The Counts Track Day Nova Build

[Count Vaux Alot]

Love the work on the front pannel, will you be welding the rest of the seam (under the turret and along) in the arch?
Weldings very nice again.

Edit as youve answerd above.

Thanks again Ben, i will be welding all the seams but they are covered in sealer and my grinder related wire wheel destroyed its self mid day so i could only do the seams i had already cleaned. IMO my welding could be better.

I'm in to minds about having the car on its side and stitching the floor as i'm not sure its really needed but i may flip it over just to see whats hiding under the sealer :eek:

[Benn]

Ah cool, and eeww under seal, i hate it.

Welding looks great, i still cant get my welder set right so mines sh*ite.

Do the hole chassis need stiching up?

[Count Vaux Alot]

Ah cool, and eeww under seal, i hate it.

Do the hole chassis need stiching up?

Under seal is the devil.

Did you mean 'does the whole chassis need stitching up?'

If so then no not really imo as its seen as only some thing you need to do for rallying but it can't hurt for shell rigidity and general strength.

[Benn]

Yes it is, my shower hates it too..lol
And yeah sorry i did. If it cant hurt then do it, guessing you'll be running a cage too.

[scott.parker]

Wow, you got balls! lol "just chop the rack monts out here, nad re-fit here, it's easy, common what you all waiting for? i did it " lol

Fiar play, hope it is worth it, good idea too.

And top progress, your lucky you go that garage, i was goging to do some things to my car this week, even took the cover off and dryed it out last week thinking the weather was going to be "dry" and better lol

Scott

[The Simps]

And top progress, your lucky you go that garage, i was goging to do some things to my car this week, even took the cover off and dryed it out last week thinking the weather was going to be "dry" and better lol

Scott


I know what yu mean. I havn't really touched mine for weeks and went down the barn sunday arvo with big intentions to find the car covered in snow because of the old, shonky barn roof. So I went home lol

[nova ian]

Looking good James. Cracking progress and welding. You made a sweet job on that cross member mate.

I like the idea for the rack mounts. Are you going to weld some sort of support behind the two tabs of the top two rack mount bolts?? Just that it could flex as it is??

Keep at it mate

[scott.parker]

Think he said he's still got the top part to do?

Scott

[Count Vaux Alot]

Your correct Scott i did say it isn't finished, i'm going to get on with in now!

I will be running a cage so i don't think i can justify stitching the whole shell given the time taken to prep it then weld it not to mention the added weight of all that weld! So i will just do the 'important areas' lol

The garage is great although space is tight given all the other ****e in it and the 3dogs! lol

[Count Vaux Alot]

A said above i was going to get on with finishing the rack repositioning tonight, unlike some of you luck bastids i managed to make it to work today (although i wish i hadn't bothered!) so i got on with the car when i got in!

For those of you worried about the top of the rack mounts rest easy as they are complete

http://i248.photobucket.com/albums/gg167/Count85/engbay096.jpg

http://i248.photobucket.com/albums/gg167/Count85/engbay097.jpg

Once the rack mounts were in place i needed to move the hole up for the rack to pass through the bulk head to the cabin/steering rack as so

I 'traced' the hole to get the rough shape - the tab out of the right hand side is my reference point to make sure i moved it 25mm up

http://i248.photobucket.com/albums/gg167/Count85/engbay100.jpg

Then as with the rack i moved the hole up by 25mm and marked it out then cut it out

http://i248.photobucket.com/albums/gg167/Count85/engbay101.jpg

http://i248.photobucket.com/albums/gg167/Count85/engbay102.jpg

And for those of you that like a bit of visualisation

http://i248.photobucket.com/albums/gg167/Count85/engbay103.jpg

http://i248.photobucket.com/albums/gg167/Count85/engbay104.jpg

And the rack with the steering arms straight - there is plenty of room above and below

http://i248.photobucket.com/albums/gg167/Count85/engbay105.jpg

Then i cleaned the rest of the bay, the bulk head and the shelf above up

http://i248.photobucket.com/albums/gg167/Count85/engbay106.jpg

And dusted them with primer

http://i248.photobucket.com/albums/gg167/Count85/engbay107.jpg

http://i248.photobucket.com/albums/gg167/Count85/engbay108.jpg

And a pic of the rack hole re located

http://i248.photobucket.com/albums/gg167/Count85/engbay109.jpg

Job done for tonight :thumb:

[Adam]

Top work, really liking this build :)

[Count Vaux Alot]

Thanks Adam!

[AlexW]

Top work man (I forgot about the corsa servo etc, il do it right now. Expect a PM in about 10mins)

[Count Vaux Alot]

Thanks i really need it by the weekend as i want to get that corner of the engine bay sorted!

Thanks i appreciate it :D

[The Simps]

how does the rack position in the cabin? can you still use a std dash and mounting points etc?

How rude, quality as always dude! I've been spreading the rep so hopefully you can have some more soon ;)

[G8WCC]

really liking this build count:thumb:
top work with the rack position makes good sense

[Count Vaux Alot]

how does the rack position in the cabin? can you still use a std dash and mounting points etc?

Hey dude, i'm not 100% sure about the rack to column but, i think the column wont fit the rack now mounted as standard, in my situation this isn't a problem as i'm going to move the column anyway and perhaps use a cav or calibra adjustable column for optimum steering wheel positioning once seated!

Thanks to every one for the positive comments too keep the rep coming lol lol

[The Simps]

Hey dude, i'm not 100% sure about the rack to column but, i think the column wont fit the rack now mounted as standard, in my situation this isn't a problem as i'm going to move the column anyway and perhaps use a cav or calibra adjustable column for optimum steering wheel positioning once seated!

Thanks to every one for the positive comments too keep the rep coming lol lol


Sounds intriguing and :cool:

And spreading rep like herpes but still can't give you any yet! lol

[nova ian]

Looking good James, glad your getting into this, going to be another well put together car.

That cav/calibra adjustable rack sounds heavy to me! could you not put in an A frame brace with a rose joint to support a column, you could then tailor this to where you want it to be, and with a fixed drivers seat you wouldnt need to alter the position once in the right place, until you decide to run a full pedal box and shift the drivers seat further back obviously!! lol

Keep up the good work mate, looking forward to seeing some more progressings

[Benn]

Great work dude, will the inlet mainfold not hit the rack tho? Just a thought..

[Count Vaux Alot]

Looking good James, glad your getting into this, going to be another well put together car.

That cav/calibra adjustable rack sounds heavy to me! could you not put in an A frame brace with a rose joint to support a column, you could then tailor this to where you want it to be, and with a fixed drivers seat you wouldnt need to alter the position once in the right place, until you decide to run a full pedal box and shift the drivers seat further back obviously!! lol

Keep up the good work mate, looking forward to seeing some more progressings

I am getting it to it Ian i'm funking loving it, the cav rack isn't much more to look at than the nova item (pics to follow)
Although your idea sounds good its 10x the effort and with it being fixed it would be fine when sitting in the seat but getting in and out might be an issue even with a snap off boss as the column would be gunning for your chest!

Here comes another update btw :thumb:

[Count Vaux Alot]

Great work dude, will the inlet mainfold not hit the rack tho? Just a thought..

I wouldn't have thought so as i'm using TB's and an upright manifold but if it does Mr grinder will be coming out again lol

[Benn]

Ah cool.
Love what you have done.

[Count Vaux Alot]

Hi every one a session was had again tonight....

Started off By finishing off little bits and bobs in the engine bay like seams i had missed and areas that needed priming etc.
I had left the very last of the bulk head right in the corners for some unknown reason but the were PI$$ING me off so i had them out as well

http://i248.photobucket.com/albums/gg167/Count85/engbay112.jpg

http://i248.photobucket.com/albums/gg167/Count85/engbay113.jpg

Fecking PITA spot welds!!

Then went on to finish the stitching under the front arches. The seams were then primed.

http://i248.photobucket.com/albums/gg167/Count85/engbay110.jpg

http://i248.photobucket.com/albums/gg167/Count85/engbay111.jpg

After i had all the little bits sorted i decided to 'get it on' with the seam sealer to make sure the freshly stitched seams wouldn't get any more ****e in them, not the neates job but it will do it is a track car.

http://i248.photobucket.com/albums/gg167/Count85/engbay115.jpg

http://i248.photobucket.com/albums/gg167/Count85/engbay116.jpg

http://i248.photobucket.com/albums/gg167/Count85/engbay117.jpg

http://i248.photobucket.com/albums/gg167/Count85/engbay120.jpg

http://i248.photobucket.com/albums/gg167/Count85/engbay118.jpg

http://i248.photobucket.com/albums/gg167/Count85/engbay119.jpg

And my wepons of choice

http://i248.photobucket.com/albums/gg167/Count85/engbay114.jpg



Here is the cav/calibra adjustable rack btw

http://i248.photobucket.com/albums/gg167/Count85/e150_1.jpg

http://i248.photobucket.com/albums/gg167/Count85/e2e6_1.jpg

http://i248.photobucket.com/albums/gg167/Count85/e468_1.jpg

[Count Vaux Alot]

Oh and i had a play with a logo/name for my workings...what you think?

http://i248.photobucket.com/albums/gg167/Count85/engbay121.jpg

http://i248.photobucket.com/albums/gg167/Count85/engbay122.jpg

Enjoy :D :D lol

[AlexW]

Hmm, i wonder if that would work with a standard dash.


And aint it about time you got on with the corsa servo etc lol O yer, its still sat in a box inside my car lol

[The Simps]

does the cav coloumn bolt up on the same mounts?

good work as always.

[Count Vaux Alot]

It looks to but, i will be moving the mounts so it doesn't matter! lol

[nova ian]

Nice one James... lol lol At the Count Dev!!!

[Geordie-Chris]

Nice work mate, Ive lowered the Nova column on my car this year, and extended the pedals a bit, feels so much better!! Your not as short as me tho so wont be such a massive difference to you, but to me its great!!
Liking the Cav column idea, liking the name too, all the best cars are made by a 'developments'!!

[Count Vaux Alot]

lol chris thats what i thought they always involve 'developments'

[dhdev (Oli)]

True dat :thumb:

[Count Vaux Alot]

lol

[Southie]

Some cracking work here mate. Well done :thumb:

[peester]

the work ongoing is certainly proffessional enough to start your own company

[Count Vaux Alot]

Thats very kind of you to say, it is a dream of mine and i would love to realise that in the future!

[The Simps]

you not done any work on it tonight? slacker...

[gazjoiner]

<--newbie here... keep up the good work fella! refabricating,welding ect. i'm not sure about the wide arch thing though. i do like the steering mods you have done, makes sence to move it up a little :) .gaz

[Count Vaux Alot]

I have but only a few bits, as i was interrupted by a friend whos mini was on its death bed - it resulted in me towing him home and giving up as i cba anymore.

I probably wont get back on the car until the wkend now either as i have loads of other 'bits' to do tomorrow and friday so i am in one hell of an arsed off mood now!

[Count Vaux Alot]

<--newbie here... keep up the good work fella! refabricating,welding ect. i'm not sure about the wide arch thing though. i do like the steering mods you have done, makes sence to move it up a little :) .gaz

Thanks matey and welcome! The wide arches are pure function over form in this case so whether they look ****e or not isn't an issue really imo as they serve a purpose lol

[gazjoiner]

thanks for the welcome:) yes they do what you need them to do, only saying lol! that's going to be an awsome track car you have there!! as i said keep up the good work fella:)

[Count Vaux Alot]

Hi there! SNOW DAY! i've had some time over the last two days due to the mad snow, so i got on with the car (unsurprisingly enough lol)

So here goes, first off i fitted the blanking plates i made up for the engine bay and sealed them up

http://i248.photobucket.com/albums/gg167/Count85/engbay124.jpg

http://i248.photobucket.com/albums/gg167/Count85/engbay125.jpg

Basically ready for prep and paint in the bay now other than the corsa pedal mod (hopefully collecting it tomorrow if the snow doesn't funk everything again)

Then i removed the N/S door so i could get inside easily, the door with out the door card weighed in at 18.8kgs

http://i248.photobucket.com/albums/gg167/Count85/engbay127.jpg

Now on with the dealings inside - ever ones favourite - spot weld removal time!

Out came the selector mounting point and the section of metal covering the exhaust tunnel.

http://i248.photobucket.com/albums/gg167/Count85/engbay128.jpg

Then it was heat gun and scraper time - joy!

N/S foot well

http://i248.photobucket.com/albums/gg167/Count85/engbay129.jpg

http://i248.photobucket.com/albums/gg167/Count85/engbay130.jpg

And the remains

http://i248.photobucket.com/albums/gg167/Count85/engbay131.jpg

O/S foot well

http://i248.photobucket.com/albums/gg167/Count85/engbay132.jpg

http://i248.photobucket.com/albums/gg167/Count85/engbay133.jpg

And the remains

http://i248.photobucket.com/albums/gg167/Count85/engbay134.jpg

Then out with the internal cross member type thing

http://i248.photobucket.com/albums/gg167/Count85/engbay136.jpg

And the heat gun again for the deadening under the rear seat

http://i248.photobucket.com/albums/gg167/Count85/engbay137.jpg



All the sound deadening from the interior weighed in at an amazing 4.5kgs!!


:eek:

[AlexW]

Looking good man. Didnt think mk1's had sound deadiing under the rear seats, Maybe cos its early? Learn somthing new everyday.

Let me know when you know if the cav collum fits the standard mounts. Would love to know.

Did you sell those 13inch 3spokes in the end?

[Ernie]

good work James.
No vid this time tho lol.

[Count Vaux Alot]

Once all the black tar shi£e was out i got on with removing more unwanted metal inside the cabin - drill drill

Rear seat mounting points

http://i248.photobucket.com/albums/gg167/Count85/engbay138.jpg

http://i248.photobucket.com/albums/gg167/Count85/engbay139.jpg

http://i248.photobucket.com/albums/gg167/Count85/engbay140.jpg

http://i248.photobucket.com/albums/gg167/Count85/engbay141.jpg

And a larger bracket

http://i248.photobucket.com/albums/gg167/Count85/engbay142.jpg

And the remains

http://i248.photobucket.com/albums/gg167/Count85/engbay143.jpg

This lot also weighed in at 4.5kgs

http://i248.photobucket.com/albums/gg167/Count85/engbay148.jpg

Then did a little marking out

http://i248.photobucket.com/albums/gg167/Count85/engbay144.jpg

Can you guess whats coming lol....

Not quite yet though as i wanted rid of the rear axle and tank etc first so off with the wheels, suspension and axle

http://i248.photobucket.com/albums/gg167/Count85/engbay145.jpg

And the tank

http://i248.photobucket.com/albums/gg167/Count85/engbay146.jpg

Then i decided the underside needed some attention so i needed the O/S door off to get it on the roll over frame, as it was tight up against the wall with no suspension on it etc i decided i would drop it on its belly on a pallet and put it on some trays with wheels so i could skate it about.

As so

http://i248.photobucket.com/albums/gg167/Count85/engbay152.jpg

Once the O/S was accessible i took the door off

http://i248.photobucket.com/albums/gg167/Count85/engbay151.jpg

And thats it for the moment enjoy!

[vaughanmc]

Removing sound deadening! What a boring job

I was at it for hours with a hammer and chisel before poking holes in the floor due to rot then I gave up! lol

Top work fella!

Is it staying silver ?

[Count Vaux Alot]

Looking good man. Didnt think mk1's had sound deadiing under the rear seats, Maybe cos its early? Learn somthing new everyday.

Let me know when you know if the cav collum fits the standard mounts. Would love to know.

Did you sell those 13inch 3spokes in the end?

Thinking about it my saloon doesn't have any sound deadening under the rear seat?
I'll try the cav column next week and let you all know :thumb:

As for the 3spokes i have one left which i found the other day any use to you?

[AlexW]

lol just Pm'ed you about somthing else lol

How much you want for it?

[Count Vaux Alot]

Removing sound deadening! What a boring job

I was at it for hours with a hammer and chisel before poking holes in the floor due to rot then I gave up! lol

Top work fella!

Is it staying silver ?

'Oh yes' its staying silver and the sound deadening took about an hour to remove so not too bad but it is a PITA job!

[Iain]

You've done a very neat job of drilling out those spot welds. What did you use?

[Dar]

Good work as always. You make it all look effortless :thumb:

[Count Vaux Alot]

You've done a very neat job of drilling out those spot welds. What did you use?

A drill and a spot weld drill bit and some savvy lol

[Iain]

Just something like this?

http://www.machinemart.co.uk/shop/product/details/cht467-38in-spot-weld-drill/path/

[Count Vaux Alot]

Good work as always. You make it all look effortless :thumb:

Thanks mate, i just hope it turns out well :D

[Dar]

Thanks mate, i just hope it turns out well :D
It will. Of that I am 110% certain.

[Count Vaux Alot]

Just something like this?

http://www.machinemart.co.uk/shop/product/details/cht467-38in-spot-weld-drill/path/
No matey, that looks like a skull boring device

They look like this

http://i248.photobucket.com/albums/gg167/Count85/2b14_1.jpg

There are loads on ebay

http://shop.ebay.co.uk/?_from=R40&_trksid=m38.l1311&_nkw=spot+weld+drill&_sacat=See-All-Categories

[Iain]

Thanks, Screwfix do one like that so I'll try that.

[AlexW]

Inbox now clear mate.

[scott.parker]

Good wieght removal there mate, i did the sound deadning on my old nova, and my mates! getting a pro at that **** now lol
i worked out that the rear seats and all the deadning came to just over 7 stone! crazzy eh!

Scott

[Graeme]

This build is looking really good now, I spent about an hour watching Mr Hewitts video's on Youtube this morning, looks like great fun and I envy you greatly having this to throw about on track days and a lovely saloon for the shows

[Count Vaux Alot]

Glad you liked the video...i laughed so much and have started laughing again thinking about it! lol

Any way UPDATE time!!

After finally getting my hands on a Corsa B brake pedal set up on saturday (thanks AW06!) i could get on with fitting it, so here goes....

We started with this - the raw ingredients

http://i248.photobucket.com/albums/gg167/Count85/engbay154.jpg

Then moved on the the car and the area of metal to be removed (Another note to myself just in case i forgot lol - luckily the only bit of rot on the bulk head was in this area!)

http://i248.photobucket.com/albums/gg167/Count85/engbay155.jpg

Out it comes

http://i248.photobucket.com/albums/gg167/Count85/engbay156.jpg

I then measured up and cut out a new piece of 3mm steel to fit the hole, resulting in a nice clean flat surface to mount the bias pedal box on

http://i248.photobucket.com/albums/gg167/Count85/engbay157.jpg

And i tacked it in

http://i248.photobucket.com/albums/gg167/Count85/engbay159.jpg

Once i was happy i welded the bad boy all the way round

http://i248.photobucket.com/albums/gg167/Count85/engbay161.jpg

Cleaned it all up

http://i248.photobucket.com/albums/gg167/Count85/engbay164.jpg

And stitched the front seam

http://i248.photobucket.com/albums/gg167/Count85/engbay165.jpg

Once the new metal was in place i got on with fitting the pedal unit its self (as im going for an adjustable bias pedal box see below i don't need the servo or MC)

http://i248.photobucket.com/albums/gg167/Count85/CMB0338.jpg

I know i've replaced the above shelf with new thicker metal but, i don't think this is support enough for the brake pedal given all the support brakets i took out from the origional set up.
This added to the fact that i have hurd people with the corsa B set up complain that the bulk head flexes as you depress the pedal. This got me thinking what can i use to add extra support - i came up with this...

http://i248.photobucket.com/albums/gg167/Count85/engbay168.jpg

I modified the original bracket to suit the corsa pedal, drilled a hole in the corsa pedal box and fitted the nova clutch arm (i modded it to fit properly later on in the fettling)

http://i248.photobucket.com/albums/gg167/Count85/engbay169.jpg

This was the moc up fit just taked in place

http://i248.photobucket.com/albums/gg167/Count85/engbay171.jpg

http://i248.photobucket.com/albums/gg167/Count85/engbay185.jpg

[Count Vaux Alot]

There is more to come.....

[Jay]

Well done matey, really cracking on with this, cant wait to see the end result and also will it be the lighter of the two.... Yours or Oli's? lol

[Count Vaux Alot]

It looks like this from the other side and out of the car

http://i248.photobucket.com/albums/gg167/Count85/engbay188.jpg

http://i248.photobucket.com/albums/gg167/Count85/engbay189.jpg

As you van see on the back of the pedal box i welded in a small rectangle of 5mm plate to add support to the bracket and give a decent mounting point for the pedal

http://i248.photobucket.com/albums/gg167/Count85/engbay190.jpg

http://i248.photobucket.com/albums/gg167/Count85/engbay192.jpg

Then it was latte time again :gay:mmmmmmm

http://i248.photobucket.com/albums/gg167/Count85/engbay193.jpg

As i said before the nova clutch pedal was just temporarily positioned until i got the bracket right, so once i had finished the bracket on the brake pedal i went on to make sure the clutch arm support was secure.

If you look at the picture below the bar to the corsa pedal from the clutch arm (the bit the clutch arm pivots on) doesn't sit flush up against the corsa pedal box, it sits at an angle this means you can't tighten it up properly.

http://i248.photobucket.com/albums/gg167/Count85/engbay181-1.jpg

So to cure this i removed the original fitting from the nova with a hole saw and did the same with the corsa pedal so it would accept the original nova one giving a flat surface for the pivot bar to tighten up to as so

http://i248.photobucket.com/albums/gg167/Count85/engbay194.jpg

http://i248.photobucket.com/albums/gg167/Count85/engbay195.jpg

Welded it in

http://i248.photobucket.com/albums/gg167/Count85/engbay197.jpg

And neatened it up

http://i248.photobucket.com/albums/gg167/Count85/engbay198.jpg

Jobs a good un!

http://i248.photobucket.com/albums/gg167/Count85/engbay202.jpg

http://i248.photobucket.com/albums/gg167/Count85/engbay203.jpg

This also brought the nut and washer on the inside of the corsa pedal away from the moving parts on the inside (the piston to the bias pedal box)

And there is more....fecking 15 pic cr@p!!

[nova ian]

Nice innovative touches there James, liking it alot matey!! That brake pedal assembly shouldn't budge at all, deffo a worth while idea.

Your going to be catching me up now! lol good work man

[Count Vaux Alot]

Once i was happy with that lot i went on to mod the pedal its self

http://i248.photobucket.com/albums/gg167/Count85/engbay209.jpg

And a quick clean up - bish bosh!

http://i248.photobucket.com/albums/gg167/Count85/engbay212.jpg

All fitted

http://i248.photobucket.com/albums/gg167/Count85/engbay206.jpg

Then i turned the car round on its new found giant skate and fitted it with the roll over frame - can you guess what is coming next lol

Turned around

http://i248.photobucket.com/albums/gg167/Count85/engbay213.jpg

http://i248.photobucket.com/albums/gg167/Count85/engbay214.jpg

Frame on

http://i248.photobucket.com/albums/gg167/Count85/engbay221.jpg

Crane on

http://i248.photobucket.com/albums/gg167/Count85/engbay219.jpg

Up

http://i248.photobucket.com/albums/gg167/Count85/engbay223.jpg

And over

http://i248.photobucket.com/albums/gg167/Count85/engbay227.jpg

Giving great access to the underside

http://i248.photobucket.com/albums/gg167/Count85/engbay230.jpg

This allows access to the seams on the underside of the engine bay that i haven't stitched yet and to tidy up a few areas that are a little scabby as well as to remove all the brackets from the brake and fuel pipes along with any other unwanted metal. Once ive done them i'll give it a good coat of stone chip and under seal.

Scabby areas - nothing serious mind

http://i248.photobucket.com/albums/gg167/Count85/engbay232.jpg

http://i248.photobucket.com/albums/gg167/Count85/engbay234.jpg

http://i248.photobucket.com/albums/gg167/Count85/engbay235.jpg

And relax :D

[Count Vaux Alot]

Well done matey, really cracking on with this, cant wait to see the end result and also will it be the lighter of the two.... Yours or Oli's? lol

It will be very interesting to see who is lighter lol Oli's car will be a tough feet to beat though!

[Count Vaux Alot]

Nice innovative touches there James, liking it alot matey!! That brake pedal assembly shouldn't budge at all, deffo a worth while idea.

Your going to be catching me up now! lol good work man

Cheers Ian i hope the pedal won't budge! Brakes are a very important area that may people seem to over look!
I will be catching you soon, do you think i will get mine finished first?? lol

[discoinferno]

very very nice like the pedal design and fabrication very impressive

[The Simps]

excellent work as always James! Can't beat a good spit roast.

I will be giving you some more rep soon but apparantly I've STILL not spread enough around!!! lol

[AlexW]

Great work. Good to finaly see the old corsa stuff get used.

Really liking the pedal setup. Looks proper! Fancy doing mine later in the year? lol

[Plug]

would love to have the space to roll over like that,

Top build and great fabrication :thumb:

[dhdev (Oli)]

It will be very interesting to see who is lighter lol Oli's car will be a tough feet to beat though!
I'll be amazed if it gets within 50kgs ;)

[Count Vaux Alot]

lol lol Oli you are sure of your self arn't you - If trackday's car was 740kgs then mine should be lighter and i think i have a chance at being within 50kgs of your 640kgs....

[Jonlem]

Oli, was your car weighed when it was corner weighted or on a weighbridge ?

[dhdev (Oli)]

Oli, was your car weighed when it was corner weighted or on a weighbridge ?

Both :thumb:

And James, who says mine will be 640kgs ;)

[Count Vaux Alot]

Who says i wont be within 50kgs of you....lol

[Jonlem]

Both :thumb:

And James, who says mine will be 640kgs ;)

Fair play then, what does Lee's weigh then ?

I assumed his would be a bit lighter with the carbon doors etc..

[Ernie]

Looking good James keep it up.

[Count Vaux Alot]

Quick update from tonight - nothing ground breaking though...

Started cleaning the underside

http://i248.photobucket.com/albums/gg167/Count85/engbay240.jpg

http://i248.photobucket.com/albums/gg167/Count85/engbay241.jpg

http://i248.photobucket.com/albums/gg167/Count85/engbay242.jpg

Saved myself another 0.4kgs losing these little feckers

http://i248.photobucket.com/albums/gg167/Count85/engbay246.jpg

Resulting in this

http://i248.photobucket.com/albums/gg167/Count85/engbay247.jpg

http://i248.photobucket.com/albums/gg167/Count85/engbay248.jpg

And this soon to be parting company with the shell lol

http://i248.photobucket.com/albums/gg167/Count85/engbay249.jpg

And continued cleaning (and saving weight by removing funking under seal :roll: lol)
The end result looking like this

http://i248.photobucket.com/albums/gg167/Count85/engbay250.jpg

http://i248.photobucket.com/albums/gg167/Count85/engbay251.jpg

[Jay]

As above looking great, got a rough idea when it will be done?

[Count Vaux Alot]

Fair play then, what does Lee's weigh then ?

I assumed his would be a bit lighter with the carbon doors etc..

Lee 303 are you talking about JB???

[Count Vaux Alot]

As above looking great, got a rough idea when it will be done?

I should have it done by the end of time :p

[The Simps]

you sound like a bunch of women talking about all this weight loss :p

[Count Vaux Alot]

To alter power to weight ratio you have two options... alter power or alter weight.

So weight saving is worth considering (not to mention the handling benefits of being lighter and the fuel consumption on a long run lol the last bit was a joke for all you haters lol)

[Jonlem]

Lee 303 are you talking about JB???

Yes, identical cars really except Lee has carbon doors and I didn't think his was as light as Olis, my mistake though

[Benn]

Why remove the spare wheel well? Didnt someone work out it weights funk all.. Or if it for better under body flow?

[Count Vaux Alot]

Why remove the spare wheel well? Didnt someone work out it weights funk all.. Or if it for better under body flow?

It weights considerably more than the 2mm piece of ali sheet replacing it,
it will allow for me to fit a centre mounted exhaust that is lighter than a conventionally routed exhaust due to less bends equalling less pipework equalling less weight and an under car diffuser a la Dar if i get round to it lol

[Benn]

Cool. Good work.

[The Simps]

You can also bolt your fuel pumps & swirl pot to the Ali plate to make it all very accessable and removable as one unit if you so desired.

[dhdev (Oli)]

Yes, identical cars really except Lee has carbon doors and I didn't think his was as light as Olis, my mistake though

It's all the little bits that add up, he was running standard pedal set-up (don't think he's weighed it recently), he has 16" wheels, he has door-cards iirc, etc etc.
And James, don't forget improved braking and reduced wear on components :cool: On the fuel consumption issue, i managed 53mpg when running mine in driving to Newquay and back at 56mph lol

Good work though dude, it's gonna be a featherweight for sure :thumb:

[Rick Draper]

Lee303 is on a proper pedal box setup by tilton or someone, very basic wiring, aim dash etc.

[dhdev (Oli)]

But also has twin mirrors, roof scoop, larger dia brakes, thicker shafts, heavier box, steel wings, etc etc... ;)

[Benn]

Oli, see your pms on Mig.

[Count Vaux Alot]

It's all the little bits that add up, he was running standard pedal set-up (don't think he's weighed it recently), he has 16" wheels, he has door-cards iirc, etc etc.
And James, don't forget improved braking and reduced wear on components :cool: On the fuel consumption issue, i managed 53mpg when running mine in driving to Newquay and back at 56mph lol

Good work though dude, it's gonna be a featherweight for sure :thumb:

Good point Oli about the braking and reduced wear, thats a very respectable figure for your consumption too! lol

Cheers for the positive comments BTW :thumb:

[Count Vaux Alot]

Oli, see your pms on Mig.

whats all this??

[dhdev (Oli)]

whats all this??

They're called PM's for a reason ;)lol

[Count Vaux Alot]

Yer thats fair enough...but get them off my wip! lol

[Count Vaux Alot]

Here a little update for tonight - i haven't got a great deal done due to having to make the dinner for myself and the missus :roll: combined with a general lack of enthusiasm after banging my head right on the corner of the garage door giving me one funk of a head ache! And finding some thing rather annoying last night - details below....

Here the damage to sed skull it was through a hat too!

http://i248.photobucket.com/albums/gg167/Count85/engbay.jpg

Got my front hub carriers and rear axle sand blasted today i think they came out well for £15 for the lot!

http://i248.photobucket.com/albums/gg167/Count85/engbay252.jpg

http://i248.photobucket.com/albums/gg167/Count85/engbay253.jpg

http://i248.photobucket.com/albums/gg167/Count85/engbay254.jpg

http://i248.photobucket.com/albums/gg167/Count85/engbay255.jpg

Then i painted the axle in acid etch primer ready for a top coat, i'm leaving the hub carriers as they are until i find out about having them machined out to fit the VW bearings.

http://i248.photobucket.com/albums/gg167/Count85/engbay263.jpg

http://i248.photobucket.com/albums/gg167/Count85/engbay264.jpg

Here is a comparison of the nova and cav steering columns. The Cav item is 0.5kgs heavier than the Nova item and should go in quite easily with a little persuasian.

http://i248.photobucket.com/albums/gg167/Count85/engbay257.jpg

I also made up the basis for the spare wheel well blank, the fold is to go up against the rear panel its made of 2mm thik ali.

http://i248.photobucket.com/albums/gg167/Count85/engbay260.jpg

I cleaned up the under bulk head area and primed the bare metal, then sealed the seam

http://i248.photobucket.com/albums/gg167/Count85/engbay266.jpg

http://i248.photobucket.com/albums/gg167/Count85/engbay267.jpg

While i was there i wipped these off every little bit counts!

http://i248.photobucket.com/albums/gg167/Count85/engbay262.jpg

Then got board and messed around with the dog lol

http://i248.photobucket.com/albums/gg167/Count85/engbay265.jpg

[Count Vaux Alot]

Now here is the sh/t bit i found these lurking under the scabs of rust on the O/S sill (i haven't had a good look at the N/S yet as its facing the floor).

http://i248.photobucket.com/albums/gg167/Count85/engbay243.jpg

http://i248.photobucket.com/albums/gg167/Count85/engbay244.jpg

http://i248.photobucket.com/albums/gg167/Count85/engbay245.jpg

As you can see there are some (about 5 in total) very small holes along the sill. Most of the material surrounding the holes has thinned so i will be replacing the O/S sill and probably the N/S also at this rate!

[John]

Spare wheel well alloy 2mm? won't 1mm suffice? lol.

Ouch head injury looks nasty!

[Graeme]

Can't you get in trouble for messing about with your dog? lol

[Count Vaux Alot]

Spare wheel well alloy 2mm? won't 1mm suffice? lol.

Ouch head injury looks nasty!

I thought this at first but after looking at 1,2,3mm sheets of ali the 2mm was the preferred option as 1mm just felt to thin!

[Count Vaux Alot]

Can't you get in trouble for messing about with your dog? lol

Its good to see some one has picked up on the technical content...:tard:

[Graeme]

I'm loving the build mate and watching it closely, that little foot note made me laugh thats all

[Ash]

This is going to be some build mate! Really impressed by the pedal support/s - Top work.

[Benn]

Erm the holes in the sill are drain holes dude, they are ment to be there, but may have rusted amount them.

Why the cav colloum? Adding weight?

beams and hubs look good, are the hand brake guilds the normal ones?

[Adam]

Looks a nasty cut there!!! not good

Bead blasting looks well, good price too.

Btw you do know the sills have a few drain holes in them normally...? (hope im not stating the obvious lol )
Not really worth changing the sill for tiny bits like that...

Edit-Never saw Benns post.....

[Count Vaux Alot]

I'm loving the build mate and watching it closely, that little foot note made me laugh thats all
Its ok i knew as soon as i typed it some one would pick up on it but thought funk it lol

Ash thanks for the comments i hope it will be a right tool

And in response to both Adam and Benn i haven't got this far not being able to distinguish the difference between drain holes and rust holes lol....if you see the first there is a drain hole in the very right corned its both larger and rounder! Considering the damage is worse now than the pic as i gave it a 'prod' with a screw driver and the fact that most of the sill is really thin i will be replacing this one if not both.

Both sills have been ordered btw :thumb:

[Count Vaux Alot]

Erm the holes in the sill are drain holes dude, they are ment to be there, but may have rusted amount them.

Why the cav colloum? Adding weight?

beams and hubs look good, are the hand brake guilds the normal ones?

First comment answered above :thumb: lol

The cav column is adjustable so you can achieve optimum wheel positione once seated in the car!

The axle is an early MK1 item so they have different H/brake cables :D

[Adam]

Fair play if youve already ordered them, might as well sort it 100% whilst youve got the welder out, Lol.

[The Simps]

update punk?

[Count Vaux Alot]

I've mostly been food poisoned this week so non until tomorrow lol

[Jonlem]

If you can James get someone to press the panel that will replace the spare wheel well, not that its a massive issue but it helps reduce noise and also adds a bit of strength.

Nice injury btw

[Count Vaux Alot]

UP DATE!!

During the week before death a la food poisoning i finished off the stitching on the under side of the engine bay and gave it some primer

http://i248.photobucket.com/albums/gg167/Count85/engbay268.jpg

http://i248.photobucket.com/albums/gg167/Count85/engbay269.jpg

Then gave the rear beam a lick of paint...i like the blue

http://i248.photobucket.com/albums/gg167/Count85/engbay270.jpg

http://i248.photobucket.com/albums/gg167/Count85/engbay271.jpg

Then today i had Oliver (TRACKDAYNOVA) over to give me a hand (it was a good job he did come over as i felt rough all day and he was a great help!)

He did a super job of stripping then gutting the doors they went from around 22kgs as a whole door (without the card) down to 11kgs fully stripped and then down to 9kgs gutted (this is with out the plastic windows though) so a saving of 13kgs a side!!!

The doors as they started at 22kgs each

http://i136.photobucket.com/albums/q161/neocapture/ncTC1.jpg

The strip begins

http://i136.photobucket.com/albums/q161/neocapture/ncTC2.jpg

The left door at 9kgs and right door at 11kgs

http://i136.photobucket.com/albums/q161/neocapture/ncTC3.jpg

HHHHMMMM sexy smoooooth

http://i136.photobucket.com/albums/q161/neocapture/ncTC4.jpg

[John]

Top work fella, how'd you get the seams so clean before welding?

[The Simps]

Hope you're feeling better dude. Good progress and neat job from Olly on the doors! Grinder and steady hand? or air nibbler?

[Count Vaux Alot]

While Olly was getting on with the doors i started on the rest of the underside of the car cleaning the back end up (funking crust and under seal!!)

As it started

http://i136.photobucket.com/albums/q161/neocapture/ncTC6.jpg

Rear chassis legs cleaned

http://i136.photobucket.com/albums/q161/neocapture/ncTC7.jpg

Some general messing about lol

http://i136.photobucket.com/albums/q161/neocapture/ncTC8.jpg

http://i136.photobucket.com/albums/q161/neocapture/ncTC9.jpg

Removal of the exhaust bracket

http://i136.photobucket.com/albums/q161/neocapture/ncTC10.jpg

And on to the spare wheel well

The beginning

http://i136.photobucket.com/albums/q161/neocapture/ncTC11.jpg

The middle

http://i136.photobucket.com/albums/q161/neocapture/ncTC12.jpg

The end

http://i136.photobucket.com/albums/q161/neocapture/ncTC13.jpg

The wheel well weighed in at 4.8kgs and the ali at 2.6kgs so a saving of 2.2kgs and a flat floor for the centre exit and any splitter
type device i might wish to craft

http://i136.photobucket.com/albums/q161/neocapture/ncTC5.jpg

http://i136.photobucket.com/albums/q161/neocapture/ncTC14.jpg

I cut out the ribs so the ali would lay flat

http://i248.photobucket.com/albums/gg167/Count85/engbay272.jpg

Shaped the panel

http://i248.photobucket.com/albums/gg167/Count85/engbay278.jpg

And trial fitted it

http://i248.photobucket.com/albums/gg167/Count85/engbay279.jpg

A few rivets and some sticky later and its home for good

http://i248.photobucket.com/albums/gg167/Count85/engbay281.jpg

[Count Vaux Alot]

And the inside (it looks like a lepper did the sealer but bollox to it)

http://i248.photobucket.com/albums/gg167/Count85/engbay287.jpg

http://i248.photobucket.com/albums/gg167/Count85/engbay288.jpg

http://i248.photobucket.com/albums/gg167/Count85/engbay289.jpg

The doors side by side

http://i248.photobucket.com/albums/gg167/Count85/engbay294.jpg

http://i248.photobucket.com/albums/gg167/Count85/engbay296.jpg

And the remains of the day lol

http://i248.photobucket.com/albums/gg167/Count85/engbay293.jpg

[Count Vaux Alot]

Top work fella, how'd you get the seams so clean before welding?

Just a wire wheels on a grinder buddy!

[The Simps]

oooh some more!

[The Simps]

really nice job on the wheel well, looks really neat and thought out.

[Count Vaux Alot]

Hope you're feeling better dude. Good progress and neat job from Olly on the doors! Grinder and steady hand? or air nibbler?

Yer i'm feeling better but still not 100% - its the valentines plans i had that were ruined that made me feel really bad and the £150 each i lost on hotel bookings and comedy club tickets in london for fri night what a c u n t! :mad: :mad:

It was a grinder and a steady hand btw :thumb:

[Count Vaux Alot]

If you can James get someone to press the panel that will replace the spare wheel well, not that its a massive issue but it helps reduce noise and also adds a bit of strength.

Nice injury btw

JB i see what your saying and i could have got it pressed but didn't think DOH! if i experience buffeting or 'bong' in ollys words at high speed then i will add a brace but i plan to hang the exhaust in the centre so that should the panel from moving as much (aledergedly :confused:)

[The Simps]

£150 each! Dam it! Think what you could of bought for the nova with that!!

[Count Vaux Alot]

i know i know :cry: :cry: :cry:

[srs1]

you dont look too upset standing in the empty shell lol


top work going on here.
only just started reading this thread, work rate is awsome.
cant wait to see the end result.


all this weight of everything reminds me of women on a diet every jan/feb.

this is a mans diet.
lol

[Count Vaux Alot]

I had got over the initial hurt by then but i might suffer longer lasting pain from the missus lol.

Believe it or not i'm not rushing the work along just working at my own pace with my finger out unlike some lol lol

Thanks for the positivity btw

[Adam]

Top work as always!!!

[Jay]

Coming along nicely James, and the photo's are very good as usual Olly :thumb:

[Benn]

Wheel well plating is done very nicing, as are the doors, really nice and cleanly cut. Good work.

[vaughanmc]

Cracking work mate :)

Absolutely love the doors for some reason! Stripped out to the max

[Count Vaux Alot]

Cheers Ben!

Stripped to the max...the only way all the way :thumb:

[trackdaynova]

thanks also for the nice comments :thumb:

enjoyed working with you again today James :) we did good!

[Count Vaux Alot]

To true bud!

[t45_ste]

You seen a nice sequential? sadev? :)

[Count Vaux Alot]

All i can say is its quite local ;) :D

[t45_ste]

lol i hate secrets, tell.......

[Ernie]

yes please do.

[vaughanmc]

Absolutely immense work on this car mate :)

Will be some machine out on the track!

+1 rep ;)

[Count Vaux Alot]

In not telling until everything is for sure lol

And thanks vaughanmc you just got me my first bright green blob :thumb:

[vaughanmc]

Not a problem mate lol Nice to be nice :thumb:

[Count Vaux Alot]

Not a problem mate lol Nice to be nice :thumb:

To true +rep back!

[t45_ste]

Just one bit of advice. Iv had the sequential in the front of mine and it fowl's in alot of places, wont fit with standard width track. the quaife unit is very large though lol

[vaughanmc]

To true +rep back!

Cheers fella :thumb:

[Count Vaux Alot]

Update - only a little one though as i'm still suffering the poisioning lol Finally i have found myself a cage Big thanks to Dabsy (Dave) and to Olly (trackdaynova) for the extra tubing and cuppa on the way up there.

Right last night i collected the cage and on the way up to Derby Olly (trackdaynova) said why not pop in for a coffee so we did! Conveniently enough he had some tubing just the rigt size for the few areas on the cage that i woukd like to add to - i'm going to add a rear diagnol and possibly a brace accross the front a pillars were the dash was, i may also add another diagnol between the b pillar and the strut tops if i can bare to add the extra weight. On the other hand 'safty first' as tey say lol

The cage put together loosly on the drive, a little rough round the edges but nothing major. Its designed for a dashless car so bone @rse!

http://i248.photobucket.com/albums/gg167/Count85/cage002.jpg

http://i248.photobucket.com/albums/gg167/Count85/cage003.jpg

http://i248.photobucket.com/albums/gg167/Count85/cage004.jpg

http://i248.photobucket.com/albums/gg167/Count85/cage005.jpg

http://i248.photobucket.com/albums/gg167/Count85/cage006.jpg

Legs to the front turrets

http://i248.photobucket.com/albums/gg167/Count85/cage009-1.jpg

Door bars

http://i248.photobucket.com/albums/gg167/Count85/cage010.jpg

A total of 16 cage to shell tag points

http://i248.photobucket.com/albums/gg167/Count85/cage007.jpg

http://i248.photobucket.com/albums/gg167/Count85/cage013.jpg

http://i248.photobucket.com/albums/gg167/Count85/cage012.jpg

This is how it was mounted to the rear strut tops/inner arches but i think i will be changing this.

http://i248.photobucket.com/albums/gg167/Count85/cage016.jpg

And some Ollys old pole that i should be putting to good use....

http://i248.photobucket.com/albums/gg167/Count85/cage017.jpg

http://i248.photobucket.com/albums/gg167/Count85/cage020.jpg

Its now away being cleaned as i CBA so hopefully it will come back looking not too shabby!

[Southie]

http://i248.photobucket.com/albums/gg167/Count85/cage004.jpg



This shot reminds me of the playground around the corner from me. Poor kids :D Have you and Olly been swinging on it lol

What colour is the cage going to be? It looks like its seen some hammer :thumb:

[Count Vaux Alot]

This shot reminds me of the playground around the corner from me. Poor kids :D Have you and Olly been swinging on it lol

What colour is the cage going to be? It looks like its seen some hammer :thumb:
Poor kids! The kids were fine once we had plied them with sweets...

Anyway the cage is going to be the same colour as the rear axle below as it will tie in with the seats! The cage has been through a bit by the looks of it but it will be great once finished.

http://i248.photobucket.com/albums/gg167/Count85/engbay271.jpg

[Mike]

Oooooohhh posh cage! Door bars AND forward triangulation!!!

Nice colour blue mind!

[Count Vaux Alot]

Thanks Mike i was happy with it, it should look a little better once i'm done not going mad though :roll:.

[bowman]

that cage is in better nick than the one i'm gettinglol ....

I plan to modifiy mine to stop short of the dash board, are you going chop your dash?

[Count Vaux Alot]

Do i have a dash is the question....

[16xe_chris]

Oooooohhh posh cage! Door bars AND forward triangulation!!!

Nice colour blue mind!

You'll have to add some more bars too make this forward triangulation:roll: lol

love that blue:thumb:

If you want an easy way to shape your new bars to the original cage, you can use a bench drill (large hole cutter drill bits) and a few clamps!! or get a grinder with a steady hand lol

[16xe_chris]

Do i have a dash is the question....

More weight saving lol

Are you gonna drive this car with you shoes on or off :confused: you can save a few grams if you take the laces outlol

[John]

Strip the paint off the cage, and leave it off, paint weighs!

[Count Vaux Alot]

love that blue:thumb:

If you want an easy way to shape your new bars to the original cage, you can use a bench drill (large hole cutter drill bits) and a few clamps!! or get a grinder with a steady hand lol

Glad you like the colour, i take it you mean put the hole saw on the bench grinder?
As for the shoes i wont be wearing socks let alone shoes lol lol

[Count Vaux Alot]

Strip the paint off the cage, and leave it off, paint weighs!

Worth a thought lol

[Jay]

Looking good james, shame your so far away would love to see this beast getting built.

[Count Vaux Alot]

I should be well enough by the weekend to give it another seeing to...

[wilson_sri]

Loving your work :) Coming along nicely.

[Count Vaux Alot]

There is more to come lol i have a few more things i wish to try watch this space :D

[Graeme]

Loving this build, it gets better and better

[Adam]

Nice purchase on the cage there. I was interested myself, but it was a little too hardcore for what i want :(
I.e. would mean having the hack the ends of the dash etc off

[The Simps]

I should be well enough by the weekend to give it another seeing to...


Make sure you get some work done on the nova aswell ;) baboom tish!


Cage looks good. You sorted the g unit you wanted?

[nova ian]

Coming together nicely now James, The spec of this is going to be crazy!

Good stuff mate:thumb:

[dhdev (Oli)]

Cage looks heavy :eek: :p

Nice wotk as always James, beam looks lovely :thumb:

[Count Vaux Alot]

I knew you of all people would say that and i'm going to weight it at some point to find out what the damage is....but its a necessary addition of weight imo as i prefer my head the shape it is and not like a squashed melon!

Oli i also wondered what size space you are running? is it 25mm with a 7inch rim on a 45ET?

[dhdev (Oli)]

I knew you of all people would say that and i'm going to weight it at some point to find out what the damage is....but its a necessary addition of weight imo as i prefer my head the shape it is and not like a squashed melon!

Oli i also wondered what size space you are running? is it 25mm with a 7inch rim on a 45ET?

Definately necessary weight, safety is one area where weight can be added IMO, it also stiffens the shell obviously and that's a plus :)

It is a 25mm spacer, and I think you are right on the offset and width, I'll pop down the garage in a minute and take a look, although it may be hard to see without wheel removal.

[16xe_chris]

Glad you like the colour, i take it you mean put the hole saw on the bench grinder?
As for the shoes i wont be wearing socks let alone shoes lol lol


yeah just so your trimming the end up, you can buy an actual shaper for the cage bars but its a bloody forunte for the sake of using it a few times.

you can just use a grinder for a quick job and fill the large gaps with weld lol

[Count Vaux Alot]

As we are still on the subject of the cage i got it back from sand blasting today nice and clean well worth the investment imo and no effort what so ever lol

It came out like this...the pics are sh!te BTW as it was dark

http://i248.photobucket.com/albums/gg167/Count85/cage001-1.jpg

http://i248.photobucket.com/albums/gg167/Count85/cage002-1.jpg

http://i248.photobucket.com/albums/gg167/Count85/cage004-1.jpg

http://i248.photobucket.com/albums/gg167/Count85/cage005-1.jpg

http://i248.photobucket.com/albums/gg167/Count85/cage007-1.jpg

Then i got some primer on it

http://i248.photobucket.com/albums/gg167/Count85/cage008-1.jpg

http://i248.photobucket.com/albums/gg167/Count85/cage014-1.jpg

http://i248.photobucket.com/albums/gg167/Count85/cage015-1.jpg

With the last of the primer in the gun i gave the underside of the spare wheel well area a light coat

http://i248.photobucket.com/albums/gg167/Count85/cage009-2.jpg

[John]

looking good! Not too much paint mind though lol. You having a fuel cell, or keeping the original tank?

[Benn]

Weld in a chicken dash, and the mount the dails you need to that, no need for a heavey dash. Love it dude.

[Count Vaux Alot]

looking good! Not too much paint mind though lol. You having a fuel cell, or keeping the original tank?

I'm keeping the original tank (i have an injection one) as i don't think a cell is worth it at the moment - the original tank is in a good position and doesn't weight a great deal.

[Count Vaux Alot]

Weld in a chicken dash, and the mount the dails you need to that, no need for a heavey dash. Love it dude.

The RSPB might have something to say about me welding a chicken in to my car and mounting dials on it....lol lol lol

[dhdev (Oli)]

Nice work on the cage, the blasting definately seems worth it. I couldn't see any info on the wheels, the drums blocked my line of sight. Next time I have it out the garage I'll whip a wheel off and check.

[Count Vaux Alot]

Thanks mate you on msn? I have a few other questions lol

[dhdev (Oli)]

The missus has just arrived (driven down from the midlands) so I'll get castrated if I go on MSN. For future reference i'm dhdev@hotmail.com if you wanna add me, although I'm rarely on, I'll PM my mobile no. ;)

[Count Vaux Alot]

Nice one Boss i understand, my missus is the same lol

[srs1]

cage has cleaned up nice.

should look good once all finished off in the blue.

[Count Vaux Alot]

Does anyone know how much wider (track) a cavalier/calibra/astra/corsa is than a nova?

[The Simps]

*simps sits in front of his pc holding his hands so far apart*

[The Simps]

are you thinking from a spacers point of view? can you not place a cav shaft next to a nova one and measure the difference?

[Count Vaux Alot]

are you thinking from a spacers point of view? can you not place a cav shaft next to a nova one and measure the difference?

Yes i am thinking for a spacers point of view - and if i had a cav shaft i could lol hence i asked instead!

Basically i wish to know how much width i will gain by fitting cav shafts so i can then see if my other plan - details to follow will work - confused? so am i....

[The Simps]

I know what you're trying to do. I've got a standard shaft but its at my workshop so no use to you whatsoever at this time! If no one comes back to you by the morning i'll measure it when I'm up there tomorrow.

[Count Vaux Alot]

I'm trying to avoid fitting wheel spacers or going for 8inch wide front wheels as it will probably track like funk all over the place!

[The Simps]

Can you not just run corsa bottom arms, steering rack and modify the coilovers mounts?

[Count Vaux Alot]

I just want to know what i can gain track wise from the wider stuff off of any one of the above cars as just the wider corsa/cav/cali/astra stuff may not be enough...I will be running my own bottom arms a modded nova rack and a spacer of some sort if all works out

[Benn]

The RSPB might have something to say about me welding a chicken in to my car and mounting dials on it....lol lol lol

lol sorry that should be chicken bar...

[Count Vaux Alot]

I know what you're trying to do. I've got a standard shaft but its at my workshop so no use to you whatsoever at this time! If no one comes back to you by the morning i'll measure it when I'm up there tomorrow.

I bet you forgot??

[Count Vaux Alot]

Made a bit of head way with the car today although i had to work until 12 :mad: needed the extra ££ as i've been off sick, anyway got in full of enthusiasm and decided to tackle the sill - a job i didn't really want to do (as it was only because of the rust that it needed replacing) to remove and could have done without doing as ive got loads of other bits to be getting on with but its doen now :D

Here is how.....

one full sill repair panel

http://i248.photobucket.com/albums/gg167/Count85/sillandturrets001.jpg

Offered up, marked out and cut to size

http://i248.photobucket.com/albums/gg167/Count85/sillandturrets002.jpg

http://i248.photobucket.com/albums/gg167/Count85/sillandturrets003.jpg

Then i removed the old sill and cleaned up the ****e underneath

http://i248.photobucket.com/albums/gg167/Count85/sillandturrets007.jpg

http://i248.photobucket.com/albums/gg167/Count85/sillandturrets005.jpg

much better

http://i248.photobucket.com/albums/gg167/Count85/sillandturrets008.jpg

And welded the new metal in - not the prettiest of jobs but no more rust never the less.

http://i248.photobucket.com/albums/gg167/Count85/sillandturrets009.jpg

http://i248.photobucket.com/albums/gg167/Count85/sillandturrets011.jpg

I puddle welded were the original spot welds were

http://i248.photobucket.com/albums/gg167/Count85/sillandturrets012.jpg

and did a small repair further up the arch

http://i248.photobucket.com/albums/gg167/Count85/sillandturrets013.jpg

I'm going to leave the 'metal' finish as i cba with filler its a track car so aesthetics arn't as important and the nosh will only add more weight. I haven't a clue what the repair will look like once the car is on its belly again (dog sh!t i imagin) as its hard to see with the car on its side, but its done now.

After a session with the grinder and a sanding disc i got some primer on the new metal - job done!

http://i248.photobucket.com/albums/gg167/Count85/sillandturrets001-1.jpg

http://i248.photobucket.com/albums/gg167/Count85/sillandturrets004-1.jpg

http://i248.photobucket.com/albums/gg167/Count85/sillandturrets008-1.jpg

Once this task was complete i could get on with some thing more interesting....

[Count Vaux Alot]

I rolled these today can you guess what they are for??

http://i248.photobucket.com/albums/gg167/Count85/sillandturrets015.jpg

http://i248.photobucket.com/albums/gg167/Count85/sillandturrets016.jpg

[Ernie]

rear turrets

[Count Vaux Alot]

They started off like this

http://i248.photobucket.com/albums/gg167/Count85/engbay140.jpg

http://i248.photobucket.com/albums/gg167/Count85/engbay141.jpg

did a bit of arty drawing - which i changed just after doing them....doh!

http://i248.photobucket.com/albums/gg167/Count85/sillandturrets018.jpg

and some cutting

http://i248.photobucket.com/albums/gg167/Count85/sillandturrets020.jpg

out she comes

http://i248.photobucket.com/albums/gg167/Count85/sillandturrets022.jpg

http://i248.photobucket.com/albums/gg167/Count85/sillandturrets023.jpg

and finished at this point, ready to continue tomorrow :D

http://i248.photobucket.com/albums/gg167/Count85/sillandturrets024.jpg

Can anyone guess what these are for? ;)

http://i248.photobucket.com/albums/gg167/Count85/sillandturrets027.jpg

[Count Vaux Alot]

rear turrets

Give that man a goldfish :thumb:

[srs1]

they look like you are going to plate the sills you were unsure of.

if they are smaller then they look as camera angle is teasing us, then i'd say something to do with supports under the wheel well for the exhaust.

this is a good wip thread, showing people every little bit, section at a time

[Adam]

Good stuff!

You make things look simple :)

[Benn]

Liker the turrets.

[General Baxter]

dr count,

what you doing with the rear seat brackets ?

[AlexW]

Baxter the ones from the front of the floor are now in my car.

Good progess dude. Really liking this build.

[Count Vaux Alot]

they look like you are going to plate the sills you were unsure of.

if they are smaller then they look as camera angle is teasing us, then i'd say something to do with supports under the wheel well for the exhaust.

this is a good wip thread, showing people every little bit, section at a time

Check back in he thread O/S sill has been dealt with and its nothing to do with the exhaust so guess again lol

Thanks btw :D

[Count Vaux Alot]

dr count,

what you doing with the rear seat brackets ?

Which ones baxter? As AW said he has two of them....

[Jay]

Did you get the rear turrets done today James.

[Count Vaux Alot]

Oh yes update in a mo pending photo bucket faf...

[Jay]

Cooool

[Count Vaux Alot]

Today after spending two hours searching various DIY shops for grinder sanding disc backing pads i finally got on with the car.

I started by finishing off the aperture for the turret so the fit was nice and tight

http://i248.photobucket.com/albums/gg167/Count85/turrets1002.jpg

http://i248.photobucket.com/albums/gg167/Count85/turrets1003.jpg

Offered up the rolled sheet that will end up as the turret to check the fit

http://i248.photobucket.com/albums/gg167/Count85/turrets1005.jpg

And from inside the car

http://i248.photobucket.com/albums/gg167/Count85/turrets1007.jpg

http://i248.photobucket.com/albums/gg167/Count85/turrets1008.jpg

http://i248.photobucket.com/albums/gg167/Count85/turrets1009.jpg

Then once i was happy with the general fit (which took ages i will admit) i made up a 'lid' for the turret and welded it up to the rolled sheet - it was taking shape nicely

http://i248.photobucket.com/albums/gg167/Count85/turrets1010.jpg

http://i248.photobucket.com/albums/gg167/Count85/turrets1011.jpg

http://i248.photobucket.com/albums/gg167/Count85/turrets1012.jpg

http://i248.photobucket.com/albums/gg167/Count85/turrets1013.jpg

http://i248.photobucket.com/albums/gg167/Count85/turrets1015.jpg

MMMmm penetration

http://i248.photobucket.com/albums/gg167/Count85/turrets1016.jpg

[General Baxter]

im after the complete set for the back end :(

[Jay]

Your fabrication skills are amazing.

[Count Vaux Alot]

Then i fitted it up to the car again and marked out the general shape inside the wheel arch and cut the turret to shape

http://i248.photobucket.com/albums/gg167/Count85/turrets1020.jpg

I then cleaned all the crud off the surface around the turret aperture and the seams around the turret (were i wanted to weld)

http://i248.photobucket.com/albums/gg167/Count85/turrets1022.jpg

This is how it looks in the car with its lid on

http://i248.photobucket.com/albums/gg167/Count85/turrets1024.jpg

http://i248.photobucket.com/albums/gg167/Count85/turrets1026.jpg

http://i248.photobucket.com/albums/gg167/Count85/turrets1027.jpg

Then i started to weld it in - inner arch side first

http://i248.photobucket.com/albums/gg167/Count85/turrets1028.jpg

http://i248.photobucket.com/albums/gg167/Count85/turrets1032.jpg

And i stitched the seams up

http://i248.photobucket.com/albums/gg167/Count85/turrets1030.jpg

Then cleaned up all the edges - finished on this side

http://i248.photobucket.com/albums/gg167/Count85/turrets1034.jpg

Here's a quick on with the rear axle in place tp show the rear shock mounting point

http://i248.photobucket.com/albums/gg167/Count85/turrets1035.jpg

http://i248.photobucket.com/albums/gg167/Count85/turrets1038.jpg

Moving to the inside of the car it was time for yet more welding

top

http://i248.photobucket.com/albums/gg167/Count85/turrets1041.jpg

down the turret

http://i248.photobucket.com/albums/gg167/Count85/turrets1042.jpg

http://i248.photobucket.com/albums/gg167/Count85/turrets1044.jpg

And bottom

http://i248.photobucket.com/albums/gg167/Count85/turrets1045.jpg

[Count Vaux Alot]

And shes home

http://i248.photobucket.com/albums/gg167/Count85/turrets1046.jpg

http://i248.photobucket.com/albums/gg167/Count85/turrets1047.jpg

http://i248.photobucket.com/albums/gg167/Count85/turrets1048.jpg

One down one to go :thumb:

Again started off with a mark up

http://i248.photobucket.com/albums/gg167/Count85/turrets1043.jpg

Then the first cut

http://i248.photobucket.com/albums/gg167/Count85/turrets1051.jpg

And some further butchery this ending today's session hope you enjoyed it lol

http://i248.photobucket.com/albums/gg167/Count85/turrets1052.jpg

http://i248.photobucket.com/albums/gg167/Count85/turrets1054.jpg

[Count Vaux Alot]

Your fabrication skills are amazing.

Cheers Jay! :thumb:

[Benn]

Thats fantastic, your welding is art.

[Adam]

Are you 100% sure the metal your using for the turrets is thick enough??

A lot of stress will go through there, the original turret is triple skinned and that doesnt even hold the weight of the car(on a std spring/damper setup)

Just a thought :)

[shy witness]

looks like a nice job your doing there m8.



another good progress thread with good updates and pictures etc.



makes for interesting reading.


cheers

[Count Vaux Alot]

The Saloon is fine still....And if they give up the floor will catch it! The original turret are triple skinned in places not the whole thing. I may consider reinforcing the top of the turret if i feel the need.

[Count Vaux Alot]

looks like a nice job your doing there m8.



another good progress thread with good updates and pictures etc.



makes for interesting reading.


cheers

Cheers buddy imo its not worth doing a WIP if its not interesting to read lol

[The Simps]

excellent prep and well thought out work as always James. One day you WILL let me have your babies!

[Ernie]

Nice work james. i just love the way you just get on with it and make some thing if you know what i mean.

[dhdev (Oli)]

:cool:

[Count Vaux Alot]

Simps - any time mate my stud fee is quite high though....

Ernie - i know what you mean but to see if it works you have to give it a try - watch this space ;) :thumb:

Oli - Thanks you have PM!

[dhdev (Oli)]

No I don't :tard:

[Count Vaux Alot]

You do now - i hadn't written it then....

[Adam]

The Saloon is fine still....And if they give up the floor will catch it! The original turret are triple skinned in places not the whole thing. I may consider reinforcing the top of the turret if i feel the need.
Fair do's mate :thumb:

[MK999]

Is that welding all done with a standard 'home' mig setup? as it seems to lack the 'ripples' you normally see with mig welds, the inside of that turret you made is mostly really smooth. Apologies if it's bee ncovered before but I'll admit i haven't read all 40 odd pages lol

[Count Vaux Alot]

Is that welding all done with a standard 'home' mig setup? as it seems to lack the 'ripples' you normally see with mig welds, the inside of that turret you made is mostly really smooth. Apologies if it's bee ncovered before but I'll admit i haven't read all 40 odd pages lol
Hi mate this is my welder it is a 'home' mig set up using 10A fuse plug so can run of a standard 13A household plug and i think its 160A out put. I love it its great!

http://i248.photobucket.com/albums/gg167/Count85/turrets1065.jpg

I'm guessing you mean the weld is flat and not risen like it sits on top like a slug? Thats the result of good penetration and correct wire to welding speed :thumb:

[Count Vaux Alot]

Today's update -

Finished fettling the turret hole (this took the best part of 2 hours to get it just right :eek:)

http://i248.photobucket.com/albums/gg167/Count85/turrets1055.jpg

http://i248.photobucket.com/albums/gg167/Count85/turrets1058.jpg

http://i248.photobucket.com/albums/gg167/Count85/turrets1059.jpg

Then i turned my attention to the turret its self and gave it a good lidding

http://i248.photobucket.com/albums/gg167/Count85/turrets1060.jpg

Welded it home

http://i248.photobucket.com/albums/gg167/Count85/turrets1063.jpg

http://i248.photobucket.com/albums/gg167/Count85/turrets1064.jpg

http://i248.photobucket.com/albums/gg167/Count85/turrets1062.jpg

Then i decided to address an issue that was in the back of my mind when i first made these up and was then brought to the for front by Adam on the previous page (and is mentioned every time anyone turrets anything to be fair)...I did some research asked a few peeps what they thought and came to my own solution so here it is - turret strengthening!

I cleaned the internal faces of the turret up and ground the weld back a little

http://i248.photobucket.com/albums/gg167/Count85/turrets1066.jpg

Made up a 'second skin' for the top of the turret as i believe the body to be strong enough

http://i248.photobucket.com/albums/gg167/Count85/turrets1067.jpg

They go together like this on the inside of the turret

http://i248.photobucket.com/albums/gg167/Count85/turrets1068.jpg

I then acid etched the internal faces of the strengthening plates and fitted it all together with some clamps to hold it all in place

http://i248.photobucket.com/albums/gg167/Count85/turrets1069.jpg

http://i248.photobucket.com/albums/gg167/Count85/turrets1071.jpg

http://i248.photobucket.com/albums/gg167/Count85/turrets1072.jpg

[The Simps]

^ top thinking boss!

[Count Vaux Alot]

And welded it all in....'Hi nice to meet you I R Mr strong as funk turret and you are?'

http://i248.photobucket.com/albums/gg167/Count85/turrets1076.jpg

http://i248.photobucket.com/albums/gg167/Count85/turrets1073.jpg

http://i248.photobucket.com/albums/gg167/Count85/turrets1074.jpg

I will be cleaning these up tomorrow, while i was waiting for the welder to cool i salvaged the the std profiled top section to use on top of the new turrets as a locator for the suspension bush etc.

http://i248.photobucket.com/albums/gg167/Count85/turrets1077.jpg

As so

http://i248.photobucket.com/albums/gg167/Count85/turrets1079.jpg

http://i248.photobucket.com/albums/gg167/Count85/turrets1080.jpg

http://i248.photobucket.com/albums/gg167/Count85/turrets1081.jpg

Satisfied people? :confused: anyway enjoy :thumb:

[The Simps]

my god man!! think off the weight!!

[MK999]

Hi mate this is my welder it is a 'home' mig set up using 10A fuse plug so can run of a standard 13A household plug and i think its 160A out put. I love it its great!

I'm guessing you mean the weld is flat and not risen like it sits on top like a slug? Thats the result of good penetration and correct wire to welding speed :thumb:

The ripples I meant, if you run your finger along it, normally even a really good weld will not be smooth, thought it might be caused by the intermittant sparking of a mig setup and you were using a different method, but apparently not! I can actually just see it in your really close up pics but it's hard to spot, really really even welds all very impressive skills :cool:

You actually answered something I wondered for a while actually, how people can run 100+ amp welders on home circuits, where I know the biggest breaker in our house is 80 amp, but that's the output not the input :thumb:

All good info, I'll have to start reading this thread from the beginning sometime soon, not sure how I missed it :D

[Count Vaux Alot]

They arn't actually that heavy as a lot of what you see gets cut away leaving the shape of the inner arch. Tomorrow when i cut the turret to the inner arch profile i will weigh it and compare it to the weight of the removed metal from the original arch.

[Adam]

Top bombing

[Count Vaux Alot]

The ripples I meant, if you run your finger along it, normally even a really good weld will not be smooth, thought it might be caused by the intermittant sparking of a mig setup and you were using a different method, but apparently not! I can actually just see it in your really close up pics but it's hard to spot, really really even welds all very impressive skills :cool:

You actually answered something I wondered for a while actually, how people can run 100+ amp welders on home circuits, where I know the biggest breaker in our house is 80 amp, but that's the output not the input :thumb:

All good info, I'll have to start reading this thread from the beginning sometime soon, not sure how I missed it :D

Glad i could help please read from the beginning if you have a spare day lol

[The Simps]

They arn't actually that heavy as a lot of what you see gets cut away leaving the shape of the inner arch. Tomorrow when i cut the turret to the inner arch profile i will weigh it and compare it to the weight of the removed metal from the original arch.


I was only jibbing but weigh away!


*I think I might need to add a sarcasm meter next to my posts! lol

[Count Vaux Alot]

Top bombing

Thanks Adam do you think they look strong enough now?

[Count Vaux Alot]

I was only jibbing but weigh away!


*I think I might need to add a sarcasm meter next to my posts! lol

I know you were matey just thought i'd respond factually for a change lol

[Rick Draper]

Looking good. Had a look at my Rally design escort turrets earlier and they use a similar gauge of steel to yours but have a double skinned top which is what you have done now.

[Count Vaux Alot]

Looking good. Had a look at my Rally design escort turrets earlier and they use a similar gauge of steel to yours but have a double skinned top which is what you have done now.

Thanks for pointing that out Rick :thumb:
It further confirms my thoughts that the turrets needed something more unfortunately i don't have anything to compare mine to so had to just suck it and see before coming to an end result. I'll probably have to change them again but they don't call it a work in progress for nothing.

[Adam]

Thanks Adam do you think they look strong enough now?
:thumb:

[dhdev (Oli)]

Perfect ;)

[Count Vaux Alot]

Perfect ;)

Glad you agree! Cheers again :thumb:

[Rick Draper]

I will get you some decent close up pics of my rally design turret tops tomorrow if you want?

[Count Vaux Alot]

That would be spot on matey thanks!

[Mike]

You actually answered something I wondered for a while actually, how people can run 100+ amp welders on home circuits, where I know the biggest breaker in our house is 80 amp, but that's the output not the input :thumb:

Any standard UK spec consumer unit should be able to cope with a 100+ Amp device? Ive never had nay issues with breakers going out when using mine?

I only Ive get a problem when I switch to 110v in the workshop when the pillar drill is on stand by and the bench grinder is in use lol

Anyway, some top progress, and some prefection welding pictureed there!!!

[Count Vaux Alot]

Cheers Mike :thumb:

[The Simps]

whats stronger.

4mm plate or 2x2mm double skinned?

[MK999]

Depends which way you load/hit it I'd say, in the case of those turret tops you're gonna get a little more flex with 2x2mm, which means it'll hold up to a higher load for short lengths of time generally (you can probably stand on a riot shield and not be filled with confidence, but the way it flexes means bricks don't go straight through it) but if you loaded it up on a stress tester you'd probably get a lower break point compared to 4mm.

I'd say the 2x2 is more likely to bend/deform under use, but less likely to fail, unless the welds go from the flexing of the material around them, but they're probably stronger than the material itself lol

[Rick Draper]

Here are some pics:
http://img.photobucket.com/albums/v444/RickDraper/CIMG3829.jpg
http://img.photobucket.com/albums/v444/RickDraper/CIMG3830.jpg
http://img.photobucket.com/albums/v444/RickDraper/CIMG3831.jpg
http://img.photobucket.com/albums/v444/RickDraper/CIMG3832.jpg
On second look the top plates welded in are twice the thickness of the first plate welded in to the top.

[Count Vaux Alot]

whats stronger.

4mm plate or 2x2mm double skinned?

As said its a toss up depending on how you look at it....

[Count Vaux Alot]

Here are some pics:

On second look the top plates welded in are twice the thickness of the first plate welded in to the top.

Thanks for those Rick I'm satisfied that mine will be strong enough as they are esp once i have the cage etc mounted to the turrets.

[Count Vaux Alot]

Evening peeps i've been on it again dealing with these turrets and after tonight's mincing i'm nearly there with only some tidying up left to do!!

I started out cleaning up the N/S turret ready to be made a permanent fixture of the shell

http://i248.photobucket.com/albums/gg167/Count85/turrets1082.jpg

http://i248.photobucket.com/albums/gg167/Count85/turrets1083.jpg

Then went on and cleaned off the funking under seal around the turret hole what a c u n t of a job that is

http://i248.photobucket.com/albums/gg167/Count85/turrets1086.jpg

http://i248.photobucket.com/albums/gg167/Count85/turrets1087.jpg

I cut the turret to size and fitted it up for the first time - some alterations to the hole were needed...

http://i248.photobucket.com/albums/gg167/Count85/turrets1088.jpg

Then after even more fettling (at least a hour!) i finally tacked the turret in

http://i248.photobucket.com/albums/gg167/Count85/turrets1091.jpg

http://i248.photobucket.com/albums/gg167/Count85/turrets1092.jpg

And welded it home for good - drop the bomb!

http://i248.photobucket.com/albums/gg167/Count85/turrets1102.jpg

http://i248.photobucket.com/albums/gg167/Count85/turrets1103.jpg

http://i248.photobucket.com/albums/gg167/Count85/turrets1104.jpg

http://i248.photobucket.com/albums/gg167/Count85/turrets1106.jpg

http://i248.photobucket.com/albums/gg167/Count85/turrets1107.jpg

While i was waiting for the poor welded to cool off i decided i would make up the strengthening plates for the other turrets in the same way as before

http://i248.photobucket.com/albums/gg167/Count85/turrets1093.jpg

Then i cleaned up the inside of the first turret on the O/S ready for the plates

http://i248.photobucket.com/albums/gg167/Count85/turrets1094.jpg

Primed, fitted and tacked the plated in to position

http://i248.photobucket.com/albums/gg167/Count85/turrets1097.jpg