Corsa Servo - Worth it?

[Mike]

This worth doing, from a weight/space point of view? (Battery will be in boot regardless, washer tank will also be moved to balance weight)

What kinda weight is there to be saved?

Pics please, get whoring.

Mike.

[AlexW]

I guess CG is the best to ask, look through the 1st pages of his WIP shows a couple of pics of it in there i belive.

Im also thinking of doing this simply to do away with the bar and Imo its a no brainer.

[General Baxter]

no mike, dont even think about it, the corsa needs to stop aswell lol

[Adam]

Ask DHdev, and Nathan too. As they both run a corsa setup

[burgo]

piece of piss mike. ill help with it if you want. do the corsa wiper motor mod aswell whilst your there.

commence pic whoring

http://i12.photobucket.com/albums/a226/sclurgess/nova101.jpg
http://i12.photobucket.com/albums/a226/sclurgess/nova79.jpg
http://i12.photobucket.com/albums/a226/sclurgess/nova39.jpg
http://i12.photobucket.com/albums/a226/sclurgess/nova9.jpg
http://i12.photobucket.com/albums/a226/sclurgess/nova10.jpg

want anymore lol

[Mike]

Fook does look simple TBH, what do you do with the holes left in the bulkhead? Just weld a plate over them I guess?

Corsa wiper mod? Pray tell?

[Sloth]

only bit i dont like is cutting and welding the pedal, is there another way round it?

[loggyboy]

I did it partly to save weight but you can feel a slight improvement in brake feel. The main reason i did mine is beacuse I wanted to fit the corsa steering column too.
Mine:

saves alot of metal:
http://www.loggyboy.com/images/MeritMk2/CorsaBrake/NovaBrakeVCorsa.jpg

Im sure i recall FlUsHSimOn (BRoadGhost) weighing the bar it at 10kgs?? seems alot so i probly remember wrong.

http://www.loggyboy.com/images/MeritMk2/CorsaBrake/BulkheadHole1.jpg

I wanted a smooth surface to ensure a water tight seal on the Corsa Plate.

http://www.loggyboy.com/images/MeritMk2/CorsaBrake/Plate4.jpg

http://www.loggyboy.com/images/MeritMk2/CorsaBrake/Plate5.jpg

http://www.loggyboy.com/images/MeritMk2/CorsaBrake/BulkheadHoleFinal.jpg

http://www.loggyboy.com/images/MeritMk2/CorsaBrake/InsideBulkhead4.jpg

http://www.loggyboy.com/images/MeritMk2/CorsaBrake/ServoInPlace.jpg

Fluid bottle is tight fit (Nova 4 way M/C and corsa fluid bottle)

http://www.loggyboy.com/images/MeritMk2/CorsaBrake/FluidBottleClearance.jpg

I used the standard corsa clutch pedal and mount and drilled it in to the corsa brake pedal frame it was a good fit:

http://www.loggyboy.com/images/MeritMk2/CorsaBrake/PedalBracket.jpg

http://www.loggyboy.com/images/MeritMk2/CorsaBrake/ClutchPedalBar1.jpg

http://www.loggyboy.com/images/MeritMk2/CorsaBrake/CorsaPedalFinal1.jpg

Then I just cut the corsa pedal half way along and took about an 25-40mm out. Cant find pics of that tho.

[Mike]

Superb info chaps :D

I take it the Nova Clutch/Throttle pedal all refit back in place with no/minimal mods then?

[loggyboy]

see above on clutch (last 3 pics). throttle is unaffected.

[AlexW]

What pipes did you use for the servo/inlet sizzle?

[loggyboy]

vacuum hose? i bought some 'supposed' vacuum hose from ebay, that simply collapsed under the pressure, so I left it as that, dont really need a servo anyway! Not when you have big brakes and no weight.

can see it here:

http://www.loggyboy.com/images/MeritMk2/CorsaBrake/BrakeServoFinal.jpg


also found a welded pedal pic:

http://www.loggyboy.com/images/MeritMk2/CorsaBrake/CorsaPedalWelded.jpg

[burgo]

mike the corsa wiper motor mod is simply using the corsa wiper motor. the nice thing about it is its tucked right up out the way plus it plugs straight in.

loggy you went abit hardcore cutting such a big hole

[AlexW]

Sorry to ask questions in mikes thread but im looking to do this to my nova soon aswell.

You use the nova pedal rather then like people ive seen use the standard corsa one, Was there a reason??

In your opion is it better to use the nova Master cylinder?

[Count Vaux Alot]

In your opinion is it better to use the nova Master cylinder?

I wondered this as well, Burgo are you just running one line to the front and one to the rear? If so then surely this is simpler than the 4 line option with the nova MC? please correct me if im wrong. :confused:

[loggyboy]

loggy you went abit hardcore cutting such a big hole

The standard panel isnt at all level with lots of drainage and 'reinforcement'? ridges/dips, I didnt want to weld the corsa plate in so need a decent sized flat surface to get a good water tight seal.



Sorry to ask questions in mikes thread but im looking to do this to my nova soon aswell.

You use the nova pedal rather then like people ive seen use the standard corsa one, Was there a reason??

In your opion is it better to use the nova Master cylinder?

Which pedal do you mean? I cut down the corsa brake pedal, and used the nova throttle and clutch ones.

I went with the nova MC as it has 4 outputs, the Corsa one i had came with 2 (i assume it goes to an ABS or a splitter unit on the corsa)

[Adam]

Use some high pressure fuel pipe for the vacuum pipe. Works fine on my current vacuum hose.

[pul16v]

ive also done this basically mines piped up exactly as a corsa just raped a corsa from scrapers n fitted pipework and rear brake restrictors on mine . gives a nice solid pedal feel unlike the std nova one which i thinks awfull . if you can meassure and capable of weding well and fabricateing its very easy

phil

[burgo]

i used the 2 - 4 splitter off the corsa altho i cut it in half so i could run one brake line to the back and then split it

[The Simps]

Here's mine, not finished yet tho. Still got the peddle to finish off adjusting.


http://img.photobucket.com/albums/v310/TheSimps/Nova/Nova%20Coupe%20Project/03-07-0812.jpg

Chopped old nova brake pedal...

http://img.photobucket.com/albums/v310/TheSimps/Nova/Nova%20Coupe%20Project/03-07-084.jpg

Ground out brake support from back panel...

http://img.photobucket.com/albums/v310/TheSimps/Nova/Nova%20Coupe%20Project/03-07-082.jpg


Chop down bar, refit chopped off brake pedal, swivel round and weld up...

http://img.photobucket.com/albums/v310/TheSimps/Nova/Nova%20Coupe%20Project/05-07-081.jpg
http://img.photobucket.com/albums/v310/TheSimps/Nova/Nova%20Coupe%20Project/05-07-082.jpg

[The Simps]

You can also do the corsa washer bottle mod too.

Heat up the tab on the bottle and bend it down and then make a bracket for it. I re-used the old battery clamp bracket that came out when doing the corsa brake setup...

http://img.photobucket.com/albums/v310/TheSimps/Nova/Nova%20Coupe%20Project/11-07-08.jpg
http://img.photobucket.com/albums/v310/TheSimps/Nova/Nova%20Coupe%20Project/11-07-081.jpg
http://img.photobucket.com/albums/v310/TheSimps/Nova/Nova%20Coupe%20Project/11-07-083.jpg
http://img.photobucket.com/albums/v310/TheSimps/Nova/Nova%20Coupe%20Project/16-10-0812.jpg

[burgo]

simps get the corsa wiper motor in there and get rid of that bulkhead ;)

[The Simps]

I've got a spare corsa wiper so was thinking of doing it but I'll still keep the bulkhead - I like it :D

[burgo]

fair enough. will still look better with the motor hidden tho

[The Simps]

Oh definately.

[TWAG]

Ive just done the corsa servo mod, it was pretty easy to be honest only took a couple of hours.

Ive just to do the brake lines now, after reading through this thread im very interested in using the nova master cylinder. Is it not a problem using the nova m/c verticaly when it was designed to use horizontaly?

Currently ive mounted the 4 way splitter from the corsa and started piping it the same as the non abs corsa but am i going to need to bias the rear brakes even though they are standard drums? (280mm willwoods on front)

[The Simps]

Currently ive mounted the 4 way splitter from the corsa and started piping it the same as the non abs corsa but am i going to need to bias the rear brakes even though they are standard drums? (280mm willwoods on front)


I don't know the definate answer on this one but seeing as the corsa was standard drum I can't see why not. HOWEVER, I recall reading something about corsa's have an inline adjuster towards the back of the car or something similar??

[TWAG]

I don't know the definate answer on this one but seeing as the corsa was standard drum I can't see why not. HOWEVER, I recall reading something about corsa's have an inline adjuster towards the back of the car or something similar??

Ive noticed that inline valve thing on the corsa before, thats why im a little unsure what to do. I have heard that not all corsa have them though.

[loggyboy]

Ive just to do the brake lines now, after reading through this thread im very interested in using the nova master cylinder. Is it not a problem using the nova m/c verticaly when it was designed to use horizontaly?

Mines been fine fore the last year and a half. I would assume that as its full of fluid and sealed then there is no reason for it not to work at any angle.

[craig green]

The 4 way Nova MC will be fine, luckily the Corsa reservoir will fit it enabling it to sit that way up.

I've got mine plumbed in with a 2-way split Corsa system & a Wilwood bias valve mounted in the rear lines, everything feels fine so far.

If I did it again, I would make some provisions to reinforce the battery tray area of the bulkhead/underside. I detect some flex when braking hard. Maybe a dash out welding project for the winter.

Its shown in Loggy's pics, but you have to use the old brake pedal to support the existing clutch pedal, so think about that before hacking it all away.

[burgo]

Its shown in Loggy's pics, but you have to use the old brake pedal to support the existing clutch pedal, so think about that before hacking it all away.i didnt do it that way

also i had no problems using the corsa MC and running one line to the back.

[craig green]

I've run one line to the back, using the 2 port Corsa MC.

[TWAG]

craig - did you put the bias valve in because you are running rear discs?

[loggyboy]

Its shown in Loggy's pics, but you have to use the old brake pedal to support the existing clutch pedal, so think about that before hacking it all away.

I didnt use any of the old brake pedal, the clutch pivot bar is secured to the nova bracket on the left and corsa brake 'surround' on the right.

[The Simps]

I didnt use any of the old brake pedal, the clutch pivot bar is secured to the nova bracket on the left and corsa brake 'surround' on the right.


I do like the idea of that. keeps it all still as one unit.

[loggyboy]

it was sheer luck, i hadnt planned any specific way to sort the clutch. i was antcipating fabricating something up, but pleasently, it just fell in to place.

[craig green]

craig - did you put the bias valve in because you are running rear discs?

2 reasons, partly because of the extra efficiency the discs offer & the fact there is no proportioning valve(s) on the Corsa MC & getting them rated correctly is an unknown. My bias valve is wound all the way forward & it feels fine.

[Mike]

I've run one line to the back, using the 2 port Corsa MC.

Run one line to the rear and just t-peice it off to nearside/offside I take it?

[craig green]

Yeah. Likewise the fr is T-pieced aswell.

[Mike]

Hhhmm, whilst im at it then, i may aswell add a rear disk beam & fly off handbrake & bias as it'll only add to the vehicles re-sale value anyway.

Did you use copper or stainless braided brake line though Craig?

[craig green]

Front; All copper up front into arches, Rear; braided from the M/C to boot floor, T'd into copper upto the rear braided flexi's under the boot floor.

Boot floor

http://i30.photobucket.com/albums/c323/turbocraig/NovaGSi-WIP_pics/DSCN2358.jpg

[Mike]

Where did you get the T fittings from? Rally Design or something? We've got none spare at work :( so ive got to pay for the unions an braid hose :(

[craig green]

I got the T-pieces from my local motor factors, though my local rally stockists have some from Le-mans (just repackaged stuff) which look like they have a larger internal bore & are a bit neater, but mine were abot £2 ea, wheras these others are about £4.99.

[Mike]

One last qeustion cheif, what hose diameter, for 7/16 fittings or 3/8? IIRC its 7/16?

[craig green]

Can't remember. 3/8"?

[Adam]

3/16 diameter

[loggyboy]

Hhhmm, whilst im at it then, i may aswell add a rear disk beam & fly off handbrake & bias as it'll only add to the vehicles re-sale value anyway.

If you dont have a dash, (or you dont mind the dials being missaligned with the steering wheel, do the corsa column too while your there. nothing better than being nicely aligned with the steering wheel :)

[DW-Nova]

Thinking of doing the corsa servo and pedal conversion but just got a couple of questions if anyone could help ? The corsa GSI Servo would be the best one to use yes ? are all the corsa servo baseplates and pedals the same ? i have Vectra V6 Calipers and 288mm discs on there now so can i run something like the Vectra V6 master cylinder coupled to the Corsa Servo or a cavalier SRI one as i was reccomended to use the Cav mastercylinder on the standard set-up and the nova one was not big enough to make good use of the Vectra brakes, i.e you had to push the pedal quite far down to stop quickly. Help greatly appreciated.

[The Simps]

I don't think you will be able to use the vectra MC as its ABS and as a result the bolt pattern is different.

I too am running 288mm fronts and 235mm (I think) vectra rears so will have to let you know how mine are gonna feel! lol

[burgo]

mike catch me on msn as i have everything you need ;)

[Mike]

mike catch me on msn as i have everything you need ;)

Nice one bud ;) reserve it all for me, will be on MSN later as we're taking the kids out to the fireworks in a bit :cool:

[loggyboy]

Thinking of doing the corsa servo and pedal conversion but just got a couple of questions if anyone could help ? The corsa GSI Servo would be the best one to use yes ? are all the corsa servo baseplates and pedals the same ? i have Vectra V6 Calipers and 288mm discs on there now so can i run something like the Vectra V6 master cylinder coupled to the Corsa Servo or a cavalier SRI one as i was reccomended to use the Cav mastercylinder on the standard set-up and the nova one was not big enough to make good use of the Vectra brakes, i.e you had to push the pedal quite far down to stop quickly. Help greatly appreciated.

I cant be sure but i dont think the Corsa GSI servo is any larger. Mine was from a Tigra i think, but it came from ebay so ive no idea what model etc.

I had v6 calipers on my nova SRi with a standard MC and servo, that was fine so i wouldnt worry about messing around with differen MCs, just go for what ever one you have beit nova 4 way or corsa 2 way with a splitter.

[Rick Draper]

Can anyone tell me what the thread size and pitch is of a corsa master cylinder union?

[Adam]

They will either be standard m10 or standard m12

[_JH_]

DW, an early Cav 2.0 non ABS M/C fits, looks just like a nova but with a number 22 on it instead of 20.

Plenty of people will say not to bother, but many who've tried it rate it. No harm giving it a go.

[dan23]

where do you get the wiring kit from to go from boot to engine bay
does it have to bought new or can one be sourced in a scrapie i know some new bmw s have the battery in boot as standard but cant think of any old cars that the wires could be sourced from

[DaveyLC]

DW, an early Cav 2.0 non ABS M/C fits, looks just like a nova but with a number 22 on it instead of 20.

Plenty of people will say not to bother, but many who've tried it rate it. No harm giving it a go.

Does the bottle still fit onto the cav M/C?

[DaveyLC]

where do you get the wiring kit from to go from boot to engine bay
does it have to bought new or can one be sourced in a scrapie i know some new bmw s have the battery in boot as standard but cant think of any old cars that the wires could be sourced from

Wires for relocating the battery?

AES is your friend:

http://www.autoelectricsupplies.co.uk/

They do the wire, connectors and stock a really neat battery terminal relocation box for a few squids:

http://www.autoelectricsupplies.co.uk/product/161

[loggyboy]

For the battery, I used an old 4awg wiring kit, which i added to the standard loom using a maxifuse holder and 125amp fuse. I then welded the original battery earth bolt to the transmission tunnel and used the original earth wire.

Its a bit of a bodge as id like to used some proper battry wire but it works fine so im not fussed at mo. I plan to rewire the whole loom anyway.

[dan23]

1.2 corsa have pressure regulatoring vavles on the rear .1.4 an 1.6 models have a spring type regulator can either of these be used on nova (i doubt the spring type can how about the 1.2 items)?

when you remove the servo from corsa can you remove it with the master cylindr still attached or do you need to seperate the two?(if they have to be seperated is a new seal required?

can someone list what tools i will need as i am off to scrappy tomorrow ?

[dan23]

also what if a servo /mc from diesel corsa was used is it the same or bigger