Free nova saloon project...... [Archive] - Performance Nova Group

bowman

31-12-08, 03:35 PM

Hi everyone... about 2 years ago i started a nova v6 project..

http://img118.imageshack.us/img118/4720/dsc00074gp5.jpg (http://imageshack.us)
http://img118.imageshack.us/img118/dsc00074gp5.jpg/1/w640.png (http://g.imageshack.us/img118/dsc00074gp5.jpg/1/)

The engine got fitted, but then i got pissed off with the amount of rot it was hiding and scrapped the car.... luckily i have another one.....

About a year ago i was talking to mate at work. He had been dealing with death in the family and was clearing their estate. I happened to mention the above project, and he told me the council wanted the car out of the garage is aunty had. Aparently if you own a council garage and then die they get it back or somthing? Anyway he said it was a nova saloon on a D reg! i got very exicted think it would be 2dr... as most that age are. He said had been sat there for 9 years and she had owned it from new. If i could shift it that day i could have it!... so i did

http://img118.imageshack.us/img118/9580/dsc00123zi2.jpg (http://imageshack.us)
http://img118.imageshack.us/img118/dsc00123zi2.jpg/1/w640.png (http://g.imageshack.us/img118/dsc00123zi2.jpg/1/)

It a basic spec 1.2 on an 86 D. Full poverty model! one wing mirror, coin tray instead of radio! (no areial hole tho) oddly has head rest and front and rear roll bars? Also has some sort of odd plastic under tray between the rear panel and wheel well?

Only 17500 miles from new! has full dealer service history up until 1999 when it was last taxed!

The engine bay is near mint condition, however 9 years in a damp council garage have caused a few issues. The sills have large chunks of paint that have fell off due to surface rust, as have rear arches, oddly the rust is oustide in so its not rotten! But the n/s wing is shot....:mad:

The plan... v6 idea is a no go, the engine went in my astra sport anyway... I have a nice c20ne motor which will be going in, plan being a small turbo (hence using the ne and not the seh) with a piggyback ecu or megasquirt i suspect piggy back as this project will be on stupidy low budget!

couple of pics:

http://img118.imageshack.us/img118/8972/dsc00127lu3.jpg (http://imageshack.us)
http://img118.imageshack.us/img118/dsc00127lu3.jpg/1/w640.png (http://g.imageshack.us/img118/dsc00127lu3.jpg/1/)

http://img227.imageshack.us/img227/7846/dsc00129nt0.jpg (http://imageshack.us)
http://img227.imageshack.us/img227/dsc00129nt0.jpg/1/w640.png (http://g.imageshack.us/img227/dsc00129nt0.jpg/1/)
[/URL]
[URL="http://g.imageshack.us/img227/dsc00129nt0.jpg/1/"] (http://imageshack.us)

http://img224.imageshack.us/img224/7061/dsc00126vi7.jpg (http://imageshack.us)
http://img224.imageshack.us/img224/dsc00126vi7.jpg/1/w640.png (http://g.imageshack.us/img224/dsc00126vi7.jpg/1/)

Had a quick poke around the inner wings, the splash gaurds are solid which is a very good sign... Wings to come off now for a good inspection and clean up...Will follow with some more pics....

Plug

31-12-08, 03:38 PM

shame its been vandlised (5 doors).

will keep my eye on this as i like the V6 novas

bowman

31-12-08, 03:45 PM

sorry mate i think you replied while i was editing! going to be a 2l 8v turbo... sorry to disapoint!

Plug

31-12-08, 03:49 PM

still going to be an interesting build and look like a sleeper as it has back doors

dj_wudgey

31-12-08, 04:03 PM

looks tidy enough matey ill watch this!!

bowman

31-12-08, 04:03 PM

parts collected so far...

14" 5 spoke speedlines, spokes to be painted body colour and rim polished
c20ne motor with choice of f16/f20
streetline susp kit
astra 2l sport front and rear brakes (may leave rear drumed)
new gte/gsi rad
half a hh stengthening kit (other half was on sracpped car, so may have some plates to make up)

To collect:

drive shafts 22 spline
injection tank
o/s full sill (bummer)
n/s front wing...
turbo manifold from pontiac sunbird
t2 turbo (poss t25/t3 turbo with adaptor)
let oil feed
intercooler
saab reds

for fueling, i'm considering a power commander... i had one on a R1, and simply overrides injector control to alter fueling! mappable from my laptop! Only want max 10psi, i sure 7-8 is poss on standard ecu with adj fpr. hoping for around 170bhp with good torque spread. Again budget is the aim at first. Also i dont want to do anythig to it that carnt be transfered to a mint 3dr i'll but eventualy! so body mods will be zero!

Rickyb

31-12-08, 10:54 PM

im gonna be watching this very closley looking good and exalent choise of engine.
oh also you have a P.M.

just vaux trev

01-01-09, 12:56 AM

more info on (why)this please??

paddy138

01-01-09, 02:21 AM

should be a good project but you might want to put 15 inch wheels on instead of 14 inch wheels to suit the final gear ratio

~~joycey~~

01-01-09, 04:09 AM

More door loon :D

vaughanmc

01-01-09, 11:08 AM

Some money could be made from the parts in there like the radio blank fella :)

Good project though

bowman

01-01-09, 12:28 PM

Some money could be made from the parts in there like the radio blank fella :)

Good project though

the thought had crossed my mind! I made a good few quid when i broke my 3dr! we'll see when i get the wings off etc, and really assess the condition of it. I'm not spending alot of money to save a 4dr!

bowman

01-01-09, 12:30 PM

should be a good project but you might want to put 15 inch wheels on instead of 14 inch wheels to suit the final gear ratio

the rims are mega cheap, retro look and have big ballon tyres so gearing should be fine:D budget budget budget!!

dj_wudgey

01-01-09, 04:44 PM

if you get a sterio matey ill buy the coin tray off you if you want to sell of course lol

DW-Nova

01-01-09, 06:01 PM

This sounds cool mate ! should be very interesting, good to see things being done on a budget.

dalenova

02-01-09, 05:57 PM

dont see many of these

G8WCC

02-01-09, 09:35 PM

always fancied a saloon will be good to see it finished

bowman

04-01-09, 08:33 PM

Shortest project in history! Well not really.....

The damn thing is worse than i thought... so i bought a coupe shell today, was forsale on here with hatch rear arches in, which is a mod i always liked... the shell is very solid and the money i spent on it would have been spent on arches sills front panel etc so no extra cost to the project! may actualy saved a few quid!:)

was told its B reg but wont know till the v5 is applyed for

pics soon its dark at the mo....

bowman

06-01-09, 11:12 PM

some pics of new shell, Its not much to look at now, but i cant find any rust anywhere, so thats a good start!

http://img122.imageshack.us/img122/7707/06012009096np2.jpg (http://imageshack.us)
http://img122.imageshack.us/img122/06012009096np2.jpg/1/w640.png (http://g.imageshack.us/img122/06012009096np2.jpg/1/)

http://img122.imageshack.us/img122/8463/06012009103zi9.jpg (http://imageshack.us)
http://img122.imageshack.us/img122/06012009103zi9.jpg/1/w640.png (http://g.imageshack.us/img122/06012009103zi9.jpg/1/)

inner wing/chassis rail all good, fire walls been chopped out.

http://img145.imageshack.us/img145/5104/06012009095qj3.jpg (http://imageshack.us)
http://img145.imageshack.us/img145/06012009095qj3.jpg/1/w640.png (http://g.imageshack.us/img145/06012009095qj3.jpg/1/)

http://img145.imageshack.us/img145/1341/06012009099jq8.jpg (http://imageshack.us)
http://img145.imageshack.us/img145/06012009099jq8.jpg/1/w640.png (http://g.imageshack.us/img145/06012009099jq8.jpg/1/)

very tidy arch conversion, quarter edges stepped etc, but like every one i've seen so far, the panels a little too low, may get changed using new quarter panels rather than wing panels, but that can wait!

Battery tray soild..

http://img122.imageshack.us/img122/2923/06012009106zt7.jpg (http://imageshack.us)
http://img122.imageshack.us/img122/06012009106zt7.jpg/1/w640.png (http://g.imageshack.us/img122/06012009106zt7.jpg/1/)

http://img216.imageshack.us/img216/8908/06012009097xw2.jpg (http://imageshack.us)
http://img216.imageshack.us/img216/06012009097xw2.jpg/1/w640.png (http://g.imageshack.us/img216/06012009097xw2.jpg/1/)

Still busy stripping the more door, so all ive got done was this, like the new colour?

http://img145.imageshack.us/img145/7128/06012009093ez6.jpg (http://imageshack.us)
http://img145.imageshack.us/img145/06012009093ez6.jpg/1/w640.png (http://g.imageshack.us/img145/06012009093ez6.jpg/1/)

Vauxhall Brazil Brown..... bought some halfrauds rattle cans for daft bits, will get some 2k for the bay and boot, tempted to just clean up the inside and leave it red, as you cant see it with the carpets/trim in.

Sloth

07-01-09, 12:55 AM

dude you got the 4dr still, i may have a use fer it!!!!!!!

bowman

07-01-09, 04:49 PM

if you can collect it at the weekend you can have it... still got engine+box doors, but no front sus or wheels.

Sloth

07-01-09, 06:50 PM

hmmm where are ya bud, im tempted if ya close.

bowman

08-01-09, 08:56 PM

cars in co.durham mate. note it has no front suspension, but the engine/box are still in! so difficult to move.

Sloth

08-01-09, 09:05 PM

hmm bit far but thanks, dont scrap it tho, put it in fer sale.

Rickyb

09-01-09, 11:49 PM

hows the project coming on

Sloth

09-01-09, 11:52 PM

who's mine or his?

Rickyb

09-01-09, 11:56 PM

i would have asked you your self lol.

bowman

10-01-09, 04:33 PM

just busy getting the blue 4 door stipped, off to the scrappy on monday...

really i want the shell painting before i do any thing else, makes sense since iys completely stripped, so might have to sell my R1 to fund it!:mad:

http://img81.imageshack.us/img81/1261/08092008044pl2.jpg (http://imageshack.us)
http://img81.imageshack.us/img81/08092008044pl2.jpg/1/w640.png (http://g.imageshack.us/img81/08092008044pl2.jpg/1/)

Sloth

10-01-09, 04:36 PM

your pics dont work. whats rotten on the 4dr bud?

bowman

10-01-09, 04:46 PM

inner wings and around the headlights mate, rear arches are tat as well. If it were hatch or coupe i would save it, but because a 4dr its just dog sh%t mate.

Pics show on my computer, can any else see them?

Sloth

10-01-09, 04:51 PM

ahh it sounds dead bud. shame really as the early 4dr's are nearly extinct. pics still no worky lol

~~joycey~~

11-01-09, 04:14 AM

Nice astra sport :)

bowman

11-01-09, 10:15 PM

that was my v6 conversion, its up in scotland now....

~~joycey~~

14-01-09, 03:18 AM

that was my v6 conversion, its up in scotland now....

Love mk3 astra's :) Got any pics of it?

bowman

14-01-09, 07:05 PM

Here a link to the build thread....

http://www.migweb.co.uk/forums/projects-restorations/322923-astra-sport-v6-conversion.html

thinks it the only build i've ever managed to finish!

bowman

17-01-09, 06:36 PM

had a day off today, had a trip to the paint shop for some 2k chocolate brown and some 1k converter, apparently i'm much less likey to die using this stuff instead of activtor!... oh and some nice thick highbuild primer.

though i would start in the engine bay, which to be honest was a mess! plan is to fit a corsa servo and m. cylinder so i need to see what the tray like

http://host.photogalaxy.net/thumbs/24938_17012009114.jpg (http://host.photogalaxy.net/viewer.php?id=24938_17012009114.jpg)
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Then got rid of the battery cage, which required my gas burner for the mountains of understeal!

http://host.photogalaxy.net/thumbs/61497_17012009116.jpg (http://host.photogalaxy.net/viewer.php?id=61497_17012009116.jpg)
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give the area a good coat of this stuff, essential for any nova owner these days!

http://host.photogalaxy.net/thumbs/83397_17012009118.jpg (http://host.photogalaxy.net/viewer.php?id=83397_17012009118.jpg)
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few coats of high build....

http://host.photogalaxy.net/thumbs/67430_17012009119.jpg (http://host.photogalaxy.net/viewer.php?id=67430_17012009119.jpg)
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Now for the holes that need plugging, i'm not going to run heater matrix, or blower, instead im going to run two 12v heater/coolers behind the dash. Tidy, hidden and instant heat on a morning (not that it be out in the cold anyhow!)

http://host.photogalaxy.net/thumbs/10669_17012009120.jpg (http://host.photogalaxy.net/viewer.php?id=10669_17012009120.jpg)
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cut some little discs out with my brand new tin snips, 2mm diameter larger than the holes... tacked them in with my brand new welder and used my brand new auto tint mask! (santa's knows his s%it!)

http://host.photogalaxy.net/thumbs/60008_17012009122.jpg (http://host.photogalaxy.net/viewer.php?id=60008_17012009122.jpg)
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getting the hang of the new mig now..

http://host.photogalaxy.net/thumbs/73775_17012009123.jpg (http://host.photogalaxy.net/viewer.php?id=73775_17012009123.jpg)
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all holes plugged... thats it for now, no more days off until a week monday :(

http://host.photogalaxy.net/thumbs/41574_17012009124.jpg (http://host.photogalaxy.net/viewer.php?id=41574_17012009124.jpg)
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bowman

17-01-09, 06:49 PM

oh, and looks like the car was originally met red, see top of pic 3 above... Calypso red? would that mean it could be a A or B reg?

bowman

21-01-09, 08:21 PM

Had a spare hour tonight so did a bit of mincing! Got these bad boys for xmas a few years back, really really handy! (and give off alot of heat!)

http://host.photogalaxy.net/thumbs/52446_21012009125.jpg (http://host.photogalaxy.net/viewer.php?id=52446_21012009125.jpg)
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Cut out the lip from the blower hole and welded in a bit plate

http://host.photogalaxy.net/thumbs/17843_21012009126.jpg (http://host.photogalaxy.net/viewer.php?id=17843_21012009126.jpg)
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Ground the welding on the holes from the heater matrix and brake servo

http://host.photogalaxy.net/thumbs/58639_21012009128.jpg (http://host.photogalaxy.net/viewer.php?id=58639_21012009128.jpg)
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Gave them a quick squirt of bodge.....
http://host.photogalaxy.net/thumbs/142_21012009129.jpg (http://host.photogalaxy.net/viewer.php?id=142_21012009129.jpg)
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While waiting for the bodge to dry I decided to tackle the window issue. For those who don't know (and i didnt!:roll: ) Hatch quarter glass is too big! So i trial fitted the rubber to see how much different they are:

http://host.photogalaxy.net/thumbs/43676_21012009135.jpg (http://host.photogalaxy.net/viewer.php?id=43676_21012009135.jpg)
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As you can see they fit all but the top part, the rear piller must be a different angle. So i cut out around 2 inches for the seal, and it fits nicley. Now to get some polcarb or perspex, might have a bit chew making them as i dont have any glass to make a template from.

http://host.photogalaxy.net/thumbs/67570_21012009137.jpg (http://host.photogalaxy.net/viewer.php?id=67570_21012009137.jpg)
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Will superglue the joint and seal it will a smear of tiger seal, it'll do till someone breaks a coupe!

Anyhow it raining now so shup up shop. hoping to get a big update at the weekend.

bowman

21-01-09, 08:27 PM

think this is were the clutch cable goes, its ugly and will spoil my clean smooth look!:mad:

http://host.photogalaxy.net/thumbs/76568_21012009131.jpg (http://host.photogalaxy.net/viewer.php?id=76568_21012009131.jpg)
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my idea is to cut around 10mm off the spout, cut the whole bracket off and weld it on inside of the bulkhead, smoothing off the area around in the bay?

Anyone done this before?, any comments?

bowman

11-02-09, 06:57 PM

Work has been halted for the last week or so due to our new arrival, Archie:thumb: He nine days old now and he's a little minter!

http://host.photogalaxy.net/thumbs/45198_03022009145.jpg (http://host.photogalaxy.net/viewer.php?id=45198_03022009145.jpg)
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Archie had a his first full nights sleep last night, which gave me a bit of energy, which i put ot good use of course!

http://host.photogalaxy.net/thumbs/75185_11022009164.jpg (http://host.photogalaxy.net/viewer.php?id=75185_11022009164.jpg)
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cleaned up the other corner of the scuttle, and gave it a coat of high build etch primer

http://host.photogalaxy.net/thumbs/36836_11022009168.jpg (http://host.photogalaxy.net/viewer.php?id=36836_11022009168.jpg)
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welded the clutch cable bracket on the inside, and the welded up the dimple underneath and ground it flat (ish!) Not pretty but the outside will be smoothed off later....

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http://host.photogalaxy.net/thumbs/95545_11022009171.jpg (http://host.photogalaxy.net/viewer.php?id=95545_11022009171.jpg)
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Finished off today with another coat of high build where i smoothed of the alternator clearance...

http://host.photogalaxy.net/thumbs/29714_11022009167.jpg (http://host.photogalaxy.net/viewer.php?id=29714_11022009167.jpg)
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finished smoothing the blower hole and gave it coat of etch

http://host.photogalaxy.net/thumbs/72682_11022009165.jpg (http://host.photogalaxy.net/viewer.php?id=72682_11022009165.jpg)
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Tommorows job is the corsa brake mod, my mate is scrapping his hotrod corsa he trashed last year, so releaved it of this! the original nova pedal system will be butchered, and the bracketry welded on the inside, the pedal system will still bolt in, but i cant smooth out the final holes in the bay....

http://host.photogalaxy.net/thumbs/5335_11022009170.jpg (http://host.photogalaxy.net/viewer.php?id=5335_11022009170.jpg)
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Also getting the FIA cage out of it, but it will need cleaning up and shortening slightly for the nova.... but thats for another day....;)

bowman

14-02-09, 08:56 PM

Got the corsa servo sorted oy today, here are the pics....

Firstly, I wanted to double skin the battery tray area to eliminate flex under braking so cut out a panel from the original corsa mount:

The mount:

http://host.photogalaxy.net/thumbs/41848_14022009173.jpg (http://host.photogalaxy.net/viewer.php?id=41848_14022009173.jpg)
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then the bit i need cut out:

http://host.photogalaxy.net/thumbs/53140_14022009174.jpg (http://host.photogalaxy.net/viewer.php?id=53140_14022009174.jpg)
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the plate is around 2mm thick and will do nicley... Next i marked out were i wanted the servo and cylinder to sit, and cut it out, the hole needed to be smaller than the mounting plate, as need a surface to weld to. The problem with the battery tray is the rain channels make it uneven, so i snipped the edges of the channel and bent it up to make it sit flush with the plate, difficult to make out in the pics:

http://host.photogalaxy.net/thumbs/66103_14022009176.jpg (http://host.photogalaxy.net/viewer.php?id=66103_14022009176.jpg)
[Open Image (http://host.photogalaxy.net/viewer.php?id=66103_14022009176.jpg)] [Hosted by (http://host.photogalaxy.net) PhotoGalaxy.com (http://www.photogalaxy.com)]

next I tacked the mounting plate in position, then stiched welded it on

http://host.photogalaxy.net/thumbs/32504_14022009178.jpg (http://host.photogalaxy.net/viewer.php?id=32504_14022009178.jpg)
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Then fully welded, plugged a few spot weld holes too:

http://host.photogalaxy.net/thumbs/78958_14022009179.jpg (http://host.photogalaxy.net/viewer.php?id=78958_14022009179.jpg)
[Open Image (http://host.photogalaxy.net/viewer.php?id=78958_14022009179.jpg)]
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Servo in place

http://host.photogalaxy.net/thumbs/81335_14022009180.jpg (http://host.photogalaxy.net/viewer.php?id=81335_14022009180.jpg)
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The res cap just say touches the bonnet, as i wont be using this bonnet, i havent cut it, but a small recess in the bonnet frame will sort that out.

http://host.photogalaxy.net/thumbs/53267_14022009181.jpg (http://host.photogalaxy.net/viewer.php?id=53267_14022009181.jpg)
[Open Image (http://host.photogalaxy.net/viewer.php?id=53267_14022009181.jpg)] [Hosted by (http://host.photogalaxy.net) PhotoGalaxy.com (http://www.photogalaxy.com)]

I'm pleased to say, welding the clutch cable plate on the inside of the bulkhead has worked a treat! I test fitted both pedals, obviously the corsa pedal will require tweeking. I'll leave this until later as dont know were the other pedals will sit until the cables are in place..

Next i need to sort out the clutch pedal shaft, which i sfloating on the right side! to sort this i hacked up part of the original set up... i cut away the area in red:

http://host.photogalaxy.net/thumbs/75396_clutch_mod_1.JPG (http://host.photogalaxy.net/viewer.php?id=75396_clutch_mod_1.JPG)
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Trimed it down a touch and weld it on to the corsa brake cage.... works a treat and i can put the bolt back on the end of the clutch shaft!

http://host.photogalaxy.net/thumbs/28824_14022009183.jpg (http://host.photogalaxy.net/viewer.php?id=28824_14022009183.jpg)
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Now I know I dont need the last remaining holes, time to flush them out!

Bit of plate, that was once a wing!

http://host.photogalaxy.net/thumbs/73984_14022009185.jpg (http://host.photogalaxy.net/viewer.php?id=73984_14022009185.jpg)
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Welded up and ground flat:
http://host.photogalaxy.net/thumbs/50302_14022009186.jpg (http://host.photogalaxy.net/viewer.php?id=50302_14022009186.jpg)
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A skim of bodge to finish up todays carry on....

http://host.photogalaxy.net/thumbs/38029_14022009187.jpg (http://host.photogalaxy.net/viewer.php?id=38029_14022009187.jpg)
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Next time.... finishing of the bay smoothing and paintin it if the weather permits, and I'll be liberating the OMP cage from a poorly corsa hotrod!

Cost of todays mods £0. Total to date £150...:thumb:

bowman

14-02-09, 09:03 PM

Oh, and won this on ebay for £5.50! will be modded to fit the 8v head....Bargin! :thumb:

Incidently the sellers id was Vauxhallnovaman? anyone on here?

.jpg]http://host.photogalaxy.net/thumbs/91122_6f57_1[1].jpg (http://host.photogalaxy.net/viewer.php?id=91122_6f57_1[1)
[.jpg]Open Image (http://host.photogalaxy.net/viewer.php?id=91122_6f57_1[1)] [Hosted by (http://host.photogalaxy.net) PhotoGalaxy.com (http://www.photogalaxy.com)]

The Simps

14-02-09, 09:19 PM

good progress mate, coming along nicely.

If you turn the servo round 90 deg it will clear the bonnet...

http://img.photobucket.com/albums/v310/TheSimps/Nova/Nova%20Coupe%20Project/14-02-09001.jpg

~~joycey~~

14-02-09, 09:28 PM

bowman

14-02-09, 09:30 PM

Should have spotted that really! will do matey.....cheers :thumb:

Count Vaux Alot

14-02-09, 09:30 PM

A valid attempt with the corsa brake mod there, are you sure that isn't going to flex the bulk head under breaking?

bowman

14-02-09, 09:31 PM

Wots this "ment" to fit then?

Listing said D16, i guess thats something to do with hondas?

bowman

14-02-09, 09:33 PM

A valid attempt with the corsa brake mod there, are you sure that isn't going to flex the bulk head under breaking?

I hope not, or my bodge might crack!lol I was thinking of bracing it with part of the old setup, copying what you did, but it seems pretty solid, i guess i wont know for sure until its all pumbed and bled.

bowman

18-02-09, 10:47 AM

Well, bad news on the manifold, the dipsh^t who put it on ebay has refused to part with it......... why list somthing on a no reserve auction if have no intention of selling cheaply? The hunt continues....

I have however found a turbo!....

http://img5.imageshack.us/img5/3072/trubo209062020copyyk7.jpg (http://imageshack.us)
http://img5.imageshack.us/img5/trubo209062020copyyk7.jpg/1/w640.png (http://g.imageshack.us/img5/trubo209062020copyyk7.jpg/1/)

Its a borg warner (schwitzer) s1bg, considered an unpgrade for a t25, has slightly bigger compressor aparentley, its described a newly recon'd, unused! bargin price £39.99! I think its oil cooled only, which will save some plumbing work....:thumb: got it from a asset liquidation company on ebay... we'll see when/if it arrives......:roll: (includeds all gaskets, bolts/nuts and actuator!)

The Simps

18-02-09, 12:05 PM

$hitter on the manifold, I know your pain! I won a cav turbo wheel for 99p and the guy just ignored me. He only had a feedback of 5 so I assume he'll just restart a new account?

Fingers crossed the turbo is as described!

bowman

19-02-09, 12:07 PM

WOW turbo arrived first thing this morning! less than 24hrs! opened it up and i'm over the moon! Although it seems a bit on the large side! oops...! lol

heres some pics:

http://img6.imageshack.us/img6/120/18022009192pw3.jpg (http://imageshack.us)
http://img6.imageshack.us/img6/18022009192pw3.jpg/1/w640.png (http://g.imageshack.us/img6/18022009192pw3.jpg/1/)

http://img218.imageshack.us/img218/1055/18022009195xi9.jpg (http://imageshack.us)
http://img218.imageshack.us/img218/18022009195xi9.jpg/1/w640.png (http://g.imageshack.us/img218/18022009195xi9.jpg/1/)

http://img218.imageshack.us/img218/5765/18022009197uv9.jpg (http://imageshack.us)
http://img218.imageshack.us/img218/18022009197uv9.jpg/1/w480.png (http://g.imageshack.us/img218/18022009197uv9.jpg/1/)

Dont know much about these turbo's, maybe someone could shed dome light on it for me?

The Simps

19-02-09, 08:49 PM

WOW!! Thats almost as big as my schlong!

Mike

19-02-09, 08:53 PM

Listing said D16, i guess thats something to do with hondas?

Correct, that is a Honda 1.6 manifold chap.

bowman

14-03-09, 09:09 PM

i havent updated this for a while, so heres what i've been upto....

first of all i was totally sick of working outside in the wind and rain, so spent two full days clearing out the garage and finally got the nova in!

http://host.photogalaxy.net/thumbs/24833_09032009228.jpg (http://host.photogalaxy.net/viewer.php?id=24833_09032009228.jpg)
[Open Image (http://host.photogalaxy.net/viewer.php?id=24833_09032009228.jpg)] [Hosted by (http://host.photogalaxy.net) PhotoGalaxy.com (http://www.photogalaxy.com)]

Started having a good old poke around and found some rot!!! AArgghhh....:cry:

http://host.photogalaxy.net/thumbs/50925_09032009229.jpg (http://host.photogalaxy.net/viewer.php?id=50925_09032009229.jpg)
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Now depessed, i decided some retail theropy would cheer me back up, so onto ebay, and made another attempt to obtain a turbo manifold!... Won this for £45....

http://host.photogalaxy.net/thumbs/74285_aa47_1.jpg (http://host.photogalaxy.net/viewer.php?id=74285_aa47_1.jpg)
[Open Image (http://host.photogalaxy.net/viewer.php?id=74285_aa47_1.jpg)] [Hosted by (http://host.photogalaxy.net) PhotoGalaxy.com (http://www.photogalaxy.com)]

will need a new flange cutting and some tweking but should do the job!... its for a ford zetec turbo, but a ford item, so i guess its focus rs item?..:confused:

Also bagged some FK coilovers for £100 off a chap on another well known vaux forum....their new, but have been fitted to car, not driven, so saved me £70...
http://host.photogalaxy.net/thumbs/33332_14032009245.jpg (http://host.photogalaxy.net/viewer.php?id=33332_14032009245.jpg)
[Open Image (http://host.photogalaxy.net/viewer.php?id=33332_14032009245.jpg)] [Hosted by (http://host.photogalaxy.net) PhotoGalaxy.com (http://www.photogalaxy.com)]

Went to collect tham at DFD and landed a pair of mk1 hatch wings too! feel happier now... :thumb:

bowman

14-03-09, 09:26 PM

With new enthusiam i set about sorting the splash guard...

tried and test CAD methodlol
http://host.photogalaxy.net/thumbs/94223_09032009230.jpg (http://host.photogalaxy.net/viewer.php?id=94223_09032009230.jpg)
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Then marked it, and cut out of my big ass sheet of 2mm steel

http://host.photogalaxy.net/thumbs/85453_09032009231.jpg (http://host.photogalaxy.net/viewer.php?id=85453_09032009231.jpg)
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Cut away a good portion of the metal toensure i got all rot out,

http://host.photogalaxy.net/thumbs/95672_09032009232.jpg (http://host.photogalaxy.net/viewer.php?id=95672_09032009232.jpg)
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Weldedin the new piece and ground it with a flapper disc, i'm quite chuffed as its the neatest repair i've done yet..

http://host.photogalaxy.net/thumbs/69663_09032009233.jpg (http://host.photogalaxy.net/viewer.php?id=69663_09032009233.jpg)
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Carrying on with my role, i gave the full side and bay a good soaking of high build primer

http://host.photogalaxy.net/thumbs/25471_14032009244.jpg (http://host.photogalaxy.net/viewer.php?id=25471_14032009244.jpg)
[Open Image (http://host.photogalaxy.net/viewer.php?id=25471_14032009244.jpg)] [Hosted by (http://host.photogalaxy.net) PhotoGalaxy.com (http://www.photogalaxy.com)]

http://host.photogalaxy.net/thumbs/99836_14032009243.jpg (http://host.photogalaxy.net/viewer.php?id=99836_14032009243.jpg)
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Happy with that, i gace the lot a quick guide coat of satin black and flattened it all back with 400grit

http://host.photogalaxy.net/thumbs/95384_14032009249.jpg (http://host.photogalaxy.net/viewer.php?id=95384_14032009249.jpg)
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http://host.photogalaxy.net/thumbs/46394_14032009251.jpg (http://host.photogalaxy.net/viewer.php?id=46394_14032009251.jpg)
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http://host.photogalaxy.net/thumbs/42760_14032009252.jpg (http://host.photogalaxy.net/viewer.php?id=42760_14032009252.jpg)
[Open Image (http://host.photogalaxy.net/viewer.php?id=42760_14032009252.jpg)] [Hosted by (http://host.photogalaxy.net) PhotoGalaxy.com (http://www.photogalaxy.com)]

http://host.photogalaxy.net/thumbs/60899_14032009250.jpg (http://host.photogalaxy.net/viewer.php?id=60899_14032009250.jpg)
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http://host.photogalaxy.net/thumbs/66974_14032009248.jpg (http://host.photogalaxy.net/viewer.php?id=66974_14032009248.jpg)
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With my hands sore, and being alittle dizzy from fumes, i had to call it a night!, hopfully engine will be getting moved to the garage next week, for a quick rebuild and tart up!......:thumb:

The Simps

14-03-09, 09:29 PM

looking forward to watching it come together dude.

bowman

14-03-09, 09:30 PM

once the shells painted it will fly together, very few bits left to source....

sold this aswell, to fund the more 'posh' parts, that i can't find on ebay for buttons!

http://host.photogalaxy.net/thumbs/2738_24022009205.jpg (http://host.photogalaxy.net/viewer.php?id=2738_24022009205.jpg)
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hc coupe

19-03-09, 12:58 PM

Hi,

Its made a really good read. Looking forward to see how the arches come out once finished (I’m a little sceptical to be honest but its something new to me).

Best of luck with your build !

+rep for the effort too :thumb:

Tom

L14MNP

19-03-09, 02:40 PM

shame its been vandlised (5 doors).

will keep my eye on this as i like the V6 novas

4 door fail.

dj_wudgey

19-03-09, 07:30 PM

coming together well that dude!! well done any way!

DW-Nova

19-03-09, 08:00 PM

Thats looking good mate ! Liking the turbo too !! it looks pretty big hey, you've a couple of nice bikes by the looks of it too, goin to be sellin mine and my dads shared CBR 600 to help fund mine, should be a good setup once done, you still going to be running with a power commander ?

bowman

19-03-09, 08:10 PM

thanks for the comments guys....

as for the fueling, i've found a set of volvo t5r red injectors in my shed which fit the fuel rail, think they are 350cc, will have to check. Going to run a raising rate fpr, and standard managment at 12psi. Word is ecu can handle this but no more. So not going to bother with a commander now. May go megasquirt at a later date.

Will be opening up the head chamber and getting the standard pistons dished out to lower the c/r. All trial and error really, luckily i have 2 engines to play with!

nova_saloon

19-03-09, 09:36 PM

coming along isnt it, keep[ the good work up, and its always good to treat them with nice expensive bits isnt it

bowman

19-03-09, 09:47 PM

picking these up tommorow! 600mile round trip though!lol

http://host.photogalaxy.net/thumbs/47680_101_0030.jpg (http://host.photogalaxy.net/viewer.php?id=47680_101_0030.jpg)
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shaneyboi35

20-03-09, 10:53 AM

my old seats :) just read the whole build john looks good mate i will keep my eye on it !

hc coupe

20-03-09, 11:21 AM

Was nice to meet you and good luck with the build.Hope the windows fit ok !

bowman

20-03-09, 04:35 PM

cheers guys! thanks for waiting about for me! just got in half and hour ago, 640mile round trip! i'm fooked. off to bed!lol

Just got to wait a fortnight to see if i tripped any of the 500,000,000 speed cameras i passed!......

Sloth

20-03-09, 04:52 PM

sorry if ive missed the post, but what lump ya running?

bowman

21-03-09, 06:15 PM

c20ne turbo matey

bowman

26-03-09, 10:11 PM

Got a few bits dropped off on monday:

x2 C20NE motors, with harnesses and ecu's, and f16cr and a set of speedline 14" alloys with new maxxiss tyres on.... and some custom shafts with cv's (made for corsa hot rod, but slightly shorter so may fit?) bargin £100. :thumb:

http://host.photogalaxy.net/thumbs/29578_23032009270.jpg (http://host.photogalaxy.net/viewer.php?id=29578_23032009270.jpg)
[Open Image (http://host.photogalaxy.net/viewer.php?id=29578_23032009270.jpg)] [Hosted by (http://host.photogalaxy.net) PhotoGalaxy.com (http://www.photogalaxy.com)]

the engine at the front of the pic has a knocking bottom end, so will be stripped for spares.... its an early NE with narrow V belt and slim flywheel. these items will swapped onto the other a late model NE.

Wasted no time and first thing tuesday morning i set about stripping the knackered engine...

http://host.photogalaxy.net/thumbs/16643_24032009279.jpg (http://host.photogalaxy.net/viewer.php?id=16643_24032009279.jpg)
[Open Image (http://host.photogalaxy.net/viewer.php?id=16643_24032009279.jpg)] [Hosted by (http://host.photogalaxy.net) PhotoGalaxy.com (http://www.photogalaxy.com)]

Head off reavelled a loverly set of bores and pistons, will probably rebuild this bottom with machined piston and reground crank for future boost increases, but for now its banished to the shed.!

http://host.photogalaxy.net/thumbs/2201_24032009276.jpg (http://host.photogalaxy.net/viewer.php?id=2201_24032009276.jpg)
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Next whipped the nasty pot type flywheel of the good motor.....

http://host.photogalaxy.net/thumbs/39063_24032009281.jpg (http://host.photogalaxy.net/viewer.php?id=39063_24032009281.jpg)
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Fitted the early one on, difference is obvious! (yes its not torqued up yet!)

http://host.photogalaxy.net/thumbs/24332_24032009283.jpg (http://host.photogalaxy.net/viewer.php?id=24332_24032009283.jpg)
[Open Image (http://host.photogalaxy.net/viewer.php?id=24332_24032009283.jpg)] [Hosted by (http://host.photogalaxy.net) PhotoGalaxy.com (http://www.photogalaxy.com)]

Pully to fit removed, needs to be machined to remove the drive for the ps:

http://host.photogalaxy.net/thumbs/55513_24032009284.jpg (http://host.photogalaxy.net/viewer.php?id=55513_24032009284.jpg)
[Open Image (http://host.photogalaxy.net/viewer.php?id=55513_24032009284.jpg)] [Hosted by (http://host.photogalaxy.net) PhotoGalaxy.com (http://www.photogalaxy.com)]

Next up, stripped the good engine of all ancilleries, and manifolds for a good degreasing... came out quite well i thought.

http://host.photogalaxy.net/thumbs/81316_24032009286.jpg (http://host.photogalaxy.net/viewer.php?id=81316_24032009286.jpg)
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with the manifold removed i finally had a template for turbo manifold.

http://host.photogalaxy.net/thumbs/31340_24032009287.jpg (http://host.photogalaxy.net/viewer.php?id=31340_24032009287.jpg)
[Open Image (http://host.photogalaxy.net/viewer.php?id=31340_24032009287.jpg)] [Hosted by (http://host.photogalaxy.net) PhotoGalaxy.com (http://www.photogalaxy.com)]

So next i cut the factory flange form the zetec manifold, and offered it up to the ne motor...... bugger me backwards the ports are in exactly the same place 93mm apart! this is going save a of work!

http://host.photogalaxy.net/thumbs/19190_24032009285.jpg (http://host.photogalaxy.net/viewer.php?id=19190_24032009285.jpg)
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Gasket layed over the manifold:

http://host.photogalaxy.net/thumbs/41653_24032009288.jpg (http://host.photogalaxy.net/viewer.php?id=41653_24032009288.jpg)
[Open Image (http://host.photogalaxy.net/viewer.php?id=41653_24032009288.jpg)] [Hosted by (http://host.photogalaxy.net) PhotoGalaxy.com (http://www.photogalaxy.com)]

finally, a teaser of were the turbo will sit... with the turbo high i can drill and tap into the dipstick/breather hole for the oil return, again saves a lot of chew.... just hope the bonnet will shut!lol

http://host.photogalaxy.net/thumbs/23853_23032009272.jpg (http://host.photogalaxy.net/viewer.php?id=23853_23032009272.jpg)
[Open Image (http://host.photogalaxy.net/viewer.php?id=23853_23032009272.jpg)] [Hosted by (http://host.photogalaxy.net) PhotoGalaxy.com (http://www.photogalaxy.com)]

so for now it will be boring prep on the shell, while the manifold and turbo gaskets are away getting copied in 10mm stainless plate.

Plug

26-03-09, 10:32 PM

mock up of turbo looks good :thumb:

will that not hit the front panal ?

where bonet catch is?

bowman

26-03-09, 10:42 PM

from pics i've seen theres a fair bit of clearence with the 8v having a narrow head. Failing that my slam is already cut, i'll just fit bonnet pins and not bother with one!lol

Plug

26-03-09, 10:51 PM

yea areo catches look good and lockable :thumb:

Steve

27-03-09, 12:27 AM

Didnt realise you were going for a turbo 8v! +rep for you matey.

Thats quite strange the way the manifold of the zetec matches up to the vaux gasket, at least it'll save you alot of hassle.

bowman

27-03-09, 07:02 PM

i was chuffed to fu$k when i saw that! turns out its not a zetec turbo manifold, just a bog standard 2.0l zetec or duratec one, apparently all the later engines use this... i did a search and theres a few on ebay for pennies!:thumb:

bowman

27-03-09, 07:14 PM

yea areo catches look good and lockable :thumb:

i've been eyeing them up, the flush ones that mount under the bonnet skin look good.

bowman

28-03-09, 09:29 AM

Found this old pic hidden away in bowls of me pc! shows how the arch conversion looks finished... i will be using mk1 bumpers though......

http://host.photogalaxy.net/thumbs/7014_Saloon1.jpg (http://host.photogalaxy.net/viewer.php?id=7014_Saloon1.jpg)
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Count Vaux Alot

28-03-09, 10:19 AM

Please tell me you arn't hatch arching your saloon???

Steve

28-03-09, 12:00 PM

Same as, its just doesn't look quite right.

Tommydewe

28-03-09, 06:39 PM

very nice build!
will be watching this one!
goood luck and keep up the hard work!
im now going to look at your astra one :D

bowman

28-03-09, 10:47 PM

Please tell me you arn't hatch arching your saloon???

it was already done when i bought the shell, may get re-quartered in the future, but for now its going to have to have hatch arches in.

bowman

24-07-09, 10:04 PM

Hi Dudes!...havent updated this in a very long time. Mostly because i broke my arm in four places, popping them out of my arm in the process!

So thanks a little evil basta$d called Banshee Sho (an evil device sent to earth by the Devil himself, for those who dont know), I now have 2 plates and 12 screws in my forearm!

the offending artical:

http://host.photogalaxy.net/thumbs/65412_DSC00267.jpg (http://host.photogalaxy.net/viewer.php?id=65412_DSC00267.jpg)
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If anyone is interested in buying some death, keep an eye on the forsale section!

Anyway, after 2 operations and about 10 weeks of pain, i started to potter around in the garage.
The lower valance will be on show, being a mk1, but its had the corners cut out, probably for boost pipes, The panel was 100% solid so seemed a shame to to cut it out (and waste £30!) So I set about making some new pieces.

http://host.photogalaxy.net/thumbs/17870_02072009346.jpg (http://host.photogalaxy.net/viewer.php?id=17870_02072009346.jpg)
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First the old card template, them cut out of .8mm steel, and bent into shape agaist the front panel

http://host.photogalaxy.net/thumbs/64208_02072009347.jpg (http://host.photogalaxy.net/viewer.php?id=64208_02072009347.jpg)
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http://host.photogalaxy.net/thumbs/29930_02072009348.jpg (http://host.photogalaxy.net/viewer.php?id=29930_02072009348.jpg)
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http://host.photogalaxy.net/thumbs/29284_02072009350.jpg (http://host.photogalaxy.net/viewer.php?id=29284_02072009350.jpg)
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Done.... then I made a horible discovery! Fibre glass rust repairs on the inner wings!!!!! NOOOOOO! I cant belive someone would do that!

Chipped all that F.G. crap of, cut away the rot and made a peice to weld in

http://host.photogalaxy.net/thumbs/68183_24072009366.jpg (http://host.photogalaxy.net/viewer.php?id=68183_24072009366.jpg)
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Then started to remove the under seal.... good god! the last owner must have just drowned it in this stuff to hide the rust from me!

http://host.photogalaxy.net/thumbs/91267_24072009369.jpg (http://host.photogalaxy.net/viewer.php?id=91267_24072009369.jpg)
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To make matters worse, my gas runs out, then i hit a corroded patch in the mig wire, causing the feed to stick constantly! WHAT ELSE IS GOING TO GO WRONG!
More rot and plates!

http://host.photogalaxy.net/thumbs/12687_24072009367.jpg (http://host.photogalaxy.net/viewer.php?id=12687_24072009367.jpg)
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Nearly done, going to go over all the welds again with some fresh wire and gas, then I guess I have to re-smooth the bay due to the heat damage! Ggggrrrr!:mad:

Also going to sell a load of bits I've bouhgt recently to clear some room in the garage for my new streetfighter project:

http://host.photogalaxy.net/thumbs/24501_24072009370.jpg (http://host.photogalaxy.net/viewer.php?id=24501_24072009370.jpg)
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Nice shiney K5 1200 Bandit...... Best warm up the grinder and mig welder!

auzzy2000

24-07-09, 10:15 PM

empty your inbox mate!!!

bowman

24-07-09, 10:17 PM

done mate...

The Simps

25-07-09, 09:29 AM

rot is annoying but uve done a tidy job sorting it. Kudos.

bowman

25-07-09, 10:09 AM

cheers matey, i've scraped the last two for rot... not going to give up this time! I've spent 10 weeks watching American hot rod on discovery, really inspired my to do it right!lol

dj_wudgey

25-07-09, 10:36 AM

yea good work matey!!

saloonwoody

25-07-09, 08:09 PM

looks good m8 :) bummer about the arm but those mini moto's are a menace, iv got 6 points cos of one lol oh and streetfighters FTW ~:)

stuartp

25-07-09, 08:33 PM

5 door saloons ftw!!!

saloonwoody

25-07-09, 09:04 PM

5 door saloons ftw!!!
more door loons are four door and this is a two door anyhoo lol lol lol

bowman

08-11-09, 11:44 PM

Not done much for a while on this, so thought i'd get my finger out...

the car was due to go to the paint shop in few days, so set about prepping the panels..... usual story of horror and found rot in the 'mint' dorrs i had been sold! :cry: (i was to pissed off to take pics)

http://host.photogalaxy.net/thumbs/85827_27102009526.jpg (http://host.photogalaxy.net/viewer.php?id=85827_27102009526.jpg)
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Welded in a panel to repair....

http://host.photogalaxy.net/thumbs/52726_27102009527.jpg (http://host.photogalaxy.net/viewer.php?id=52726_27102009527.jpg)
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grinder.....

http://host.photogalaxy.net/thumbs/41668_30102009530.jpg (http://host.photogalaxy.net/viewer.php?id=41668_30102009530.jpg)
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skin of bodge, high build and a block flatten and all is well (12 hours and no finger prints later!lol )...then did the other door, boot lid and bonnet.

http://host.photogalaxy.net/thumbs/51216_31102009536.jpg (http://host.photogalaxy.net/viewer.php?id=51216_31102009536.jpg)
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Had a idea to help with the smooth engine bay look, so i welded in a panel between the bulkhead and wing rail... cleans it up and creates a stiff box section in a stressed area, which can't hurt... (yes i know the gutter is now blocked! it needs drilling out!lol )

http://host.photogalaxy.net/thumbs/32687_30102009533.jpg (http://host.photogalaxy.net/viewer.php?id=32687_30102009533.jpg)
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To finish off, i did an bit of work on the filler cap