http://img171.imageshack.us/img171/7329/30102008632ck0.jpg

Then my few hr's hard work inside.

http://img201.imageshack.us/img201/2741/30102008638sk9.jpg

Mike has some before/after pics of the sound deadening, and some better quality ones of the other work,and im sure he will upload his of the 3mm new plates he's cut, there spot on mate :thumb:

Scott

[mikec123]

Pics of the drivers side splash before the grinder killed it.

http://i275.photobucket.com/albums/jj320/mikec1234567/DSSPLASH.jpg?t=1225473315

http://i275.photobucket.com/albums/jj320/mikec1234567/DSSPLASH1.jpg?t=1225473370


http://i275.photobucket.com/albums/jj320/mikec1234567/DSSPLASH2.jpg?t=1225473407

After i cut the bad bits out of the splashguard i made a hardboard template
http://i275.photobucket.com/albums/jj320/mikec1234567/PIC_0830.jpg?t=1225473515

Then i transfered it on to 3mm steel and cut the shape out
http://i275.photobucket.com/albums/jj320/mikec1234567/Splashguarddriver.jpg?t=1225473596

Pic of the inside of my car before Scott's efforts. Thanks again
http://i275.photobucket.com/albums/jj320/mikec1234567/insidecarbefore.jpg?t=1225473705

[BRoadGhost]

3MM is miles to thick to work with ~ look at the fracture in the hardboard too, you'll never bend the steel like that.

Plus what a waste of material ~ the template should have been laid onto the very edge of the steel not 20MM in.

[scott.parker]

3MM is miles to thick to work with ~ look at the fracture in the hardboard too, you'll never bend the steel like that.

Plus what a waste of material ~ the template should have been laid onto the very edge of the steel not 20MM in.

Mike used the hard board as it was essayer to keep a good edge to it,not like card bord etc.
3mm steel was the thinnest his mate could get there hands on (it was free)
We have already bent the steel into position,he's just not put any pics up off it, and yes Mike and i both thought it should probably join straight to the edge, but also thought it was best to leave some over hang,put the wing back on,then temp clamp the new bit in place as to mark out on the back where to put the final cut.

Scott

[Mike]

3MM is miles to thick to work with.

Ive never had issues when working with 3mm sheet steel?

[Adam]

1mm is plenty for the splash gaurds and stuff like that.
Its also easy to cut/bend(hence the work with comment)

[scott.parker]

1mm is plenty for the splash gaurds and stuff like that.
Its also easy to cut/bend(hence the work with comment)

True Adam, but as said Mike's mate could only get 3mm at the time and it was FREE.

Scott

[BRoadGhost]

Thank god you're not removing the heater claiming the payoff in weight loss is worth it then.

[almond]

True Adam, but as said Mike's mate could only get 3mm at the time and it was FREE.

Scott
good enough reasson for me:D

looking good fella. what would we do without grinders :confused:lol

[mikec123]

I had no problem working with 3mm steel.Never have! I only used 3mm because it was free!!!!!!!!

[scott.parker]

Right as me and mike are out of work now he (we) have more time on our hands,so Ive popped over to help out a few times in the last few weeks,and here's a mini update on things.

Mike's mate Simon has finished all the welding to the car (without any more fires :D ) and the inner wings are all done (mike has pics of this I'm sure)
The bay is prepped and ready for spraying over Christmas,i hope to have a go at the spraying my self..:)

So back to last week, i popped by and asked if he needed a hand with anything,and we decided while the engine and box are out and separated they should get cleaned up/painted etc, so thats what we set about doing so..

Box was cleaned of all grime by mike,now we start the prep, main prep was done using drill wire brush attachments etc,then some finishing with sand paper/wet n dry, GM's finish from the cast is so so shocking:wtf:

Prep of box.
http://img241.imageshack.us/img241/6607/photo0006smallnd5.jpg

not much has been prep in this pic,you can see theres still some grime/dirt on it,and Ive not yet took the rust/paint of the black cover yet.
http://img241.imageshack.us/img241/6217/photo0009smallje4.jpg

While cleaning, we noticed these codes,Ive got no idea what it is,but sure some of you do lol
http://img241.imageshack.us/img241/5149/photo0007smallkt4.jpg

http://img241.imageshack.us/img241/8693/photo0013smallxy2.jpg

http://img241.imageshack.us/img241/3432/photo0016smallzy6.jpg

[scott.parker]

Check the **** in the casting!:roll:

http://img241.imageshack.us/img241/458/photo0014smallye2.jpg

http://img241.imageshack.us/img241/9962/photo0017smallof9.jpg

http://img241.imageshack.us/img241/884/photo0018smallnz6.jpg

http://img241.imageshack.us/img241/1281/photo0019smallce3.jpg

http://img241.imageshack.us/img241/9941/photo0025smalllx3.jpg

All the paint/rust sanded off..

http://img241.imageshack.us/img241/6246/photo0026smallef9.jpg

Zinc primer on the bottom/diff cover, filler primer on the top where it was badly pitted in the casting,and what ever els we could find got slung on it lol

http://img241.imageshack.us/img241/4321/photo0028smallfu9.jpg

And bit of drying under the lights..
http://img241.imageshack.us/img241/5140/photo0031smalllo0.jpg

[scott.parker]

Forgot to say these pictures are all taken using my new phone, samsung toco (touch screen) 5 mega pixel, lol Ive got a new digi cam for Christmas thats 10 mega pixel.

Anyway, it was onto some more coats of primer,before quick dry then first top coats.
Diff plate,under box in first coat etc

http://img241.imageshack.us/img241/2950/photo0033smallhx9.jpg

http://img241.imageshack.us/img241/1421/photo0036smallic5.jpg

First coat's of Hammerite smooth silver brushed onto box casing.

http://img241.imageshack.us/img241/3915/photo0066smallza0.jpg

http://img241.imageshack.us/img241/8207/photo0065smallxa8.jpg

http://img241.imageshack.us/img241/6928/photo0067smalllk2.jpg

While i was there the next day Mike had started to clean up the block/head and turbo/exhaust manifold etc, while i was holding the exhaust down pipe and he was cleaning i noticed it seamed to be moving about allot,so we investigated (as it was heat wraped) and found the down pipe was split:eek:

Hence to say Mike was not happy,and we called it a day at that..

(ref fro Mike LOTNS)

http://img241.imageshack.us/img241/1018/photo0060smallwj3.jpg

So at some point he's now got to get the down pipe re-made.


Scott

[Mike]

Looking good Mike/Scott.

Sorry about my phone cutting you off the other evening mate, its been playing havoc the last few days!!! You get a chance to looks at any of the downpipes I told you about mate?

[scott.parker]

Yeah couldn't seen any worth going to the hassle of buying one, mike's just going to try get one made.

[Mike]

Ok mate, was worth a try though chap.

[mikec123]

cheers for the pics scotty:thumb: Good camera on that phone!

[wilson_sri]

Looks to be coming on well!

Dont suppose you have any detailed picture of how your turbo to AFM hose was?

[scott.parker]

Wilson, i don't think it had a GM set up(if you mean like the standard AFM box etc?) Nova Niel who use to own the engine before did a lot of custom bits to it, and I'm not 100% sure if thats what you mean or not, i could find a pic of the engine if it would help?

Scott

[mikec123]

A few more updates i undersealed the splash guards and in the arches

http://i275.photobucket.com/albums/jj320/mikec1234567/driverschasisleg-1.jpg?t=1230134221


Started to clean the engine up
Here it is with the exhaust manifold off

http://i275.photobucket.com/albums/jj320/mikec1234567/engine.jpg?t=1230134381


I then took the inlet manifold off and cleaned it with my wire brush attachment that fits in my drill
http://i275.photobucket.com/albums/jj320/mikec1234567/inletcleanedup.jpg?t=1230134431

Then i gave it 2 coats of hammirite smooth silver
http://i275.photobucket.com/albums/jj320/mikec1234567/inletpainted.jpg?t=1230134524

http://i275.photobucket.com/albums/jj320/mikec1234567/inletpainted.jpg?t=1230134524

I also painted my rocker cover with a heat resistant paint then im going to spray it the same colour as the car!

http://i275.photobucket.com/albums/jj320/mikec1234567/rockercover.jpg?t=1230135420

I have just taken my car to a friend of mine and iam spraying the engine bay on saturday!

[scott.parker]

Dude not sure if you meant to,but the last two inlet pics are the same?

Looks all good though, and that paint on the rocker looks quite nice as it is lol might use that on mine!

So are you spraying the bay on sat or am still going to try it?

Scott

[wilson_sri]

Wilson, i don't think it had a GM set up(if you mean like the standard AFM box etc?) Nova Niel who use to own the engine before did a lot of custom bits to it, and I'm not 100% sure if thats what you mean or not, i could find a pic of the engine if it would help?

Scott
Mines isnt standard gm set up either. Got a hose rungs from the turbo to the standard AFM. No air box though, goes to a k&n air filter.

I think its the same set up as it has the hole cut in the wing. Pics of engine would help.

[scott.parker]

Mines isnt standard gm set up either. Got a hose rungs from the turbo to the standard AFM. No air box though, goes to a k&n air filter.

I think its the same set up as it has the hole cut in the wing. Pics of engine would help.

Not the best pic, but im sure mike has better.

http://img241.imageshack.us/img241/5994/15092007006xj6.jpg

http://img241.imageshack.us/img241/5994/15092007006xj6.jpg

Scott

[mikec123]

Pic of the inlet with injectors back in ready to back on the engine

http://i275.photobucket.com/albums/jj320/mikec1234567/inletpainted2.jpg?t=1232048192

[mikec123]

Pics of the engine bay which i sprayed up over xmas

http://i275.photobucket.com/albums/jj320/mikec1234567/enginebaypaint.jpg?t=1232128559


http://i275.photobucket.com/albums/jj320/mikec1234567/enginebaypaint3.jpg?t=1232128602


http://i275.photobucket.com/albums/jj320/mikec1234567/enginebaypaint2JPG.jpg?t=1232128646


http://i275.photobucket.com/albums/jj320/mikec1234567/enginebay4.jpg?t=1232128692

[Jay]

Looking good mate, i like fresh paint :)

[scott.parker]

Look really good, ill have to pop over and have a gander!

Also dude you should ask on here about them fuel pressure regulaters.

Scott

[craig green]

Bloody nice paint job on the engine bay by the looks of things.

keep at it matey.

[mikec123]

Cheers for the comments. i put the inlet back on the engine yesterday just got to get my new clutch, have my flywheel lightened and sort out a new downpipe then the engines ready to go back in.Lack of money has ground me to a hault at the moment.:eek:

[jimbob-mcgrew]

the mighty 1.6 8v.. with added turbo! very nice.
any idea what the brake per ton is mate ? i reckon its prob around 220, depending on interior bits, which must be rapid.
hell of alot of resto work gone into this :thumb:
im liking the solid engine mounts too.

[mikec123]

cheers buddy havent got a clue what the brake per tonne is.:thumb:

[scott.parker]

the mighty 1.6 8v.. with added turbo! very nice.
any idea what the brake per ton is mate ? i reckon its prob around 220, depending on interior bits, which must be rapid.
hell of alot of resto work gone into this :thumb:
im liking the solid engine mounts too.

Taken with a lrge pich of salt, this is from http://www.letstorquebhp.com/calculator.asp


Power at Flywheel (BHP) : 191
Weight without Driver (KG) : 790
Power to Weight Ratio (BHP Per Ton) : 245.65
0- 60 (Secs) : 5.050
0- 100 (Secs) : 12.54
60- 100 (Secs) : 7.49
Quarter Mile (Secs) : 13.46
Terminal Speed (MPH) : 103.58
Drag Strip Quarter Mile (Secs) : 13.26
Drag Strip Terminal Speed (MPH) : 105.51

But hey, we wont know till we test it he Dude! :thumb:

Scott

[mikec123]

Cheers dude. Im impressed with that lets hope it does something near that:thumb:

[Edd]

as said engine bay looks good. as im building a 1.6 8v turbo il keep a eye on this one.

[mikec123]

Be interesting to see what you are up to. Do you have a project thread?:thumb:

[ben doodar]

nice work gone into that,good write up aswell. love the idea of a 1.6 8v turbo, bet its ace to drive. ive often thought about turboing my 2.0 8v, but i can imagine the mapping manegment being too expensive. i know it says you bought the complete engine with ecu etc. what sort of money do you think you would pay for the manegment + mapping etc.
does anybody use megasquirt? my mate who is into his mk2 golf's said alot of them boys use mega squirt on the golf forums. my boss's friend uses a mega squirt system in an off roading landrover aswell, but i never get chance to pick his brains about it.

also did you ever go to a vauxhall/ford show in coventry maybe 3-5 years ago. sure it was at a county show ground or somthing...

[jimbob-mcgrew]

oo scott u cheated on the weight ! lol
just did a calculation with a 70 kilo driver sat in it, comes out 225 brake per ton.
thats still serious brown trousers from my point of view lol

[Edd]

Will be starting a project thread very soon. got lots of bits already.

[scott.parker]

nice work gone into that,good write up aswell. love the idea of a 1.6 8v turbo, bet its ace to drive. ive often thought about turboing my 2.0 8v, but i can imagine the mapping manegment being too expensive. i know it says you bought the complete engine with ecu etc. what sort of money do you think you would pay for the manegment + mapping etc.
does anybody use megasquirt? my mate who is into his mk2 golf's said alot of them boys use mega squirt on the golf forums. my boss's friend uses a mega squirt system in an off roading landrover aswell, but i never get chance to pick his brains about it.

also did you ever go to a vauxhall/ford show in coventry maybe 3-5 years ago. sure it was at a county show ground or somthing...

Ill try answer some for you mate, Neil who use to own it spent £K's on the engine/setup etc, I think for the DTA and all the parts gathered to get it working was near to £3000 (not sure though) so it's not really worth while doing it (unless your lucky like him, engineer @Rolls-Royce) and have the money to do so..
20ltr 8v turbo’s are really good, or even on TB’s! That’s worth thinking about doing.

And I think I know the show your on about mate, I’ll dig you out a pic.

Scott

[ben doodar]

am not going to bother messing with the 8v, alot of people think there not worth while, but they do go well, and easy to work on in a nova.
but for them extra few ponnies, im just going go for a redtop.
yh i thought it would be a costly affair turboing the 1.6 really cool tho.
thats why i asked about the megasquirt as it can be done on the cheap, just out of interest really.

yh see if you can dig the pictures out from the show, you may remeber my mates 1.7td nova on the mobile rolling road there? chucking out alot of black smoke haha.

[scott.parker]

Well today I went round to mikes, the plan was: take of rear suspension, disconect brakes/hand brake, and remove rear beam so it can be de-rusted Polly bushed and painted up!

So off we go...we jacked the car up, put it on axle stands then undid the nuts from the top the shocks, making sure threes a jack under the beam to take the weight.
The undone the shocks from the beam, and removed the springs (we were both confident we know how to get to this point)LOL

Now we were a bit in un charted waters as neither me more Mike had take the rear brake lines apart, more disconnected a hand brake set up before!

So quite a bit of fiddling and swearing later (WD40 was needed big time LOL 18 years of sh1te) we got the brake lines disconnected by undoing them where they join to the flexi lines from the solid part (bracket on the rear beam)

Now were stumped! Neither of us knows how to get the handbrake cable off from the back of the drums; bit of luck I had a Hanes nova manual in back of my car.
Bit of reading and swearing and we soon had them disconnected (lets hope they go back the same)
so then it was time to undo the bolts to the beam and drop it..

http://img222.imageshack.us/img222/2856/photo0123smallhh5.jpg

http://img222.imageshack.us/img222/2201/photo0124smallyg1.jpg

Now I know some of you can do this in your sleep, but for us it was all unknown and a dam bit of fun.
So we though huh good bit of work done, at this point mike went of to make some tea.
So I started looking at the rear inner arches, I found some dark loose under seal (you can see it in one of the other pics) I pulled at to find it was a huge lump of filler covered over with sh1te loads of under seal!!
Well I was shocked and so was mike, well we both thought sod it he's done the front end, so let’s see what lerking under the rear arches is!

Let the rot fest begin!!

http://img222.imageshack.us/img222/6308/photo0125smallpj1.jpg

http://img222.imageshack.us/img222/4483/photo0127smallnj4.jpg

http://img222.imageshack.us/img222/1758/photo0126smallzu5.jpg

Iffy sping plate (can you buy these??)

http://img222.imageshack.us/img222/3776/photo0128smallhp4.jpg

How would you go about fixing/platting the chassis leg part??

http://img222.imageshack.us/img222/6213/photo0142smallxi4.jpg

These are all of the off?drives side.

Now the near side looked better at first inspection...

http://img222.imageshack.us/img222/6052/photo0129smallwq1.jpg

Opps!

http://img222.imageshack.us/img222/9803/photo0130smallog8.jpg

Then the nasty supprise we hoped we wound not find..

http://img222.imageshack.us/img222/5705/photo0131smallxe8.jpg
http://img222.imageshack.us/img222/4579/photo0144smallsh2.jpg

Mike Needs some advise on the best way to tackle sorting this bit, how do you go about plating it? can you buy the spring monuts??

[scott.parker]

Mike then said well may aswell get grinding it out! so he set to it straight away lol fair play!
I kept and eye on the iside for him as some sparks were going through into the car (dont want another fire)

http://img230.imageshack.us/img230/1101/photo0132smallcr3.jpg

http://img230.imageshack.us/img230/1118/photo0134smallce4.jpg

http://img230.imageshack.us/img230/9749/photo0137smallvr4.jpg

http://img230.imageshack.us/img230/7932/photo0133smalltq5.jpg

http://img230.imageshack.us/img230/8476/photo0138smalljo3.jpg

Nice...:roll:

http://img230.imageshack.us/img230/454/photo0141smallow7.jpg

http://img230.imageshack.us/img230/6348/photo0140smallsh1.jpg

So weather pending the other side will get attacted as well tomo!

To be honest im just as gutted as mike is, as we never thought it would be this bad, but theres no going back, and might as well do a propper job, so what started as a small restoration is now a BIG one lol

Least the engine looks nice now..:D

http://img230.imageshack.us/img230/7117/photo0145smallek4.jpg

Keep your head up dude, i'll help as much as i can.

Scott

[Steve]

Sh!t that is a nasty surprise! good to see it hasnt put you off, especially with all the other work
thats gone into it. Engine does look good :cool:

[scott.parker]

Sh!t that is a nasty surprise! good to see it hasnt put you off, especially with all the other work
thats gone into it. Engine does look good :cool:

lol just a bit, i dont think he wants to take the skirts off as he's too worried what we'll find...

[ben doodar]

fair play to you both for the hard work going in, i rember when i started to find more n more rot on my car, p!ssed me off no end, really dis-hearten's you. i hate welding rotten cars, it really aint a nice job!! so credit to you both for your hard work..

[mikec123]

cheers for the pics dude! as Scott said need a little advice as to what to do with the chasis.:thumb:

[Adam]

Jesus, thats quite a bit of rot! :(

[Mike]

Jebusususs! Some structal rot that chap!!! Chin up though lads, a little time and patience will get that sorted :thumb:

[CorsaBBoomer]

Not as rotten as mine so there is always hope...
Love the engine setup :thumb:

[scott.parker]

So while cleaned that up he got on grinding out the nearside rear arch, he thought it was best to cut more out then was needed just so we could inspect inside the chassis. Good job too as it's well gone! :eek:

Driver/off side cleaned and acid rust coated

http://img230.imageshack.us/img230/463/photo0150smalljs7.jpg

So the plan for this side is: Plate inside the chassis leg over where the spring cup is, and underneath it, re-build the lip, and make good to inner arch, mend the chassis leg/toe eye area/stone grad-seal etc.


Near side cut out and looking nasty as fook!


http://img405.imageshack.us/img405/2739/photo0148smalldd7.jpg

http://img504.imageshack.us/img504/5373/photo0149smalloq5.jpg

So me and mike talked through what was the best idea for this side, and we think that it's best to cut the chassis leg from behind the beam mount to just past the spring cup, then use this to copy/form a new one from

We then started on the rear beam as it started raining, first off removing the anti-roll bar from it, and then we tried for ages to get the swing arm bushes out (first one we did took about 20mins lol)

Then i realised there was a faster way, so NOTE for anyone wanting to remove old bushes from there rear beam, the quickest way i found was to cut with a hacksaw round the rubber sides, leaving 5mm of the metal bush showing either side, then just hit it with a hammer and it will come straight out! :thumb:

http://img132.imageshack.us/img132/6015/photo0146smallqd2.jpg

http://img504.imageshack.us/img504/331/photo0147smallgu5.jpg

Scott

[mikec123]

Cheers again Scott for the help and the pics:thumb:

[mikec123]

Done abit of work on the rear beam today because it kept raining. Spent about 30 mins with my drill with the wire wheel attachments to clean the rust off. Ive cleaned the left side.

http://i275.photobucket.com/albums/jj320/mikec1234567/beam.jpg?t=1233174110

Uncleaned
http://i275.photobucket.com/albums/jj320/mikec1234567/beam2.jpg?t=1233174192

Cleaned
http://i275.photobucket.com/albums/jj320/mikec1234567/beam3.jpg?t=1233174271

[Jay]

Looks good matey, keep up the good work. :thumb: Nice to see a member doing some work themselves for a change. lol

[Mike]

Cracking along chap :D

[Ernie]

Scott phoned me about this the other day and dont look to bad.Keep up the good work mate.

[scott.parker]

Yeah im more intrested in saving this car then sorting my own, and i think it's cus there is still a part of me that's in love with the silky V lol

[craig green]

The rot on the rear of this one reminds me exactly of mine.

I chose to turret the rear wheel houses so that the chassis legs arent structural in terms of supporting the weight of the car.

See my WIP if you can find it. 1st page or so.

[krobinson]

Nasty Rust there, if only chassis legs were easier got then you could just fit two new ones :(

[scott.parker]

The rot on the rear of this one reminds me exactly of mine.

I chose to turret the rear wheel houses so that the chassis legs arent structural in terms of supporting the weight of the car.

See my WIP if you can find it. 1st page or so.

I said this Craig, and im sure mike would but at the mo he's not flush enought to buy any rear coilovers, he's using my old spax RSX spring/shock kit

Keith if we could find a doner car for pennies it would be done!:thumb:

[mikec123]

Done some more work on my car. I took my fuel tank off thought it was good idea as im going to be welding next week on the rear chasis leg and it needs a clean and paint up.

http://i275.photobucket.com/albums/jj320/mikec1234567/tank.jpg?t=1233438126


Next i took the drums off the beam four 8mm alllen bolts for each drum they were abit rusty.Finished cleaning the beam with a sanding disc on my grinder.

http://i275.photobucket.com/albums/jj320/mikec1234567/beamcleanedup.jpg?t=1233438378

Next i put 2 coats of Hammirite anti rust primer on ready for some Hammerite smooth black tomorrow.
http://i275.photobucket.com/albums/jj320/mikec1234567/beaminprimer3.jpg?t=1233438525

http://i275.photobucket.com/albums/jj320/mikec1234567/beaminprimer2.jpg?t=1233438586

http://i275.photobucket.com/albums/jj320/mikec1234567/beaminprimer.jpg?t=1233438645


I also made a plate to go inside the chasis leg to strengthen the spring cup part of the chasis will be welding monday hopefully. Just need to clean up inside the chasis leg.

http://i275.photobucket.com/albums/jj320/mikec1234567/chasisplate.jpg?t=1233438809 (http://javascript<b></b>:void(0);)

[scott.parker]

Looks good dude, dont forget to clean the ARB as well.

Has that surface rust come back since we cleand it up?

Scott

[krobinson]

Looking good, hopeing to be ready for PV?

[mikec123]

Would be nice if i could get it ready for then! cheers for the coments:thumb:

[mikec123]

Right removed my rear panel yestersay drilled all the spot welds and seperated from the shell. I've ordered another rear panel from Beevers should be with me this week. Here's a couple of pics.It does look like a skip in the first one.lol

http://i275.photobucket.com/albums/jj320/mikec1234567/rearpaneloff.jpg?t=1234343291

Drivers side corner

http://i275.photobucket.com/albums/jj320/mikec1234567/bootfloor1.jpg?t=1234343343

Passenger side

http://i275.photobucket.com/albums/jj320/mikec1234567/bootfloor.jpg?t=1234343391


Rear panel not a good pic but you can still see the rot along the bottom

http://i275.photobucket.com/albums/jj320/mikec1234567/rearpanel.jpg?t=1234343446

[Ernie]

Keep up the good work.
It will get there in the end.

[Adam]

Keep up the good work.

[CorsaBBoomer]

http://i275.photobucket.com/albums/jj320/mikec1234567/bootfloor1.jpg?t=1234343343


Massive work mate :thumb:

Maybe an odd question but could you take a picture from the inside looking out the back? Would be helpfull as I'm doing the same ;)

Cheers!

Tom

[scott.parker]

Nice one dude, get the grinder on the boot floor now,chop chop lol

PS: your nickname should be mikey arc eye

[mikec123]

Right got more done on the car today the rear panel turned up from Beevers

http://i275.photobucket.com/albums/jj320/mikec1234567/newrearpanel.jpg?t=1234374839

Tried the panel in place, not a bad fit:thumb:

http://i275.photobucket.com/albums/jj320/mikec1234567/rearpanelinplace.jpg?t=1234375650




Started with the drivers side i cut out the rot from the boot floor. I used my Jigsaw with a metal cutting blade did it quite easy as the boot floor is quite thin.

http://i275.photobucket.com/albums/jj320/mikec1234567/bootfloorcutout.jpg?t=1234375110

Next i made a cardboard template of the piece i had just cut out then transfered it to metal. Just in place at the mo.

http://i275.photobucket.com/albums/jj320/mikec1234567/bootfloorreplacement.jpg?t=1234375232

I had to cut the chasis leg by the toeing eye because it was rotten so i drilled the spot welds holding the toeing eye onto the chasis and will be able to re-use it. Then i had to make a box section for the chasis leg. Everything is just clamped in place at the mo i need to clean around where im going to weld.

http://i275.photobucket.com/albums/jj320/mikec1234567/chasislegnew.jpg?t=1234375421

http://i275.photobucket.com/albums/jj320/mikec1234567/chasislegnewunderneath.jpg?t=1234375559

[mikec123]

Thanks for all the coments. CorsaBBoomer i will take a pic tomorrow for you.:thumb:

[Edd]

liking the progress, keep it up. all be worth it when its finished.

[scott.parker]

Just goes to show any sod can do this lol

dude looks good, little bit more in that corner though by the back lip.

Scott

[kevster]

keep up the good work.

[tom_bish]

Well saved - some good work gone in here mate

I did this to an SR a couple years ago which turned out to be a little more rusty than i first thought.

[Rickyb]

omg i cant belive how much work this needed but fair play to you for cracking on with it good work lads.

[GDN16v]

Good progress, and nice work!!:thumb:

[craig green]

Nice work again.
It just reminds me exactly of what my shell (GSi) was like.

It will be worth it in the end.

[mikec123]

Abit of an update! Just cleaning the underneath of the the boot floor and chasis. Cleaned all the rust off back to bare metal then treated it with hammarite Krust then primed it with anti rust primer.


You can see the rust treatment in this pic.

http://i275.photobucket.com/albums/jj320/mikec1234567/underneath.jpg?t=1236845822

Spare wheel well in primer.

http://i275.photobucket.com/albums/jj320/mikec1234567/underneath1.jpg?t=1236845891


Drivers side chasis where the rear beam attaches. Pic is abit blurry.

http://i275.photobucket.com/albums/jj320/mikec1234567/underneathchasisleg.jpg?t=1236845987

[Edd]

Nice to see you have made more progress. When you hoping to have it back on the road?

[scott.parker]

Cool cool dude, getting there, thanks again for yesterday, oh got time to do an hr tonight, check my wip.

Scott

[mikec123]

no worries dude will check it out.
Hopefully get it ready for next summer :thumb:

[mikec123]

After cleaning the rust off and rust treating the underside of the car where the fuel tank sits i put a couple coats of hammirite anti-rust primer on.

http://i275.photobucket.com/albums/jj320/mikec1234567/underneath2.jpg?t=1236890785

Whilst the primer was drying i thought i would clean the filler neck up. This is how it was after it came off the car. Pretty dirty and rusty. Did think about buying a new one if it was not saveable.

http://i275.photobucket.com/albums/jj320/mikec1234567/fillerneck.jpg?t=1236890972

Got my drill with a sanding disk on the end and various wire wheel attachments and took it back to bare metal.

http://i275.photobucket.com/albums/jj320/mikec1234567/fillerneck1.jpg?t=1236891086

Next i covered it in hammarite krust. Just to make sure ive killed as much rust as i could. It turns a purpley blue colour.

http://i275.photobucket.com/albums/jj320/mikec1234567/fillerneck2.jpg?t=1236891207


Next i put a couple of coats of primer on.

http://i275.photobucket.com/albums/jj320/mikec1234567/fillerneck3.jpg?t=1236891319

Then finally two coats of hammirite black smooth.

http://i275.photobucket.com/albums/jj320/mikec1234567/fillerneck4.jpg?t=1236891396

[vaughanmc]

Looking good mate!

You going body colour underneath ?

[scott.parker]

After seing that filler neck the other day i didnt think it would clean up as good as that!

Good job dude. Might do my beam.

Scott

[dj_wudgey]

good work matey!! glad to see more progress being made on it fella!!

[mikec123]

Looking good mate!

You going body colour underneath ?

Not sure yet. might just stone guard.

[mikec123]

It rained abit today so couldnt really get on with the car so got my old dials which got burnt in the welding incident and transplanted the speedo dial into my new set i got from Scott.Parker. Cheers again scotty.

http://i275.photobucket.com/albums/jj320/mikec1234567/dials1.jpg?t=1236967509

http://i275.photobucket.com/albums/jj320/mikec1234567/dials.jpg?t=1236967732

[vaughanmc]

Nothing like the old GSi 6-dials :)

[mikec123]

Nothing like the old GSi 6-dials :)
Thats why i was so desperate to get hold of some. Thankfully scott still had his.:D

[scott.parker]

Dude if your old fuel gage is savable use it as mine was iffy remember!

[mikec123]

cheers dude forgot!:tard:

[mikec123]

Pic of the boot floor in undereal

http://i275.photobucket.com/albums/jj320/mikec1234567/bootnew.jpg?t=1237724092

[scott.parker]

Get the pics of the new plating up! Top jobs dude..

[mikec123]

will do probably be later:thumb:

[mikec123]

Right rear panel time! First of all i put a couple of coats of primer then trial fitted it.
http://i275.photobucket.com/albums/jj320/mikec1234567/rearpanel2.jpg?t=1239210372

Passenger side
http://i275.photobucket.com/albums/jj320/mikec1234567/rearpanel3.jpg?t=1239210505

Passenger side from the inside. Also in the pic is where i have replaced the boot floor.
http://i275.photobucket.com/albums/jj320/mikec1234567/rearpanel4.jpg?t=1239210638

Drivers side from the inside.
http://i275.photobucket.com/albums/jj320/mikec1234567/rearpanel5.jpg?t=1239210730

I thought i would use the original spot weld holes so i spotted it on.
http://i275.photobucket.com/albums/jj320/mikec1234567/rearpanel6.jpg?t=1239210814

Before i went any further i put the rubber seal round the rear panel and shut the boot to make sure it closed ok.
http://i275.photobucket.com/albums/jj320/mikec1234567/rearpanel7.jpg?t=1239210992

http://i275.photobucket.com/albums/jj320/mikec1234567/rearpanel7.jpg?t=1239210992

I took my side skirts off today and had a look at the sills which aren't to bad, very suprising, i think those big stupid side skirts did me a favour protecting the sills. Pics to follow.

[scott.parker]

Nice one dude, boot floor looks a top job! I'll pop over tomo have a look, great to see she's getting there slowly, but not much left to do body wise really..

Scott

[craig green]

That looks like a top repair job, wanna do mine? LOL

[Rickyb]

looking good dude are thay dear to buy them back panels?

[mikec123]

lol
That looks like a top repair job, wanna do mine? LOL

[mikec123]

looking good dude are thay dear to buy them back panels?

No there fairly cheap i got mine from Beevers Auto Panels £87.26 delived. Good quality after market panels. Cheers for the comment.:thumb:

[dj_wudgey]

good work mate!!

[Edd]

Nice to see more progress.

[scott.parker]

Dude you put the annoying boot lock bolt in the new one yet?

Scott

[mikec123]

Yep it's in!

[mikec123]

Bit more done, stripped the stone guard from inside of the passanger side rear arch to see whether any nasty suprises were hiding.Not bad abit of rust.

http://i275.photobucket.com/albums/jj320/mikec1234567/psreararch.jpg?t=1239637899

[mikec123]

More progress stripped the stoneguard from the underside of the car. Found a couple of nasty bits but on the whole not to bad, few random pics of the underneath
http://i275.photobucket.com/albums/jj320/mikec1234567/SP_A0009.jpg?t=1243878865

http://i275.photobucket.com/albums/jj320/mikec1234567/SP_A0010.jpg?t=1243878987

http://i275.photobucket.com/albums/jj320/mikec1234567/SP_A0011.jpg?t=1243879082

http://i275.photobucket.com/albums/jj320/mikec1234567/SP_A0012.jpg?t=1243879151

[mikec123]

Also i fabricated some panels to go in the rear arches where i cut out the original arch lining so i could get at the inside of the chasis by the spring cup plates because there was alot of rot which i have cut out and plated on the inside of the chasis leg to give extra strengh. I will weld them on tomorrow as i have ran out of welding wire.

Driver's side

http://i275.photobucket.com/albums/jj320/mikec1234567/SP_A0008.jpg?t=1243879551

Passenger side

http://i275.photobucket.com/albums/jj320/mikec1234567/SP_A0007.jpg?t=1243879640

[scott.parker]

Looks good dude, should be ready in time for pv after all..






















lol

[mikec123]

yeah PV 2010 lol

[scott.parker]

Oh i got the tickets through and my pass, so all we need now is you to remember the way, as my light don't work in the nova lol

[mikec123]

Cool Cool we will find i hope :tard:

[mikec123]

Right stonechipped some of the underneathand the rear arches, i bought a draper stone chip gun made life easier. I also put my tank back on and changed a few fuel pipes and but my rear shocks and beam back on.

http://i275.photobucket.com/albums/jj320/mikec1234567/PIC_1041.jpg?t=1245003409

http://i275.photobucket.com/albums/jj320/mikec1234567/PIC_1040.jpg?t=1245003452

12mm Fuel pipe for the breather pipe that goes through the chasis
http://i275.photobucket.com/albums/jj320/mikec1234567/PIC_1037.jpg?t=1245003511

http://i275.photobucket.com/albums/jj320/mikec1234567/PIC_1043.jpg?t=1245003616

http://i275.photobucket.com/albums/jj320/mikec1234567/PIC_1038.jpg?t=1245003675

http://i275.photobucket.com/albums/jj320/mikec1234567/PIC_1042.jpg?t=1245003748

http://i275.photobucket.com/albums/jj320/mikec1234567/PIC_1039.jpg?t=1245003814

[scott.parker]

Mike whats going on in the last pic? the welds on the seam look all strange? like it's not covered..

Will have to come have a look this week.

Scott

[mikec123]

Sprayed my rear springs today

http://i275.photobucket.com/albums/jj320/mikec1234567/PIC_1050.jpg?t=1245081541

[mikec123]

Abit more done firstly a couple of pics of the stoneguarding and the tank in place.

http://i275.photobucket.com/albums/jj320/mikec1234567/SP_A0014.jpg?t=1245693261

http://i275.photobucket.com/albums/jj320/mikec1234567/SP_A0015.jpg?t=1245693436

And a pic of the beam about to be fitted

http://i275.photobucket.com/albums/jj320/mikec1234567/SP_A0016.jpg?t=1245693469

Rear beam fitted and springs in place

http://i275.photobucket.com/albums/jj320/mikec1234567/SP_A0017.jpg?t=1245693536

[Jay]

Nice :D

[mikec123]

Right bought some copper/Nickel brakeline and some M10 and M12 fittings ready to replace my old lines

http://i275.photobucket.com/albums/jj320/mikec1234567/SP_A0025.jpg?t=1245693704

Pic of the front drivers side replacement line

http://i275.photobucket.com/albums/jj320/mikec1234567/SP_A0027.jpg?t=1245693915

Pic of the master cylinder with new lines

http://i275.photobucket.com/albums/jj320/mikec1234567/SP_A0029.jpg?t=1245694064

http://i275.photobucket.com/albums/jj320/mikec1234567/SP_A0028.jpg?t=1245694112

[vxr_racing_2008]

Good stuff, keep it going:thumb:

[mikec123]

Good stuff, keep it going:thumb:
Cheers:thumb:

[Twistie]

Mikec123 hello mate nice build this is what i am looking in to building a 1.6 8v turbo but no one sells the turbo kits no more so do you no of any one that will sell them or what bits/of what car have i got to get it will all being done to a nova gsi engine

Can you help

Thanks Jake

[scott.parker]

Twistie, mate if we knew we would tel you, Neil don't even know what turbo it is, we believe it could be a Renault 5 or fiesta turbo, as it's a T2, the basics are the turbo and a compression spacer plate between two head gaskets iirc?



Oh by the way, the pipes look good dude, shame we had to traipse around then spend silly money on that flanger today! lol

Scott

[Twistie]

so Scott what bits will i need to do it all then i no a turbo i have been told to use a r5 turbo but what Else will i need mate

thanks jake

[7ova]

nice work mate :thumb:

[mikec123]

Mikec123 hello mate nice build this is what i am looking in to building a 1.6 8v turbo but no one sells the turbo kits no more so do you no of any one that will sell them or what bits/of what car have i got to get it will all being done to a nova gsi engine

Can you help

Thanks Jake

Hi Twistie i believe Courtenay have stopped stocking the turbo parts for 1.6 8v T conversion! I bought mine already converted! Your best bet is to look in the features section on here and look at my full engine spec! It's not a conversion to be took lightly, for the money you spend to do a good conversion you might aswell put an xe or a let in, the parts are easly sourced :thumb:

[GDN16v]

Full 1.6 turbo conversion in the for sale section!;)

[novaload1992]

keep er lit, good luck

[mikec123]

Just a couple of pics of my brake lines from m/c to rear beam. I used the original ones as a guide.

http://i275.photobucket.com/albums/jj320/mikec1234567/SDC11643.jpg?t=1246354482

http://i275.photobucket.com/albums/jj320/mikec1234567/SDC11644.jpg?t=1246354527

[craig green]

Good stuff mate!

Good to meet you & Scott & PV.

[mikec123]

Cheers Craig, same here nice to put a face to a name:thumb:

[mikec123]

A few more pics of my brake lines on the car

http://i275.photobucket.com/albums/jj320/mikec1234567/SDC11646.jpg?t=1247171952

http://i275.photobucket.com/albums/jj320/mikec1234567/SDC11648.jpg?t=1247172013

[mikec123]

Right took my clutch and flywheel off today

http://i275.photobucket.com/albums/jj320/mikec1234567/clutch1.jpg?t=1247766068

http://i275.photobucket.com/albums/jj320/mikec1234567/clutch.jpg?t=1247766108

http://i275.photobucket.com/albums/jj320/mikec1234567/clutch4.jpg?t=1247766152

Not sure how acurate the scales are but it weighed just over a stonne
http://i275.photobucket.com/albums/jj320/mikec1234567/clutch2.jpg?t=1247766197

[scott.parker]

See what you mean dude, that clutch does look worn, must of been slipping with nearly 200hp through a bog GM clutch plate! lol

[mikec123]

Yep time for a new clutch:d Sent the guy at autosprint an email to see how much the fly lightening is going to cost aswell

[mikec123]

Right went up to Autosprint on friday to have my flywheel lightened, i would like to say what a brillant service he offers i would reccomend him to anyone top bloke!

http://i275.photobucket.com/albums/jj320/mikec1234567/flywheellight2.jpg?t=1250959745

http://i275.photobucket.com/albums/jj320/mikec1234567/flywheellight.jpg?t=1250959814

[mikec123]

Also been cleaning my floorpan up aswell

http://i275.photobucket.com/albums/jj320/mikec1234567/floorpan.jpg?t=1250960223

[craig green]

Is it coming together or are you still welding??

[mikec123]

Tiny bit of welding to do now! Got to order my new clutch this week then i should have the engine back in :thumb:

[scott.parker]

Dude the Fly wheel looks spot on!

Did you ask about the Kent cam?

I'll have to get mine up to him at some point and get some work done to my engine, then it will be mapped and finally start to be quick! lol

[mikec123]

Dude the Fly wheel looks spot on!

Did you ask about the Kent cam?

I'll have to get mine up to him at some point and get some work done to my engine, then it will be mapped and finally start to be quick! lol

Yeah spoke to him about the cam he said i should be fine to use it, will take it up there when the car is on the road:thumb:

[scott.parker]

Cool, dude I'll call you later for a chat.

[Steve]

How much was it to get your flywheel lightened? and does he balance it as well?

[mikec123]

How much was it to get your flywheel lightened? and does he balance it as well?

Mine was £57.50 yes he balances it aswell he can only do flat fly's the pot fly's need to be put on a cnc.:thumb:

[mikec123]

Bit of an update fitted my flywheel got the right torque setting for the bolts from the haynes manual and used Loctite threadlocker

http://i275.photobucket.com/albums/jj320/mikec1234567/Flyonblock.jpg?t=1251481871

Measured up for a clutch centralising tool which my dad had turned at work
http://i275.photobucket.com/albums/jj320/mikec1234567/clutchcentralizertool.jpg?t=1251481989

http://i275.photobucket.com/albums/jj320/mikec1234567/Flywheelwithclutchlocater.jpg?t=1251482169

My Helix clutch arrived from mardi gras motorsport, i went for the organic drive plate and a new release bearing.
http://i275.photobucket.com/albums/jj320/mikec1234567/clutchnew.jpg?t=1251482331

[mikec123]

My loom arrived from nova danny1, thanks again:thumb:

http://i275.photobucket.com/albums/jj320/mikec1234567/Fusebox.jpg?t=1251482861

http://i275.photobucket.com/albums/jj320/mikec1234567/newloom.jpg?t=1251483643

[scott.parker]

Popped by the other day, it's looking good now, and the fly is spot on!

Loom was a bargain, has alarm wired into it!

[keensniper]

iv just spent 20mins looking through this:eek: and i must say ur putting a lot of work in there m8, my hats off to you,:thumb:

keep it up and dont spare on getting the rust out. Will look better than showroom condition when its donelol

[mikec123]

iv just spent 20mins looking through this:eek: and i must say ur putting a lot of work in there m8, my hats off to you,:thumb:

keep it up and dont spare on getting the rust out. Will look better than showroom condition when its donelol

Cheers dude:thumb:

Bit of an update i will put pics up tomorrow, i fitted my clutch and bolted the gearbox back onto the engine and picked up the engine crane from my mate so its going back in tomorrow:d

[mikec123]

Right ive finally got my engine back in the car after almost a year:d

Pic before it went in
http://i275.photobucket.com/albums/jj320/mikec1234567/enginegearbox.jpg?t=1251731802

I decided to pick the car up with the crane and then slide the engine in from the side
http://i275.photobucket.com/albums/jj320/mikec1234567/carup.jpg?t=1251731917

http://i275.photobucket.com/albums/jj320/mikec1234567/enginegoinin.jpg?t=1251731967

A few pics of the engine in
http://i275.photobucket.com/albums/jj320/mikec1234567/enginebkin2.jpg?t=1251732032

http://i275.photobucket.com/albums/jj320/mikec1234567/enginebkin1.jpg?t=1251732102

http://i275.photobucket.com/albums/jj320/mikec1234567/enginebkin.jpg?t=1251732146

[scott.parker]

Good going dude. it's going to look well nice, looks clean!

[mikec123]

cheers dude getting there slowly:thumb:

[scott.parker]

What you going to do about the offside mount?
Box section it?

[Steve]

looks good seeing the engine in place after all the hard work, btw isn't your rocker cover on the wrong way?

[mikec123]

Well spottedlol but its just placed on at the mo:thumb:

As for the offside mount i have spaced it down at the mo with to tubes that the bolts go through but my dad works at an aerospace company so im getting some billet aluinium to space it down to the correct height:d

[scott.parker]

Dude just found these pics for you...


lol your hair!

http://img120.imageshack.us/img120/6520/picture460nm6.jpg

And these..

Just before you ripped it apart for the re-build.

http://img410.imageshack.us/img410/9166/22042008314smallmd7.jpg

http://img410.imageshack.us/img410/4995/22042008316smallnx3.jpg

I hope these inspire you more, I'll lend my hand if you ever need dude, dont forget to ask.

Scott

[vaughanmc]

There's a Nova SR local to me that's an H reg and also ends in DAE

Nice looking car you have there fella :thumb:

[scott.parker]

looks good seeing the engine in place after all the hard work, btw isn't your rocker cover on the wrong way?

In fact i think we moved it that way round, look in above pic, it was so the catch tank had less messy pipe length all over the bay. :thumb:

[scott.parker]

There's a Nova SR local to me that's an H reg and also ends in DAE

Nice looking car you have there fella :thumb:

Ive seen a few DAE's HAE's not sure ware there register from.

[mikec123]

Right bit of progress got my ass into gear i got my new Valeo rad a pic of the old and new one, as you can see the old one was proper funked!

http://i275.photobucket.com/albums/jj320/mikec1234567/OldNewRad.jpg?t=1258304521

And fitted in place, also just trial fitted my intercooler

http://i275.photobucket.com/albums/jj320/mikec1234567/Newradinplace.jpg?t=1258304585

Also i fitted my new drivers side window ive been meaning to do this job for ages and after all the rain we had this weekend i thought was about time so i hooked a 12v battery up to the electric window motor and dropped the arm then took all the trim off and fitted the window! Didnt get chance to take any pics of it finished as just as i had finished it decided to rain:cry:

http://i275.photobucket.com/albums/jj320/mikec1234567/Driverswindow.jpg?t=1258304970

[Iain]

At least it didn't start to rain during fitting! Not seen this WIP before, engine looks very impressive.

[scott.parker]

Iain, it is one very impressive engine, use to belong to Nova Neil in his red GTE, i know with the new plans this car will be almost, if not quicker then mine..

[mikec123]

At least it didn't start to rain during fitting! Not seen this WIP before, engine looks very impressive.

Yeah suppose it could have been worse! Perfect timing:d

[mikec123]

Pic of my turbo cleaned up and a lick of paint, next job is to sort the downpipe out as it has cracked and i didnt notice as it was under heatwrap.
http://i275.photobucket.com/albums/jj320/mikec1234567/SDC11923.jpg?t=1260129551


Also got sick of buying car covers only for them to rip from the wind, the last one i bought from argos was a glorified bin bag and ripped in half in a week so got my brother to sort me out some taupalin from his work £5 and its perfect for over the winter
http://i275.photobucket.com/albums/jj320/mikec1234567/SDC11922.jpg?t=1260129756

[Steve]

lol I bought one of those shltty argos ones and most of the cover ripped off except for the elastic round the bottom lol

Nice to see an update :thumb:

[mikec123]

lol I bought one of those shltty argos ones and most of the cover ripped off except for the elastic round the bottom lol

Nice to see an update :thumb:

Exactly what happened to mine £15 waste of money:cry:

[scott.parker]

Nice one, glad you still doing bits, i got a tarp free from work for my orange one, not had it on yet though as i still use it most weekends for a bit of scooby slaying! lol

Any more thoughts on the SR wheel?

Scott

[MattBrown]

Looking very good! Few questions....

1. What did you use to remove the sealer? Undersealer?

2. What seam sealer did you use?

3. How did you get your springs so nice?

4. What paint did you use for the misc items?

[scott.parker]

Just in case mike's not on here soon..


Looking very good! Few questions....

1. What did you use to remove the sealer? Undersealer? Wire wheel attachments in a drill/grinder

2. What seam sealer did you use? tiger seal/gutter sealant stuff..

3. How did you get your springs so nice? LOT and LOTS of undercoat/primers and top cots of paint (hammerite spray on)

4. What paint did you use for the misc items? Black hammerite brush on/spray on

If im wrong mike will say other wise.

[mikec123]

Just in case mike's not on here soon..



If im wrong mike will say other wise.

Cheers dude.

1. I found a filler knife worked good with a heat gun and alot of elbow grease

2.Tiger seal is good stuff

3.Got the springs shot blasted then loads of filler primer then hammerite red

4.Like scotty said various hammerite products

[mikec123]

My xmas present from the mrs arrived today a Mocal 10 row oil cooler and firtree fittings and some areoquip hose:d

http://i275.photobucket.com/albums/jj320/mikec1234567/PIC_0445.jpg?t=1260551474

[scott.parker]

Cool, does Sam know you have it already? lol she'll be warping it up..

PS: Dude you should know better it's a cooler, not filter.

[mikec123]

Cool, does Sam know you have it already? lol she'll be warping it up..

PS: Dude you should know better it's a cooler, not filter.

Cheers dude you know what im like:tard: Yeah sam knows i have it might try and get it fitted soon if she lets me have it:thumb: Are you swinging by for that wheel this weekend?

[scott.parker]

Right.. i reckon turkey sandwiches and some beers just after Chrimbo and we should do some more work together on this this..needs a push.

[mikec123]

Needs more than a push more like a rocketlol

[scott.parker]

Why dude, whats left? sort the wiring? Looms complete so just ripp it out replace? chuck the dash back in, get all the wires from bay through and connected, then dash back in etc..

Then it's fit cooler and intercooler, new wings wheels spray time..

[mikec123]

Right got some more work done on the car, i trial fitted the manifold and turbo which needed abit of messing about because of the accuator being so close to the rad

http://i275.photobucket.com/albums/jj320/mikec1234567/manturbo.jpg?t=1262457057

What i had to do was remove the rad and then fit the manifold and turbo on to the head, then i had to take one of the bolts out of the accuator bracket to allow it to swing upwards to give me the clearance

http://i275.photobucket.com/albums/jj320/mikec1234567/acbracket2.jpg?t=1262457250

Then once the rad went in i could swing it back and tighten the bolts (rad not in place)

http://i275.photobucket.com/albums/jj320/mikec1234567/acbracket3.jpg?t=1262457351

Rad in place on this pic you can see how close it is to the accuator bracket

http://i275.photobucket.com/albums/jj320/mikec1234567/acbracket.jpg?t=1262457439

Then i found that the accuator was fouling a little clip on the back of the rad not sure what it is for but it had to come off

http://i275.photobucket.com/albums/jj320/mikec1234567/radcutoff.jpg?t=1262457565


Then i slid the accuator in from the left hand side very tight fit though

http://i275.photobucket.com/albums/jj320/mikec1234567/accator2.jpg?t=1262457642

http://i275.photobucket.com/albums/jj320/mikec1234567/accuator.jpg?t=1262457676

[mikec123]

Right also i fabricated some brackets from some ali box section for my oil cooler to fit under the slam panel in front of the rad in the top left hand corner

http://i275.photobucket.com/albums/jj320/mikec1234567/oilcoolerinplace.jpg?t=1262457807

I put my grill on so i could see how it would look and im pleased with just go to sort the pipe work out now

http://i275.photobucket.com/albums/jj320/mikec1234567/oilcoolerinplace2.jpg?t=1262457961

[andy_mk3]

Just read this thread right through! Very impressive work, that shell was fairly rotten but you're done a great job in making it mint again! This should look brilliant when done!