My fire burned rebuild

[spanishfly]

Thought I would whack up my recent nova rebuild. For all those that don't know mine is the Nova that caught fire at TOTB VII.
If you want to see how it started (oct 2006) please see http://www.migweb.co.uk/forums/projects-restorations/287511-nova-1-0-build-trackday-car.html on mig.

Just going to copy and paste from Mig...

Ok here goes.

This is what greeted me this morning... It wasn't all a bad dream!
http://img186.imageshack.us/img186/8303/firedamage001bb8.jpg

Look awful!
http://img182.imageshack.us/img182/1781/firedamage002lv1.jpg

Although I found the culprit! Mofo!
http://img514.imageshack.us/img514/8440/firedamage004pk0.jpg

New t/linkage req'd, unless I can remove the spring and replace it.
http://img514.imageshack.us/img514/1930/firedamage007we5.jpg

Bodies stripped down, cleaned with carb cleaner. Each one is FINE NO DAMAGE! TPS = Dead. Need a better clean.
http://img362.imageshack.us/img362/6271/firedamage008jk0.jpg

Arches off, all ok!!!! Coilover on passenger side seems ok! But i will remove it and inspect it properly, if in doubt rebuild!
http://img300.imageshack.us/img300/7581/firedamage009uv9.jpg

Seats removed and soaked with a bucket to get majority of dust off, going to hose down and then go to Traci's dad, he has a wet vac:)
http://img172.imageshack.us/img172/3857/firedamage013wx8.jpg

Head off due to 'might as well do it'... as you can see, no det marks no nothing, apart from it seems head to valve contact once upon a time! The gasket was starting to go between 3 and 4 and 2 and 3... It didn't look a genuine one. On the whole the engine was happy as pie! It actually said, FFS I want more nitrous and power now!
http://img177.imageshack.us/img177/7246/firedamage016dx3.jpg

The head came off and was perfect too! Maybe these early 13mm guided coscasts are the ones to have! It looked seductive!
http://img300.imageshack.us/img300/7876/firedamage015qo0.jpg

Looms all removed, it felt like it was a car in the breakers and not a beloved toy! Sort of pretending your misis is a ho!
http://img383.imageshack.us/img383/2244/firedamage021oy1.jpg

Starter to alternator wire was intact, good sign that it didn't go down the bottom of the bay.
http://img300.imageshack.us/img300/8973/firedamage020ph0.jpg

Hmm luckily the chap who owns the garage opposite was a nice guy and said not to worry about going in front of his garage as he removed his car and parked it outside! lmao
http://img383.imageshack.us/img383/3217/firedamage026gt8.jpg

What was left of the dash!
http://img352.imageshack.us/img352/1527/firedamage024dt5.jpg

All in all I think apart from cosmetics I've got away lightly! I've had Beardy at VOX-ALL offer to JIG the car for me if needed and paint the front end! Thats the sort of scene the vauxhall scene is! Still getting texts and pms today offering help! Really am speachless by the response! I reckon the car will be up and running again quicker than first thought for this very reason! The car is obviously well known and quite respected, which makes these minor set backs a challenge. Will now comply a list of what is needed.

P.S.: Strut brace is staying like that but lacquered to remind me of the day!

[spanishfly]

Finished work at 2 today, so spent a few hours before I go to JR to collect my new engine!
Bit more progress! Going to take complete engine out tomorrow. Then get the rack of and dissemble.
Random green rust gel applied! Worked well to get surface rust off!
http://img185.imageshack.us/img185/5241/firedamagerepairs048ov5.jpg

Gel removed.
http://img98.imageshack.us/img98/1931/firedamagerepairs050qp5.jpg

A bit of primer... just to keep the car from rusting! Also removed some extra un-needed weight! lmao
http://i124.photobucket.com/albums/p34/spanishflymig/Firedamagerepairs056.jpg

Rumour had it that my head had been 'ported'. Now I looked into the ports, and the valve guides on the inlet have been ground away, the inlets are quite smooth. It's an early Coscast, with 13mm guides. Any gen!?
http://img517.imageshack.us/img517/361/firedamagerepairs061uj9.jpg
http://i124.photobucket.com/albums/p34/spanishflymig/Firedamagerepairs064.jpg

Now I need a generator that will power my Compressor, angle grinder and drill. Even better would be if it could do my MIG too! off to JR's more update soon!

[spanishfly]

So todays lil bit of work so far!

First thing was to clear up the garage and sort out what to keep and what to throw.
http://img530.imageshack.us/img530/1210/garageclean001ss6.jpg

Generator and compressor behind the car...you never know!
http://img393.imageshack.us/img393/5214/garageclean003xg1.jpg

Rack out...
http://img151.imageshack.us/img151/5287/garageclean004ty2.jpg

Slam panel modified.
http://img201.imageshack.us/img201/7626/garageclean007wg1.jpg

Scuttle panel painted.
http://img389.imageshack.us/img389/6598/garageclean009hb9.jpg

Just as I got home to have some lunch, this turned up :beer: Quick rack by Quaife.
http://img389.imageshack.us/img389/1927/garageclean010ru8.jpg

So may have some fun this evening playing with it!
Few more bits to my 'I need list'.
Windscreen rubber surround
Bearings for top mounts.
Headlights
clear front indicators

[spanishfly]

Todays update...
One engine in good cond...Need to get new bearings and things.
http://img169.imageshack.us/img169/1343/novarebuild001ey1.jpg

One corsa pedal...
http://img376.imageshack.us/img376/3746/novarebuild003fw3.jpg

Gearbox cleaned and re painted...
http://img157.imageshack.us/img157/3826/novarebuild006mt0.jpg

One clean battery tray.
http://img170.imageshack.us/img170/3135/novarebuild007dh8.jpg

One fitted corsa pedal...
http://img371.imageshack.us/img371/7853/novarebuild015us3.jpg

Which meant I could lose this weight and play in the pedal.
http://img231.imageshack.us/img231/918/novarebuild014ve0.jpg

I wasn't sure that I used the disc enough.
http://img122.imageshack.us/img122/3576/novarebuild008nq3.jpg

Pedal needs bending and shortening.
http://img338.imageshack.us/img338/3425/novarebuild017lm3.jpg

I then made some plates to cover the holes left by old brake setup. I used metal as if the unthinkable happens again, like the last metal panel it will stop fire getting in the car:D
http://img338.imageshack.us/img338/5049/novarebuild019vb4.jpg

All primed..got some 2k to do it in tomorrow, just need to find a mask as been told I really shouldn't paint without one!
http://img396.imageshack.us/img396/8675/novarebuild021qr5.jpg

I got pissed off with losing my angle grinder thing so...
http://img47.imageshack.us/img47/9332/novarebuild020ks0.jpg

Got home and this turned up.
http://img47.imageshack.us/img47/5931/novarebuild027pb9.jpg

The inside is still a horrible site. I can't really get in well enough to clean it out. I will do soone though and start on making a new wiring loom with wires I need only.
http://img187.imageshack.us/img187/994/novarebuild010ui0.jpg

Picked up some 2k paint, and brand new tie rods/ends and gaitors ready to rebuild the rack. Looking forward to getting it back now!

[spanishfly]

Ok so, did more to the nova today. First of, sprayed the bay. Hurricane grey again.
http://img90.imageshack.us/img90/9240/novabaypainting001rz5.jpg

Then sanded down and re painted. I was going to leave it as it was above, but Barry (flatout) said I would regret it. Which is true, it will never be perfect or close, as the fire created alot of pitting, if I wanted it mint I would be there 2 years. It's a track car, so looks don't bother me too much. Still, looks alright.
http://img372.imageshack.us/img372/7704/novabaypainting015jh4.jpg

Finished building the steering rack, quiafe quick rack greased, and booted.
http://img352.imageshack.us/img352/662/novabaypainting013ad9.jpg

Although I said I was going to lacquer the strut brace as it was, I couldn't slowly it just turned into a brown rusty bar. So it's going to get painted too! Barry did a good job:)
http://img383.imageshack.us/img383/199/novabaypainting016db2.jpg

Valves out of head, that was the funniest part of the day. Looks as though the head has a bit of work. Going to clean it all and see.
http://img361.imageshack.us/img361/982/novabaypainting007th3.jpg

Said valves, nice and black!
http://img352.imageshack.us/img352/9378/novabaypainting014su4.jpg
Tomorrow, finish off the bay painting. Paint a few other bit and pieces for the bay. Sort the block ready for some paint (still undecided on colour) Start re fitting engine bay pieces.... can't wait.


Thanks to Barry for his help today:)

[spanishfly]

Today was a good day as for as the engine bay is concerned! I believe i'm now on the slope back down (re fitting parts:D)
So here goes with todays update:

Holes drilled ready for the pedal strenthening plate to be bolted in.

http://img299.imageshack.us/img299/1804/pedalbox001bi4.jpg

Loads of tiger seal to try and give a seal.
http://img299.imageshack.us/img299/7344/pedalbox003xd6.jpg

Then I plumped it on, bolted it up, and used more tiger seal to stop the channel. In reality I don't really use the car in the wet, but it's worth doing!
http://img82.imageshack.us/img82/5512/pedalbox004gq3.jpg


Pedal box on, looking hardcore, I can't wait to drive it again!!!!!!
http://img440.imageshack.us/img440/3023/pedalbox005no1.jpg
Now it's time to make the brake lines and bleed etc...

Then I moved on to playing with the head. I'm going to do it myself. Used the die grinder and the drill. First things were to match the ports to the gasket/(inlet) manifold. Going up to Lee's tomorrow evening to see some of there work, and get some ideas/pointers.
http://img60.imageshack.us/img60/8108/pedalbox006xw9.jpg
http://img60.imageshack.us/img60/9994/pedalbox011sk6.jpg

Then I noticed this f**ker, oh it was an ugly c**t, I took this pic (check it's hair:() Unlike Lee303 who named and kept his spider, I carb cleanered it to death as <cockney accent> I f**king 'ate spiders!!! After I killed it, me and Barry kept having random attacks from other spiders and maggots, I had obviously killed the Don of the spider habitat in my garage!
http://img143.imageshack.us/img143/1426/pedalbox013sr8.jpg

Whilst I killed spiders, and played with things, Barry (flatout) got on with a bit of painting. We had gone to Halfords to look at a good colour combo to do the engine bay. I loved how it was before, it looked great. This time things will be a bit more subtle... or maybe not. I've had an urge to paint the mirrors etc in an illuminous colour, but we've decided it would be a bit crap looking. So although I know some people won't like it, I think it looks great.

Sand blasted L...
http://img140.imageshack.us/img140/796/pedalbox014vn8.jpg

Part of the brace, notice the RAC van in the back ground... It's brighter than the van!
http://img53.imageshack.us/img53/3152/pedalbox020ok2.jpg
http://img376.imageshack.us/img376/3/pedalbox023wz9.jpg

A few bits in the bay will go this colour. The RC is still being considered but I think we have the plan. Hopefully it'll look good! If you've seen a 'Dynorod' van, it's that colour.
http://img82.imageshack.us/img82/1354/pedalbox028tq5.jpg
Placed to see how the contrast is, I think I must have had the shakes, as all 3 pics i've taken are blurry! Notice the ally slam panel and rad are in! The colour represents fire lmao


We also cleaned the bodies and linkage... looking loads better, no snags and all line up perfectly! Yippee!!
http://img53.imageshack.us/img53/4492/pedalbox019gu1.jpg

[spanishfly]

A few pics from yesterday...
A better representation of how the orange and grey look! I love it!!!
http://img225.imageshack.us/img225/4528/brightorange017xe4.jpg

I painted the whole steering column, no longer a rust red.
http://img518.imageshack.us/img518/1566/brightorange007lg0.jpg

My tow hook...
http://img241.imageshack.us/img241/6936/brightorange015bx7.jpg

Coil pack mount, had lovely melted plastic everywhere, best I could get it was how it is. Looks ok though, better than before.
http://img518.imageshack.us/img518/5039/brightorange004ky4.jpg

'Slam panel' is now bolted in with an allen bolt and nut. Need to make a rad fixing, and get a grille to see how far faorward it can go.
http://img241.imageshack.us/img241/3562/brightorange005xd9.jpg

[spanishfly]

Salvaged top hose
http://img180.imageshack.us/img180/9586/inside009za2.jpg

Salvaged minimax
http://img176.imageshack.us/img176/60/inside010df2.jpg

The state the was inside:

http://img180.imageshack.us/img180/1421/inside018bo9.jpg
http://img180.imageshack.us/img180/1421/inside018bo9.jpg
http://img176.imageshack.us/img176/2389/inside021ye9.jpg

It then went like...
http://img505.imageshack.us/img505/6536/inside027ok9.jpg

Drivers window before...
http://img176.imageshack.us/img176/636/inside030xj3.jpg

After... also clean CF door cards. (can still get window clearer but the cloth was well dirty.
http://img505.imageshack.us/img505/7452/inside036tw1.jpg


Carbon fibre lushness restored... check!
http://img136.imageshack.us/img136/5996/inside033mr5.jpg
http://img505.imageshack.us/img505/6848/inside034og3.jpg

The remains of wiring loom, bodies, faeces and god knows what else! There was quite alot!
http://img505.imageshack.us/img505/1373/inside040se7.jpg

Out with this heavy piece of melted and cained wiring loom.
http://img176.imageshack.us/img176/986/inside025ra1.jpg

Going to make a new one up. Will only have much needed wiring. Anything else can go run and jump!

Also greased the track rods before putting the ends on, all new steering rack, check!
http://img136.imageshack.us/img136/4268/inside012vk6.jpg

Car sitting with no arches.
http://img505.imageshack.us/img505/8008/inside016mr1.jpg






Next stage sand down and re paint.

[spanishfly]

Yesterdays update:
I got bored and had the hole cutter, and a very heavy bumper.... went a bit mad and created a silly roundish square thing, so going to get a new front bumper today! Even with that removed material the bumpers must weigh 2kg!
http://img301.imageshack.us/img301/17/wings002kg2.jpg

De-stickered wing
http://img301.imageshack.us/img301/4509/wings005in8.jpg

Burnt
http://img519.imageshack.us/img519/394/wings006fs3.jpg

Then Barry file the arch lips off, should give me more space for the +4 deg castor.
http://img301.imageshack.us/img301/2292/wings010aj1.jpg

Then D/A'd back to metal where it was needed.
http://img519.imageshack.us/img519/5862/wings017oj5.jpg

And zinc primered. I like the colour too!!!
http://img442.imageshack.us/img442/3747/wings021ny3.jpg

Smoooooooth
http://img519.imageshack.us/img519/4907/wings026il3.jpg


I was also lowering my sisters boyfriends polo, that was until I took the assembly apart and the prings they supplied pigtails were too small. So of to german sweedish for a standard spring, took loads longer than I wanted!!! Oh well not in a rush with nova. Cheers again to Barry!

[spanishfly]

Well todays update!
Make shift garage.
http://img291.imageshack.us/img291/7295/interiorprep002fc2.jpg

So we removed the cage ready for a clean and a fresh coat of paint.
http://img183.imageshack.us/img183/6551/interiorprep001vk3.jpg

Roof was like...
http://img291.imageshack.us/img291/6176/interiorprep006ec3.jpg

After some thinners it was like...
http://img183.imageshack.us/img183/3460/interiorprep007mj9.jpg

Important bit done lmao
http://img183.imageshack.us/img183/295/interiorprep010wj4.jpg

Never done one of these before but ho hum will give it a go:D
http://img291.imageshack.us/img291/3862/interiorprep011ao6.jpg

Sanding down in progress!
http://img151.imageshack.us/img151/1172/interiorprep012zr9.jpg

Gel rust treatment.
http://img291.imageshack.us/img291/5246/interiorprep013em8.jpg

Rear polycarb, out.
http://img183.imageshack.us/img183/6084/interiorprep016br5.jpg

Primered the bare metal for overnight safety.
http://img72.imageshack.us/img72/4397/interiorprep025fo3.jpg
http://img135.imageshack.us/img135/1530/interiorprep030xz5.jpg

[spanishfly]

So on to today, was quite a laugh, with a good lunch break for Pizza hut (not pasta hut yet lmao)

And primed
http://img227.imageshack.us/img227/8826/paintinside011ds4.jpg

Hammerite smooth black for the roof and bulkhead, paint will never had stayed on parts of it, so it was a case of remove rust and slosh on hammerite. Look ok.
http://img227.imageshack.us/img227/7394/paintinside005ak8.jpg
http://img84.imageshack.us/img84/8551/paintinside013qm3.jpg

Then primered the dash area
http://img227.imageshack.us/img227/2996/paintinside014cd8.jpg

Then primered bare metal parts on floor, and it was ready for a coat of paint.
http://img88.imageshack.us/img88/2772/paintinside016sp3.jpg

Then onto the fun, painting... I have a 3hp 50L compressor, I've borrowed a 2.6kW generator (sounds big), my compressor has a rating of 20A, the generator puts out 9.xA :( It kept cutting out when it filled up, used for prolonged time. So I used the one in my Van we use for tyres, 0.5hp 8L 12V lmao It worked, although I had to keep waiting.



High power output, boy!
http://img88.imageshack.us/img88/5702/paintinside019jy4.jpg

Whatever tool used, it went on thats the main thing:D
http://img88.imageshack.us/img88/3/paintinside022bt3.jpg


Then the lil compressor that had been working overtime, died!
http://img84.imageshack.us/img84/9291/paintinside023mr8.jpg

Luckily, a moment of awesome bodgeness sorted it. Some 7.5mm fuel hose, and cuttings from the standard plastic hose meant to fill out the gap meant it still lives:D

and TA-DA, all painted up, drying as we speak:)
http://img84.imageshack.us/img84/3797/paintinside024vn2.jpg

http://img227.imageshack.us/img227/5856/paintinside026yw4.jpg



Not bad finish really, looks better than it was before and it's in 2K :D

[spanishfly]

What the cage look like.... Got to get new bolts tomorrow and bolt it up
http://img146.imageshack.us/img146/2610/cageisin008wb0.jpg

Discreet through the 'window'
http://img146.imageshack.us/img146/164/cageisin011nv4.jpg

Looks good against the carbon!
http://img384.imageshack.us/img384/1035/cageisin009zf7.jpg

[spanishfly]

lmao Guessed to soon, I liked the Lee's space comment though.
Plans are:
SBD slipper pistons (now just omega 87mm)
SBD Long steel rods . (normal length rods)
Kent cams (have these)
(Home) Ported polished head with +1mm paul ivey valves (have)
Solid lifters
Double valve springs (got)
SBD type C with current exhaust (already on the car)
Pimp juice
Hellier baffled sump (until dry sump money is available)
No nitrous...

Hoping for around 250bhp.

[spanishfly]

So I did some work on the Nova today:D:D:D
Most of the time was take putting together a list of what was needed in the way of parts.
So first thing was to bolt the rack on properly, grease it up enough and then finish it off.
Greased up.
http://img301.imageshack.us/img301/4469/fireext001vv4.jpg (http://imageshack.us)
http://img301.imageshack.us/img301/fireext001vv4.jpg/1/w640.png (http://g.imageshack.us/img301/fireext001vv4.jpg/1/)

Boots on.
http://img252.imageshack.us/img252/264/fireext002jv8.jpg (http://imageshack.us)
http://img252.imageshack.us/img252/fireext002jv8.jpg/1/w640.png (http://g.imageshack.us/img252/fireext002jv8.jpg/1/)
I even spent a few mins aligning the tracking (by eye) so that the car was easy to push! The quickrack is great, a little input equals aloy of output at the wheel.

Then it was onto fire extinguisher. I read the manual (don't usually), as I don't want to install it wrong and find out when it's needed. Now it states to put one nozzle in the engine bay and one in the cockpit. Experiance tells me my cockpit doesn't burn :rolleyes: so i'm thinking where to put my 2nd jet. Lee303 said I should put it by the fuel pumps (which on my car is inside near the back) I was thinking of another one in the engine bay. I still hadn't decided so i've only fitted the one while I think where to put the other. After much thought and planning I decided that I would mount the extinguisher itself behind the passenger seat, in the cage safety area. It also means the extra weight is between the wheels and not behind the rear wheels.

http://img408.imageshack.us/img408/5986/fireext006cb0.jpg (http://imageshack.us)
http://img408.imageshack.us/img408/fireext006cb0.jpg/1/w640.png (http://g.imageshack.us/img408/fireext006cb0.jpg/1/)


The jet mounted, I chose here as it would cover the tbs and fuel lines well. The jets cover 90deg, so it would mean it will cover the engine and regulator to the left. The jets cover a meter in distance.
http://img267.imageshack.us/img267/1016/fireext008ap2.jpg (http://imageshack.us)
http://img267.imageshack.us/img267/fireext008ap2.jpg/1/w640.png (http://g.imageshack.us/img267/fireext008ap2.jpg/1/)

Underneath...
http://img139.imageshack.us/img139/4884/fireext009ii8.jpg (http://imageshack.us)
http://img139.imageshack.us/img139/fireext009ii8.jpg/1/w640.png (http://g.imageshack.us/img139/fireext009ii8.jpg/1/)


.

[spanishfly]

Well today was the day to go up and fit my brake pipes and finish the extinguisher. As per recently nothing ever goes how you want it.
I was playing with the steering rack and noticed it moved, I also noticed the n/s bracket wasn't tight, so I started to wind the nut tighter and snap. Bolt broke, not an easy fix as you can't get behind the bolt. Trip to b&q and an 8mm bosch drill bit later I had drilled out the old stud. I cut down a 13mm bolt and was able to manouver it into position. Then i refitted the rack, luckily it was this one that went as the others are not at all accesable. It turns out the rack mount holes were slightly too small for the thread, I run the 8mm bit down it, and it then fitted up and I now have no rack movement.
As you can see it's the bottom bolt here...
http://img402.imageshack.us/img402/3323/brakelines001ql9.jpg (http://imageshack.us)
http://img402.imageshack.us/img402/brakelines001ql9.jpg/1/w640.png (http://g.imageshack.us/img402/brakelines001ql9.jpg/1/)

all bolted up again everything in place as it should be:D
Will get a Nyloc nut, or met lock for it.
http://img407.imageshack.us/img407/6940/brakelines003wu7.jpg (http://imageshack.us)
http://img407.imageshack.us/img407/brakelines003wu7.jpg/1/w640.png (http://g.imageshack.us/img407/brakelines003wu7.jpg/1/)

Thanks to Lee for the phone support, I lost my temper with the car by this point:(

Then I made the front lines, it's so much easier than copper pipe lines. I've done both the front lines, although I will re make the n/s/f as I don't really like how it's routed.
http://img91.imageshack.us/img91/1500/brakelines004nz9.jpg (http://imageshack.us)
http://img91.imageshack.us/img91/brakelines004nz9.jpg/1/w640.png (http://g.imageshack.us/img91/brakelines004nz9.jpg/1/)

I've mated the brakelines to normal goodrich braided hoses, like this I retain standard fixing point. When I get the wilwoods however I will have to renew the banjo end.
http://img132.imageshack.us/img132/1397/brakelines005mg1.jpg (http://imageshack.us)
http://img132.imageshack.us/img132/brakelines005mg1.jpg/1/w640.png (http://g.imageshack.us/img132/brakelines005mg1.jpg/1/)

My windscreen turned up today, well chuffed with it. Looks great. Hopefully I can work on the car tomorrow and start with what I was meant to do today.

[spanishfly]

Some of my new parts waiting to be fitted.
+1mm Paul Ivey valves, exhaust and waisted inlet.
http://img118.imageshack.us/img118/8852/3022008111cd0.jpg (http://imageshack.us)
http://img118.imageshack.us/img118/3022008111cd0.jpg/1/w640.png (http://g.imageshack.us/img118/3022008111cd0.jpg/1/)

Brian spec (SBD) omega 87mm pistons
http://img390.imageshack.us/img390/8480/3022008112mo1.jpg (http://imageshack.us)
http://img390.imageshack.us/img390/3022008112mo1.jpg/1/w640.png (http://g.imageshack.us/img390/3022008112mo1.jpg/1/)

6 point Sabelt harness
http://img390.imageshack.us/img390/9342/3022008114mh2.jpg (http://imageshack.us)
http://img390.imageshack.us/img390/3022008114mh2.jpg/1/w640.png (http://g.imageshack.us/img390/3022008114mh2.jpg/1/)

New alloy pasenger footrest
http://img212.imageshack.us/img212/1879/3022008113dz9.jpg (http://imageshack.us)
http://img212.imageshack.us/img212/3022008113dz9.jpg/1/w640.png (http://g.imageshack.us/img212/3022008113dz9.jpg/1/)

[spanishfly]

So todays update.
I pushed the car out and jacked up the rear. I then set about removing the old lines and whatnot.
http://img125.imageshack.us/img125/9638/brakelines001we1.jpg (http://imageshack.us)
http://img125.imageshack.us/img125/brakelines001we1.jpg/1/w640.png (http://g.imageshack.us/img125/brakelines001we1.jpg/1/)

As you see here, I bought some M10x1 to JIC-3 convertors, this saves faffing about if I ever need to mkae new lines.
http://img125.imageshack.us/img125/9080/brakelines002jq0.jpg (http://imageshack.us)
http://img125.imageshack.us/img125/brakelines002jq0.jpg/1/w640.png (http://g.imageshack.us/img125/brakelines002jq0.jpg/1/)

The old lines.
http://img125.imageshack.us/img125/7526/brakelines004os3.jpg (http://imageshack.us)
http://img125.imageshack.us/img125/brakelines004os3.jpg/1/w640.png (http://g.imageshack.us/img125/brakelines004os3.jpg/1/)


One hose made and fitted.
http://img125.imageshack.us/img125/2161/brakelines003cu8.jpg (http://imageshack.us)
http://img125.imageshack.us/img125/brakelines003cu8.jpg/1/w640.png (http://g.imageshack.us/img125/brakelines003cu8.jpg/1/)

Through 'bulkhead' T-piece, I decided the T can sit underneath and the main in line on top.
http://img120.imageshack.us/img120/8115/brakelines012zq7.jpg (http://imageshack.us)
http://img120.imageshack.us/img120/brakelines012zq7.jpg/1/w640.png (http://g.imageshack.us/img120/brakelines012zq7.jpg/1/)

[spanishfly]

How to make braided brake lines.
Cut the hose to the length you need it to be. I used side cutters (mine are really good) this left a perfect straight cut (very important). If you cut them with a hacksaw use a fine blade and masking tape where you cut (stops the braided fraying).
http://img114.imageshack.us/img114/6963/brakelines006bp7.jpg (http://imageshack.us)
http://img114.imageshack.us/img114/brakelines006bp7.jpg/1/w640.png (http://g.imageshack.us/img114/brakelines006bp7.jpg/1/)

While the ends are still unfrayed slide the union onto the line, remembering they should be facing either way, this saves annoying situations later.
http://img87.imageshack.us/img87/6050/brakelines007cl1.jpg (http://imageshack.us)
http://img87.imageshack.us/img87/brakelines007cl1.jpg/1/w640.png (http://g.imageshack.us/img87/brakelines007cl1.jpg/1/)

Using a screwdriver, push back the end of the braiding, this is so you can fit the shouldered olive on the end. Trim braid as required.
http://img99.imageshack.us/img99/275/brakelines008ez3.jpg (http://imageshack.us)
http://img99.imageshack.us/img99/brakelines008ez3.jpg/1/w640.png (http://g.imageshack.us/img99/brakelines008ez3.jpg/1/)

Olive fitted under the braiding, the shoulder should sit flush with the end of the inner pipe. Once again trim any extra braid.
http://img78.imageshack.us/img78/4904/brakelines009rt9.jpg (http://imageshack.us)
http://img78.imageshack.us/img78/brakelines009rt9.jpg/1/w640.png (http://g.imageshack.us/img78/brakelines009rt9.jpg/1/)

Then push the otherside of the fitting into the pipe, and screw the end of the pipe. Before I did this I made sure the pipe fitting was right out to the olive, and marked the pipe to fitting with a line, this is so when tightening up the fitting you can be sure the fitting hasn't come off the pipe slightly.
http://img205.imageshack.us/img205/8709/brakelines010ab2.jpg

Do the same the otherside, and wala one pipe fit for a king (or my nova)
http://img148.imageshack.us/img148/7057/brakelines011np8.jpg (http://imageshack.us)
http://img148.imageshack.us/img148/brakelines011np8.jpg/1/w640.png (http://g.imageshack.us/img148/brakelines011np8.jpg/1/)

[spanishfly]

So with a few hours to spare this morning I got on with the head. As I type this I can't feel my fingers lmao
Taking pictures of ports are a nightmare, however these are mid stage pics.
As you may remember i'm using +1mm Paul Ivey valves and so the ports are larger than your usual port job. The pics don't really show the work great, however I put a few up so you can get the idea. One port down 7 to go.
Valve area.
http://img396.imageshack.us/img396/2342/headport1115mx5.jpg (http://imageshack.us)
http://img396.imageshack.us/img396/headport1115mx5.jpg/1/w640.png (http://g.imageshack.us/img396/headport1115mx5.jpg/1/)

Port
http://img388.imageshack.us/img388/9235/headport1110iz0.jpg (http://imageshack.us)
http://img388.imageshack.us/img388/headport1110iz0.jpg/1/w640.png (http://g.imageshack.us/img388/headport1110iz0.jpg/1/)

[spanishfly]

That's a rough rebuild diary. I'll try remember to update it when I do the mig one.

[Riggy]

some good progress there mate , fire rats still make me laugh though

[kc_08]

alright mate did you used to own a light blue sr?
that looks excatly like where i brought my mark 1 buildings and everything lol

[Southie]

What a cracking read that was, so much better when you don't have loads of comments to read through.

To me it appears that you are probably gutted it set on fire but are also happy, so you can make it even better that before. Good work by the way :thumb:

Loving the dynorod strutbrace lol

[spanishfly]

No didn't own a light blue SR. Only a mk2 SR and SRi and a mk1 SR.

Cheers for comments:D

[The Simps]

nice to see it all condensed bud :beer:

will soon be done.

[spanishfly]

Hope so.

[Pistol Pete]

Been reading the thread you had on mig. The fire rats made a mess of my mum and dads garage last year so can only imagine what a mess it made to your Nova mate!! Good to see it all coming along in a proper bo' way lol

Got your windscreen in yet? I'm scared incase i break it lol

[Shaun_O'Donnell]

Sorry to hear about the fire, but you're making good progress.

Need one of these rats:

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/Funny%20Pics/Firefightingrat.gif

[L14MNP]

Good to see you getting this sorted mate!

[Andy]

Looking well again mate good work,what is that green rust treatment you are using?

[Pistol Pete]

Andy, i think its rust treatment gel. Slap it on, leave it to eat at the rust then i'm guessing wipe off to leave clean fresh metal. Paint/prime to stop rust returning.

[Andy]

Aye thats what i thought it was,just wondered where its available and how much/how good?

[Pistol Pete]

Ah, sorry. I would guess Halfords, bodyshop suppliers maybe??

This, small tube mind.. rust gel (http://www.halfords.com/webapp/wcs/stores/servlet/product_storeId_10001_catalogId_10151_productId_16 9513_langId_-1_categoryId_165594)

Have a browse through Hammerite products page, page 7 rust removal gel in a tub. 750ml.

[spanishfly]

Yeah it's a hammerite product, its good stuff.
Pete I have my windscreen it's still behind my bed in one piece too! Result lol

[spanishfly]

Oh the only fault with it is any left on the paint causes paint not to stick. Best of doing it one day then painting next.

[Mike]

Good read chap.

On another note, youve fitted that Anti Fire very wrong. Note, its very easy to obtain more jets for it aswell, your not just limited to 2. On our rally cars we run 2 in the bay, 2 in cockpit & 1 down onto tank/pump.

[scott.parker]

Glad to see the cars getting re-done, all looking really nice, i like the new scheam for the bay etc.

Good work.

Scott

[spanishfly]

Cheers Scott.
Mike whats wrong with it as I followed instructions so assumed it would be ok. I'm not bothering with cockpit jets as 'research' showed me that the insed doesn't go up on my car. Also I'll have a seperate handheld if the wrongun should occur inside the cockpit.

[Mike]

No, the jet in the engine bay is in a very comprimising position. I.E. Pointing upward.

How do you put a fire out with a fire extinguisher? You point & AIM AT BASE :thumb: Re-route the alloy tube & reposition the jet. In all honesty, you want at minimum of 2 in the bay area.

You can have as many fire extinguishers as you like. But there not gonna work effectivly if there not used as intended are they ;)

[Pistol Pete]

Pete I have my windscreen it's still behind my bed in one piece too! Result lol

Not gettin' any then lol;)

Mines still in its box in me mums garage. Not looking forward to fitting it TBH. But i'm sure with abit of patience it will be fine.

Looking forward to more updates.

[spanishfly]

It may not have copied across, however I wrote i'm not happy with the location and if anyone has suggestions. That there sir is what I wanted to hear :)

[spanishfly]

Not gettin' any then lol;)

Mines still in its box in me mums garage. Not looking forward to fitting it TBH. But i'm sure with abit of patience it will be fine.

Looking forward to more updates.

The other day she saw me looking at the windscreen instead of paying attention to her lollol

[Pistol Pete]

AFPMSL lol

[Mike]

I see youve removed the bulkhead bit (infront of OE battery position)

In this instance, re-route pipework for the jet/s along one side of the bay, up ACROSS the strut brace so there pointing downward INTO the bay. Wire tie the pipework back to the strut brace. Immensly more effective of a LifeLine kit.

Its your call at the end of the day. Just giving you advice from a professional angle chap.

[Mike]

It may not have copied across, however I wrote i'm not happy with the location and if anyone has suggestions. That there sir is what I wanted to hear :)

Ah, fair enough then lol

As said though, re-route using strut brace as mounting point :thumb:

[spanishfly]

Nice one Mike will do! This sort of info is why these threads are great:)

[Mike]

Nice one Mike will do! This sort of info is why these threads are great:)

True True. I spent a few years building, preparing, re-pairing & testing rally car's Spanish, ive been in the unfortunate position to have to set Anti Fires off a couple of times but have installed probably 50+. (Manual & 12v systems).

BTW, if you ever, for some reason, decided on buying a Peltor, let me know, there a doddle to fit for those that know lol

[Dar]

Nice to see the car is coming along and will be running again :thumb: Good stuff.

[Adam]

Good to see the rebuild is well under way Rob :)

[spanishfly]

Ordered my engine bits I need, so hopefully plonk that in soon too!

[Will F]

about FECKING time!!

so are you fitting the slippers now, or later on?

Credit to you mate - well done for sticking with it!

Are my cams going to see some action now then?;)

[~~joycey~~]

Great to see this being brought back to life! Saw it at TOTB looking very sorry for itself, very sad sight indeed :(

[Ernie]

Glad your cracking on with it.
Keep up the good work.

[spanishfly]

about FECKING time!!

so are you fitting the slippers now, or later on?

Credit to you mate - well done for sticking with it!

Are my cams going to see some action now then?;)

Na was going for slippers however I was offered the 87mm Omegas at a price hard to say no to.

Cheers mate:)

On the cams i'm just talking with people in the know, as it may be that they don't have enough lift for what i'm looking for, however it may be a case of try them and see what output I get. Problem with that is new shims would be needed to reshim the new cams (solids).

[spanishfly]

Cheers also to Joycey and Ernie! :)

[C-R-A-I-G]

Really Good Project this Mate.Keep up the Good Work and i hope it all goes Well:thumb:

Craig

[Mazz]

Looking good Mr.Fly, nice to see it will live again..

[~~joycey~~]

Anymore progress mate?

[Adam]

Over on MIG there is iirc

[spanishfly]

Sorry not been keeping this up to date... however here's a couple of latest pics.

http://img6.imageshack.us/img6/3208/isaidgussets2.jpg (http://img6.imageshack.us/my.php?image=isaidgussets2.jpg)

http://img16.imageshack.us/img16/4318/isaidgussets18.jpg (http://img16.imageshack.us/my.php?image=isaidgussets18.jpg)

May be worth checking mig to see how it got to this stage lmao
http://www.migweb.co.uk/forums/projects-restorations/287511-nova-1-0-build-trackday-car-137.html

[Ernie]

woop woop its a Nova again yay ...

[spanishfly]

Almost, not much left now:) Can't wait:D

[Sloth]

in the last pic, why is the caliper pointing down a bit?
looks spanking btw rob

[spanishfly]

Its a high spec conversion, the 284mm discs using 16v calipers (So lightweight, decent pedal travel better clamping) They sit like that due to mounts.

Cheers mate:)

[Sloth]

ahhhh i expected a bling reason lol. you at totb this/next year?

[spanishfly]

I may go, but will be spectating. Not using Nitrous anymore

[Graeme]

How much work was it to run r888's? I've been told they don't fit under standard arches

[DW-Nova]

I think your wings need a flat and polish mate !

[peester]

crickey, great turn around. Back from injury !

[spanishfly]

How much work was it to run r888's? I've been told they don't fit under standard arches
Dunno not run them, however atm I have Dunlop Direzza in a 195/55R15 and no problems. I did have to rear turret though, and grind back the arch lips on the front.

[spanishfly]

I think your wings need a flat and polish mate !
I couldn't be arsed to flat back as i'm not actually that bothered, however I will do it at some point, it would obviously make you happier:thumb: Sorry for my disapointing wings:(

[spanishfly]

crickey, great turn around. Back from injury !

Cheers fella, not long now! Hopefully it WILL be going Germany this year:D:thumb:

[spanishfly]

Well I thought I had better update this thread:)
So pics of the wings dry, you can tell how much better they are, no sanding or polishing straight out the gun:)
Getting better at this spray malarky lmao
http://img198.imageshack.us/img198/6397/wingsn.jpg (http://img198.imageshack.us/i/wingsn.jpg/) http://img198.imageshack.us/img198/wingsn.jpg/1/w640.png (http://g.imageshack.us/img198/wingsn.jpg/1/)

http://img30.imageshack.us/img30/492/wings2.jpg (http://img30.imageshack.us/i/wings2.jpg/) http://img30.imageshack.us/img30/wings2.jpg/1/w640.png (http://g.imageshack.us/img30/wings2.jpg/1/)

http://img30.imageshack.us/img30/2438/wings3.jpg (http://img30.imageshack.us/i/wings3.jpg/) http://img30.imageshack.us/img30/wings3.jpg/1/w640.png (http://g.imageshack.us/img30/wings3.jpg/1/)

http://img301.imageshack.us/img301/2546/wings4.jpg (http://img301.imageshack.us/i/wings4.jpg/) http://img301.imageshack.us/img301/wings4.jpg/1/w640.png (http://g.imageshack.us/img301/wings4.jpg/1/)

[spanishfly]

So spent some time on the Nova today, Flatout came to lend a hand. We got alot done:) It's so great infact we sat in it together on the intercom and made car sounds:D

I had sprayed the scuttle with a can from halfords, however the paint was weak and had no shine. So we decided it would be a good idea to spray it again using 2K. So I cracked out the heavy duty 12v 8L 0.5hp compressor in my van, to my surprise it actually not only worked but gave a good finish!
http://img3.imageshack.us/img3/4552/img3489k.jpg (http://img3.imageshack.us/i/img3489k.jpg/) http://img3.imageshack.us/img3/img3489k.jpg/1/w640.png (http://g.imageshack.us/img3/img3489k.jpg/1/)
http://img20.imageshack.us/img20/8741/img3492t.jpg (http://img20.imageshack.us/i/img3492t.jpg/) http://img20.imageshack.us/img20/img3492t.jpg/1/w640.png (http://g.imageshack.us/img20/img3492t.jpg/1/)
http://img20.imageshack.us/img20/1549/img3496d.jpg (http://img20.imageshack.us/i/img3496d.jpg/) http://img20.imageshack.us/img20/img3496d.jpg/1/w640.png (http://g.imageshack.us/img20/img3496d.jpg/1/)

We also made a bracket for the speedo clock, then flatout got all race engineer on me and made it look the part, nice bracket that:D Oh it's also Rivnutted :beer: It's very sturdy now:D
http://img196.imageshack.us/img196/5265/img3500a.jpg (http://img196.imageshack.us/i/img3500a.jpg/) http://img196.imageshack.us/img196/img3500a.jpg/1/w640.png (http://g.imageshack.us/img196/img3500a.jpg/1/)

We then moved into the engine bay, in some places there were rust patches coming through. We decided to get some grey hammerite, mixed it with black and made a close matched colour. It looks decent:)
http://img7.imageshack.us/img7/6498/img3499d.jpg (http://img7.imageshack.us/i/img3499d.jpg/) http://img7.imageshack.us/img7/img3499d.jpg/1/w640.png (http://g.imageshack.us/img7/img3499d.jpg/1/)

We then put the wings on and the car looked loads better.
http://img20.imageshack.us/img20/6344/img3497e.jpg (http://img20.imageshack.us/i/img3497e.jpg/) http://img20.imageshack.us/img20/img3497e.jpg/1/w640.png (http://g.imageshack.us/img20/img3497e.jpg/1/)

We then put the windscreen in! It wasn't hard to do at all. I had been told all these horror stories. With two people there it's easy! I need to find out how to wire it up, I have 2 cables one side and two the other. I was thinking of having lives on say the drivers side and negs the passenger. I know with the elements it doesn't matter what way current flows.
http://img43.imageshack.us/img43/9113/img3505r.jpg (http://img43.imageshack.us/i/img3505r.jpg/)


Not long now:D

[spanishfly]

So the car with its wings on, looking alot better. Want to redo the bonnet to the same standard.
http://img16.imageshack.us/img16/1029/img3507w.jpg (http://img16.imageshack.us/i/img3507w.jpg/) http://img16.imageshack.us/img16/img3507w.jpg/1/w640.png (http://g.imageshack.us/img16/img3507w.jpg/1/)

[spanishfly]

A good update today:)
Went up to the nova today to finish of ALL interior loom and wiring, only wiring left to do is engine bay parts.
So I wired up the gauges, here's the mini loom I made, they come on with the ignition:) I put an inline fuse of 5A incase, however I doubt they need one!
http://img6.imageshack.us/img6/1760/22070922.jpg (http://img6.imageshack.us/i/22070922.jpg/) http://img6.imageshack.us/img6/22070922.jpg/1/w640.png (http://g.imageshack.us/img6/22070922.jpg/1/)

I wired up the heated screen through a relay, it blew a 15A fuse, however the 25A in there now seems to be ok. Didn't get a picture of that as not much to show lmao

I wired the switch for rear fog lights, I have two and no reverse lights due to using a Euro cluster. I made the switches so that up is on.
http://img12.imageshack.us/img12/9274/2207097.jpg (http://img12.imageshack.us/i/2207097.jpg/) http://img12.imageshack.us/img12/2207097.jpg/1/w640.png (http://g.imageshack.us/img12/2207097.jpg/1/)

[spanishfly]

I wired and soldered the dash together, wired up the H/brake light and the fuel gauge says I have 12L so I'm assuming I have quite alot of fuel in the tank!? As it works from Empty to Full rather than Full to Empty. Need to get a push-to-make switch as I can wire up the S125 button. Need to earth the coolant level wire else that will do my nut in.
http://img119.imageshack.us/img119/7254/22070911.jpg (http://img119.imageshack.us/i/22070911.jpg/) http://img119.imageshack.us/img119/22070911.jpg/1/w640.png (http://g.imageshack.us/img119/22070911.jpg/1/)

I p clipped the brake line for the rear in, now it's safe and a bit tidier.
http://img44.imageshack.us/img44/5167/2207096.jpg (http://img44.imageshack.us/i/2207096.jpg/) http://img44.imageshack.us/img44/2207096.jpg/1/w640.png (http://g.imageshack.us/img44/2207096.jpg/1/)

I made a bracket to secure the center console, it's now solid and doesn't rattle. All alloy:)
http://img37.imageshack.us/img37/3406/22070921.jpg (http://img37.imageshack.us/i/22070921.jpg/) http://img37.imageshack.us/img37/22070921.jpg/1/w640.png (http://g.imageshack.us/img37/22070921.jpg/1/)

I then moved onto playing with the new F16 gearbox. I gave it a little clean up to get old cavalier dirt and grease of it! I've opted for an F16 because it had a quaife SCCR gearset inside, it also has a quaife ATB (which alot of people say a plate is better, however I like the quaife ATB and I have two so might as well keep one lmao
http://img11.imageshack.us/img11/8420/22070915.jpg (http://img11.imageshack.us/i/22070915.jpg/) http://img11.imageshack.us/img11/22070915.jpg/1/w640.png (http://g.imageshack.us/img11/22070915.jpg/1/)
http://img198.imageshack.us/img198/1365/22070910.jpg (http://img198.imageshack.us/i/22070910.jpg/) http://img198.imageshack.us/img198/22070910.jpg/1/w640.png (http://g.imageshack.us/img198/22070910.jpg/1/)

[spanishfly]

The gearbox has a Giles patented clutch arm, it is stronger. The original can bend slightly due to a hard clutch.
http://img37.imageshack.us/img37/1074/22070920.jpg (http://img37.imageshack.us/i/22070920.jpg/) http://img37.imageshack.us/img37/22070920.jpg/1/w640.png (http://g.imageshack.us/img37/22070920.jpg/1/)

I then removed the home made blank for the speedo sensor, and fitted the drive and electric bit from a corsa sport. So now I need to get a pulse convertor and I will hopefully get the Stack speedo ready:)
http://img11.imageshack.us/img11/8015/2207095.jpg (http://img11.imageshack.us/i/2207095.jpg/) http://img11.imageshack.us/img11/2207095.jpg/1/w640.png (http://g.imageshack.us/img11/2207095.jpg/1/)

I then gave the engine a clean and play with, a lubrication. Here's some pics...finally:)
Omega 88mm pistons, decked block, ARP headstuds. Notice the SBD cooling mod.
http://img11.imageshack.us/img11/5616/2207094.jpg (http://img11.imageshack.us/i/2207094.jpg/) http://img11.imageshack.us/img11/2207094.jpg/1/w640.png (http://g.imageshack.us/img11/2207094.jpg/1/)

The like standard look, looks great IMO so the engine will be staying black. Notice the late HG1 block.
http://img193.imageshack.us/img193/5627/2207099.jpg (http://img193.imageshack.us/i/2207099.jpg/) http://img193.imageshack.us/img193/2207099.jpg/1/w640.png (http://g.imageshack.us/img193/2207099.jpg/1/)

[spanishfly]

The underside, notice SBD HD main bolts. ARP2000 big end, SBD conrods, Early crank (Unground). The crank sensor disc is a billet one piece SBD thing, should mean my emerald ECU won't have any troubles trying to get a crank signal., although it didn't before anyway. Also see the back of the Fidanza
http://img12.imageshack.us/img12/9683/2207098.jpg (http://img12.imageshack.us/i/2207098.jpg/) http://img12.imageshack.us/img12/2207098.jpg/1/w640.png (http://g.imageshack.us/img12/2207098.jpg/1/)
http://img24.imageshack.us/img24/4647/22070925x.jpg (http://img24.imageshack.us/i/22070925x.jpg/) http://img24.imageshack.us/img24/22070925x.jpg/1/w640.png (http://g.imageshack.us/img24/22070925x.jpg/1/)

ARP head studs, cometic 1.3mm HG
http://img24.imageshack.us/img24/4443/22070913.jpg (http://img24.imageshack.us/i/22070913.jpg/) http://img24.imageshack.us/img24/22070913.jpg/1/w640.png (http://g.imageshack.us/img24/22070913.jpg/1/)

Giles had Jason at Hellier performance make some special washers so that you don't have to use the double standard ones.
http://img17.imageshack.us/img17/3738/22070912.jpg (http://img17.imageshack.us/i/22070912.jpg/) http://img17.imageshack.us/img17/22070912.jpg/1/w640.png (http://g.imageshack.us/img17/22070912.jpg/1/)

Fidanza alloy flywheel with modified ring gear (so it doesn't come loose), iirc 3.2KG.
http://img36.imageshack.us/img36/195/2207092.jpg (http://img36.imageshack.us/i/2207092.jpg/) http://img36.imageshack.us/img36/2207092.jpg/1/w640.png (http://g.imageshack.us/img36/2207092.jpg/1/)

I then painted this ready to fit onto the engine.
http://img11.imageshack.us/img11/6601/2207093.jpg (http://img11.imageshack.us/i/2207093.jpg/) http://img11.imageshack.us/img11/2207093.jpg/1/w640.png (http://g.imageshack.us/img11/2207093.jpg/1/)

Hopefully get some more done tomorrow, although I got a bit of private work to do.

[spanishfly]

So got up early and finished the private job before 11:D So it meant time to play with the Nova. I had Flatout round to help, and Doge5644 also came round to er make comment and hold things occasionally. I'm sure he'll be getting stuck in when engine time comes round:D
Got a fair bit done today, and I think Flatout will agree fibreglass bonnets and bonnet pins suck ****!

So first off, as you know I have my front bumper on pins. I decided to go out and buy some DZUS fasteners for the side bits so it is proper quick realese, I didn't get just any ones either, I got ducati ones!
http://img24.imageshack.us/img24/4149/wipergrillbonnet.jpg (http://img24.imageshack.us/i/wipergrillbonnet.jpg/) http://img24.imageshack.us/img24/wipergrillbonnet.jpg/1/w640.png (http://g.imageshack.us/img24/wipergrillbonnet.jpg/1/)
http://img196.imageshack.us/img196/4262/wipergrillbonnet24.jpg (http://img196.imageshack.us/i/wipergrillbonnet24.jpg/) http://img196.imageshack.us/img196/wipergrillbonnet24.jpg/1/w640.png (http://g.imageshack.us/img196/wipergrillbonnet24.jpg/1/)

[spanishfly]

I then wired up and fitted the side repeators (I said repeators)
http://img190.imageshack.us/img190/1403/wipergrillbonnet5.jpg (http://img190.imageshack.us/i/wipergrillbonnet5.jpg/) http://img190.imageshack.us/img190/wipergrillbonnet5.jpg/1/w640.png (http://g.imageshack.us/img190/wipergrillbonnet5.jpg/1/)

I then made a mount for the wiper motor assembly, no longer do I have a bolt through the scuttle. Notice the egg like mount:)
http://img193.imageshack.us/img193/237/wipergrillbonnet10.jpg (http://img193.imageshack.us/i/wipergrillbonnet10.jpg/) http://img193.imageshack.us/img193/wipergrillbonnet10.jpg/1/w640.png (http://g.imageshack.us/img193/wipergrillbonnet10.jpg/1/)

http://img24.imageshack.us/img24/5151/wipergrillbonnet16.jpg (http://img24.imageshack.us/i/wipergrillbonnet16.jpg/) http://img24.imageshack.us/img24/wipergrillbonnet16.jpg/1/w640.png (http://g.imageshack.us/img24/wipergrillbonnet16.jpg/1/)

Then it was onto mounting the bonnet. I liked the way Lee303 of Germany mounted his so I decided to do it the same-ish way:)
Flatout cut the holes for the bonnet, remember now I got no generator it's all cordless drills.
http://img190.imageshack.us/img190/8251/wipergrillbonnet6.jpg (http://img190.imageshack.us/i/wipergrillbonnet6.jpg/) http://img190.imageshack.us/img190/wipergrillbonnet6.jpg/1/w640.png (http://g.imageshack.us/img190/wipergrillbonnet6.jpg/1/)

http://img12.imageshack.us/img12/4130/wipergrillbonnet15.jpg (http://img12.imageshack.us/i/wipergrillbonnet15.jpg/) http://img12.imageshack.us/img12/wipergrillbonnet15.jpg/1/w640.png (http://g.imageshack.us/img12/wipergrillbonnet15.jpg/1/)

I made brackets to go onto the bonnet, notice the strength plate on the otherside.
http://img40.imageshack.us/img40/4048/wipergrillbonnet19.jpg (http://img40.imageshack.us/i/wipergrillbonnet19.jpg/) http://img40.imageshack.us/img40/wipergrillbonnet19.jpg/1/w640.png (http://g.imageshack.us/img40/wipergrillbonnet19.jpg/1/)
http://img196.imageshack.us/img196/8428/wipergrillbonnet23.jpg (http://img196.imageshack.us/i/wipergrillbonnet23.jpg/) [URL=http://g.imageshack.us/img196/wipergrillbonnet23.jpg/1/]

[spanishfly]

It's handy as the bonnet can be removed OR tilted up.
http://img33.imageshack.us/img33/8084/wipergrillbonnet27.jpg (http://img33.imageshack.us/i/wipergrillbonnet27.jpg/) http://img33.imageshack.us/img33/wipergrillbonnet27.jpg/1/w640.png (http://g.imageshack.us/img33/wipergrillbonnet27.jpg/1/)

We put the pins where they needed to go, however as I'm re-spraying the bonnet I haven't screwed them in yet.
http://img24.imageshack.us/img24/7497/wipergrillbonnet2.jpg (http://img24.imageshack.us/i/wipergrillbonnet2.jpg/) http://img24.imageshack.us/img24/wipergrillbonnet2.jpg/1/w640.png (http://g.imageshack.us/img24/wipergrillbonnet2.jpg/1/)

I then made a bracket for the grill
http://img24.imageshack.us/img24/8018/wipergrillbonnet13.jpg (http://img24.imageshack.us/i/wipergrillbonnet13.jpg/) http://img24.imageshack.us/img24/wipergrillbonnet13.jpg/1/w640.png (http://g.imageshack.us/img24/wipergrillbonnet13.jpg/1/)

The masters workshop...
http://img24.imageshack.us/img24/1939/wipergrillbonnet3.jpg (http://img24.imageshack.us/i/wipergrillbonnet3.jpg/) http://img24.imageshack.us/img24/wipergrillbonnet3.jpg/1/w640.png (http://g.imageshack.us/img24/wipergrillbonnet3.jpg/1/)

Once I get the oil pump it's engine in:):D

[spanishfly]

So, now that I have the zLET pump in my possesion I decided to have a quick look at the differences. I got the pump 2nd hand so also wanted to make sure all was ok. It is good as you'll see from the pics. I took it apart and gave it a clean and regrease.
The inside of the pump are majorly different, you can tell the metal is stronger due the thickness on the thinest part.
http://img119.imageshack.us/img119/9178/dscn3339.jpg (http://img119.imageshack.us/i/dscn3339.jpg/) http://img119.imageshack.us/img119/dscn3339.jpg/1/w640.png (http://g.imageshack.us/img119/dscn3339.jpg/1/)

Cogs out...
http://img24.imageshack.us/img24/3703/dscn3338v.jpg (http://img24.imageshack.us/i/dscn3338v.jpg/) http://img24.imageshack.us/img24/dscn3338v.jpg/1/w640.png (http://g.imageshack.us/img24/dscn3338v.jpg/1/)

I then cleaned it all up and taped up the important parts, took out the PRV and all other bits and pieces, gave it all a clean. The oil cooler take off has a massive allen key bolt holding it on, reckon it's a 10mm.
http://img269.imageshack.us/img269/1487/dscn3340i.jpg (http://img269.imageshack.us/i/dscn3340i.jpg/) http://img269.imageshack.us/img269/dscn3340i.jpg/1/w640.png (http://g.imageshack.us/img269/dscn3340i.jpg/1/)


What it look like roughly on the block
http://img269.imageshack.us/img269/455/dscn3337k.jpg (http://img269.imageshack.us/i/dscn3337k.jpg/) http://img269.imageshack.us/img269/dscn3337k.jpg/1/w640.png (http://g.imageshack.us/img269/dscn3337k.jpg/1/)

As you can see the zLET pick up is alot different than the cXE one. The shape is the obvious thing, however the bore on the zLET one is twice the size of the cXE one. Should be fun modding something to fit.
http://img102.imageshack.us/img102/4435/dscn3335.jpg (http://img102.imageshack.us/i/dscn3335.jpg/) http://img102.imageshack.us/img102/dscn3335.jpg/1/w640.png (http://g.imageshack.us/img102/dscn3335.jpg/1/)
http://img49.imageshack.us/img49/2295/dscn3336.jpg (http://img49.imageshack.us/i/dscn3336.jpg/) http://img49.imageshack.us/img49/dscn3336.jpg/1/w640.png (http://g.imageshack.us/img49/dscn3336.jpg/1/)


I then moved on to the sump, gave it a good clean and also removed the oil level sender in prep for it to be baffled.
http://img24.imageshack.us/img24/573/dscn3342y.jpg (http://img24.imageshack.us/i/dscn3342y.jpg/) http://img24.imageshack.us/img24/dscn3342y.jpg/1/w640.png (http://g.imageshack.us/img24/dscn3342y.jpg/1/)

[URL=http://img49.imageshack.us/i/dscn3341.jpg/]http://img49.imageshack.us/img49/5592/dscn3341.jpg

[spanishfly]

Went back to dry the car so got some pics:D

Silver pump
http://img132.imageshack.us/img132/4719/dscn3343.jpg (http://img132.imageshack.us/i/dscn3343.jpg/)

Silver dipstick tube and matt black fuel cap to replace the silly metal one!
http://img220.imageshack.us/img220/1056/dscn3345l.jpg (http://img220.imageshack.us/i/dscn3345l.jpg/) http://img220.imageshack.us/img220/dscn3345l.jpg/1/w640.png (http://g.imageshack.us/img220/dscn3345l.jpg/1/)

Matt black wiper arm.
http://img43.imageshack.us/img43/83/dscn3346i.jpg (http://img43.imageshack.us/i/dscn3346i.jpg/) http://img43.imageshack.us/img43/dscn3346i.jpg/1/w640.png (http://g.imageshack.us/img43/dscn3346i.jpg/1/)

[spanishfly]

So my calipers turned up, and I painted them! The army green was nice, just not on my car. I love the new 997 911 turbo with there yellow standout 4 pots, so I decided that was the way I wanted to go... me and flatout then had the idea that instead of using black for the 'wilwood' I would use red, which makes it match the car, but more importantly it's the Spanish flag!

I think they look great and should look good behind my matt black wheels:) Standout-tastic
http://img38.imageshack.us/img38/5601/dscn4242z.jpg (http://img38.imageshack.us/i/dscn4242z.jpg/) http://img38.imageshack.us/img38/dscn4242z.jpg/1/w640.png (http://g.imageshack.us/img38/dscn4242z.jpg/1/)

http://img41.imageshack.us/img41/2331/dscn4243s.jpg (http://img41.imageshack.us/i/dscn4243s.jpg/) http://img41.imageshack.us/img41/dscn4243s.jpg/1/w640.png (http://g.imageshack.us/img41/dscn4243s.jpg/1/)

[spanishfly]

Thats the pics sorted: Now for the talk.
Basically i've been hestitating on what cam to go for, I want a nice spread of power, that starts at about 3000rpm and continues to 8500rpm. After buying (QED 450V's, Kent 1623's) /speaking to various people (SBD, QED, Bowyer) I decided to go for some Bowyer spec'd cams. Hopefully get these in the next month along with my +1mm valve seats cut. I'm hoping for around 230bhp, anything more would be great:) This will hopefully mean my engine can go together:D I'm waiting on a baffled and gated sump, which Hellier performance are making for me.

[dj_wudgey]

glad this is getting rebuilt!! i loved this car well youve been cracking on mate which is good to see!! well mate keep up the good work!

[spanishfly]

glad this is getting rebuilt!! i loved this car well youve been cracking on mate which is good to see!! well mate keep up the good work!
:thumb::thumb:Cheers mate:)

[scott.parker]

Awesome progress dude! Sump/pump combination looks interesting, should be nice to see the outcome, also like they idea with the bracket for the AX setup, might have to steal that one, as mines still bolted through the scuttle.

Scott

[spanishfly]

Awesome progress dude! Sump/pump combination looks interesting, should be nice to see the outcome, also like they idea with the bracket for the AX setup, might have to steal that one, as mines still bolted through the scuttle.

Scott

Thats how I did mine before but as i'm going for concours... well I had more time anyway lmao

Yeah, sump will be great. He has made one before but that engine isn't running yet, so i'm gonna trial it and go from there, if they work well then he'll sell the kit to others and laser cut it all! It's cheap bearing in mind what's involved! The pump, as you can see has better designed gears, the zLET pump also comes with a Nylon PRV, so getting this pump works out about the same price as getting the SBD steel gears and NPRV, only this way round it doesn't cavitate at 8xxx rpm.

[peester]

nice one mr fly, evolution not just repair...
wilwoods have a 'my first wilwoods' kinda look to them lol
a good idea tho, if stopping 230bhp.. no nos anymore??

[Adam]

Nice work Fly

[spanishfly]

nice one mr fly, evolution not just repair...
wilwoods have a 'my first wilwoods' kinda look to them lol
a good idea tho, if stopping 230bhp.. no nos anymore??
I'm hoping the 230bhp+ will be enough to not want nitrous. lol SCCR also means nitrous isn't ideal.

[peester]

ah ha - to catch mr lee of germany..?

[spanishfly]

ah ha - to catch mr lee of germany..?

Well if we're going to be doing team shonky trackdays, it's more entertaining being next to each other hitting into eachother!

[tony k]

hello mate good to see your getting far now,did you find out a day when you can pop down,to have a look at mine cheers

[spanishfly]

hello mate good to see your getting far now,did you find out a day when you can pop down,to have a look at mine cheers
I'm in Germany next week and working till then, apart from tomorrow when I have to do the shower room. Can sort something when I'm back?

[tony k]

I'm in Germany next week and working till then, apart from tomorrow when I have to do the shower room. Can sort something when I'm back?

yeah mate thats okay,got a few odds and sodds to do to the car till then lol,let me know when you can mate thanks tho:thumb:

[spanishfly]

yeah mate thats okay,got a few odds and sodds to do to the car till then lol,let me know when you can mate thanks tho:thumb:

Will do bud:)

[spanishfly]

o last night I went to Lee's garage to use the press and pressed in my new bearings.
So today I decided it was time to fit them.
I started by replacing the sperical bearings in the top mounts, I also gave them a light sand to try remove the carbon marks and make them a bit shinier.
Removed the grease from the hubs

That fitted, I put the hubs on.
I then fitted new bleed nipples and crossover pipes to the calipers, that completed the rebuild.
http://img14.imageshack.us/img14/5862/dscn4336d.jpg (http://img14.imageshack.us/i/dscn4336d.jpg/) http://img14.imageshack.us/img14/dscn4336d.jpg/1/w640.png (http://g.imageshack.us/img14/dscn4336d.jpg/1/)

Then it was time to put my wilwoods on. I also made up new brakelines, I decided to keep the front lines one piece so there is no join.
http://img6.imageshack.us/img6/4011/dscn4338n.jpg (http://img6.imageshack.us/i/dscn4338n.jpg/) http://img6.imageshack.us/img6/dscn4338n.jpg/1/w640.png (http://g.imageshack.us/img6/dscn4338n.jpg/1/)
Going to use these discs then get some Bells and rotors when there finished, I also have fitted some Ferodo DS2500 pads.

So after doing both sides, it was time to put the wheels on...
http://img17.imageshack.us/img17/7991/dscn4339v.jpg (http://img17.imageshack.us/i/dscn4339v.jpg/) http://img17.imageshack.us/img17/dscn4339v.jpg/1/w640.png (http://g.imageshack.us/img17/dscn4339v.jpg/1/)

Look great... but whats them new marks?
http://img21.imageshack.us/img21/3807/dscn4340p.jpg (http://img21.imageshack.us/i/dscn4340p.jpg/) http://img21.imageshack.us/img21/dscn4340p.jpg/1/w640.png (http://g.imageshack.us/img21/dscn4340p.jpg/1/)

Oh f**k, so I now need a small spacer or new wheels... gonna get a spacer for now and move the wheel weights, then in a few months get the wheels I wanted. Well, not the ones I wanted as Lee has them, so other ones lmao

Will get some paint on hammerite to touch them up...
http://img21.imageshack.us/img21/4633/dscn4341u.jpg (http://img21.imageshack.us/i/dscn4341u.jpg/) http://img21.imageshack.us/img21/dscn4341u.jpg/1/w640.png (http://g.imageshack.us/img21/dscn4341u.jpg/1/)
http://img260.imageshack.us/img260/460/dscn4343.jpg (http://img260.imageshack.us/i/dscn4343.jpg/) http://img260.imageshack.us/img260/dscn4343.jpg/1/w640.png (http://g.imageshack.us/img260/dscn4343.jpg/1/)

I then got upset, and decided to fit the window wiper arm... but remembered I had left the blade at home, so I left in a huff.
http://img14.imageshack.us/img14/8397/dscn4344x.jpg (http://img14.imageshack.us/i/dscn4344x.jpg/) http://img14.imageshack.us/img14/dscn4344x.jpg/1/w640.png (http://g.imageshack.us/img14/dscn4344x.jpg/1/)

My life sucks...

[scott.parker]

lol Never mind mate could of been allot worse eh??

[MARTIN KELSON]

Looking good matey.

What wiper arm you using.
Just fitted an Uno motor as i have removed firewall on mine and mate wired it in at weekend and he says my Peugeot wiper arm can slip on the spline so just wandered what yours was as i may need to source something else to try.

Cheers

Martin

[scott.parker]

I used AX set up on mine, but it did start to slip on the spline as it's worn, so i drilled it and tapped a small screw into it.

Scott

[sparkie1401]

what size brake discs are they? info please

cars looking a lot better

[tony k]

looking good mate,not long now ay,shame about the brakes rubbing on the calpiers(nice colour),cant you just take a layer off the inside of the wheel,but as you said your getting different ones so,why did i put that lol,have a good time in germany hope it all goes well

[spanishfly]

Looking good matey.

What wiper arm you using.
Just fitted an Uno motor as i have removed firewall on mine and mate wired it in at weekend and he says my Peugeot wiper arm can slip on the spline so just wandered what yours was as i may need to source something else to try.

Cheers

Martin
Cheers mate, it's a pug 306 REAR wiper arm, I like the metal version of the earlier ones, however they also do a plastic smooth one on the later cars. I got the AX motor, believe the uno is the same spilinage though:thumb:

[spanishfly]

what size brake discs are they? info please

cars looking a lot better
280mm I believe, it's not the discs that's the problem, it's the caliper widths.:(


Cheers:)

[spanishfly]

looking good mate,not long now ay,shame about the brakes rubbing on the calpiers(nice colour),cant you just take a layer off the inside of the wheel,but as you said your getting different ones so,why did i put that lol,have a good time in germany hope it all goes well

Cheers dude, and see ya when I get back:)

[spanishfly]

Thought I would put a little guide I made for wheel studs up on here, it'll save people between £30 and £40...

For the studs themselves you have a choice:
The length is the amount remaining AFTER it's been screwed in the hub.

38mm exposed (http://www.rallydesign.co.uk/product_info.php?cPath=731_738&products_id=4721)
48mm exposed (http://www.rallydesign.co.uk/product_info.php?cPath=731_738&products_id=4722)
68mm exposed (http://www.rallydesign.co.uk/product_info.php?cPath=731_738&products_id=4723)

Nuts
open end nut (http://www.rallydesign.co.uk/product_info.php?cPath=731_734&products_id=4648)
closed end nut (http://www.rallydesign.co.uk/product_info.php?cPath=731_734&products_id=4656)

I went for the 48mm exposed stud and open end nut. This is because i'm running a 5mm spacer.

To work out what you need:
Measure the wheel thickness from the back of the wheel to the start of the taper. Ex. 15mm
The wheel nut is 22mm long (open)
So 22+13=35... so a 38mm stud will do , and leave 3mm spare...You could use a closed nut on this setup.

If for example you have the same but with a 3mm spacer, so:
22+13+3=38mm I would advise going the next stud up to leave plenty of thread.

It works out to around £20-30 for most combos :beer:

Hope this helps people, mods you wanna copy this to tech or something?

[spanishfly]

lol Never mind mate could of been allot worse eh??
Yeah I suppose, the car could have caught alight:roll: lol

[AlexW]

Stick the stud guide in articals. :)

Car looks good :)

[spanishfly]

Will do and cheers:)

[scott.parker]

Yeah I suppose, the car could have caught alight:roll: lol

I was thinking along the lines of, you put it together and then drove it like it! lol

[spanishfly]

An update with PICS!!!!

Today I started more work on the head, then got pissed off with it as I need to get a block to head dowel.
So I went and bought a sand blaster, glad I did too! Wicked job! I bought some aluminium grit abrasive in 80-120 grit.
I then took it to the throttle bodies! I warn people use googles when doing this!
Manifold before
http://img202.imageshack.us/img202/5937/dscn4383.jpg
http://img202.imageshack.us/img202/4569/dscn4384.jpg

Starting to look better
http://img7.imageshack.us/img7/7905/dscn4385f.jpg
http://img23.imageshack.us/img23/554/dscn4386.jpg


After
http://img7.imageshack.us/img7/9470/dscn4387i.jpg
http://img7.imageshack.us/img7/6739/dscn4388d.jpg
Tbs before and after...
http://img185.imageshack.us/img185/7186/dscn4389w.jpg
After
http://img340.imageshack.us/img340/6910/dscn4390.jpg
http://img7.imageshack.us/img7/7862/dscn4391t.jpg
http://img7.imageshack.us/img7/25/dscn4392p.jpg

Need to buy some new m5 allen head bolts from screwfix tomorrow!:)

I also found out what the problem is with one of my hubs, so thats sorted. Now I just need to press in one new one and i'm done! Have sent my dampers away to gaz, so should hear what they need in the next few days!

[spanishfly]

So I decided today to have a clean up of the bodies, and remove all the sand remains etc. I soaked them overnight, then used carb cleaner and an air line. There is no remains of sand:)
I bought some new bolts from screwfix, allen head m5 jobs.

I've fitted the LET yellows and trumpets as a temp measure. I want to go back to carbon fibre trumpets when funds permit and every thing else has been done.

Linkage on, cleaned and parts renewed that needed it.
http://img23.imageshack.us/img23/7339/dscn4393c.jpg

Trumpets I got of Gills (cheers) New fuel rail.
http://img42.imageshack.us/img42/8080/dscn4394po.jpg
http://img40.imageshack.us/img40/5622/dscn4395o.jpg

Lucky for me at events I take the filter off, and to run the nitrous at full horsepower I ran shorter lines. This meant my airfilter was in the car rather than in the engine!
http://img14.imageshack.us/img14/5633/dscn4396f.jpg

Looking like new-ish. Really happy with the outcome!
http://img3.imageshack.us/img3/4010/dscn4397.jpg

[Plug]

good progress mate :thumb:

at least your not letting the fire stop you

[spanishfly]

Can't let it beat me, taken longer than expected but have spent alot of cash upgrading everything!

[Benn]

Shes comming on very well dude.

[Mazz]

the sand-blaster has done a really good job cleaning up those parts, looks like new now - nice to see it going to live again..

[MattBrown]

How much was the blaster?

And be careful not to leave any grit/sand/bead/shot in the work!

[craig green]

And be careful not to leave any grit/sand/bead/shot in the work!

Fly wont need telling. Shot blasters rule though, awesome paint prepping in seconds!

[spanishfly]

It was £20 for the gun and £10 for the grit from machine mart.

I soaked them and blew them out with the airline:):D

[spanishfly]

Fly wont need telling. Shot blasters rule though, awesome paint prepping in seconds! :thumb:lol

[Spudly]

Looking good fly, not checked in for a while but really good to see this one coming back, like a pheonix from the ashes so to speak lol

[craig green]

It was £20 for the gun and £10 for the grit from machine mart.



So not done in a blasting cabinet then?

[AlexW]

Same as ive got, no need for a cabinet, just a box :D

[MK999]

So not done in a blasting cabinet then?

Think you can see his old kitchen bin with grit in the bottom in all the pics lol

edit: also have some shiny new studs sat on my desk atm, cheers for that :thumb:

[spanishfly]

NP MK999, glad I could help:)

Craig i'm gonna make a box, but that was long so just went outside in the great outdoors! Glad it rained today....

[MK999]

NP MK999, glad I could help:)

Craig i'm gonna make a box, but that was long so just went outside in the great outdoors! Glad it rained today....

I was wrong then, thought the bin with grit in the bottom was acting as the shot blasting cabinet lol

[spanishfly]

I was wrong then, thought the bin with grit in the bottom was acting as the shot blasting cabinet lol

It was but in the great outdoors. plus it didn't catch much lol

[spanishfly]

This is the latest, and has a cool guide on valves
Go to http://http://www.migweb.co.uk/forums/projects-restorations/287511-spanishflys-track-nova-coupe-turbo-178.html#post4214263 to see it. The pictures are too big and don't resize here:(

[spanishfly]

Fail

[peester]

can i ge' a reeeesize

[spanishfly]

Ah! It all makes sense now. You're one of THOSE kind of perverts!
:beer:

So todays messing:
CC'd head using a burette and a cut down number plate plastic!
http://img689.imageshack.us/img689/8449/dscn5325.jpg (http://img689.imageshack.us/i/dscn5325.jpg/)http://img689.imageshack.us/img689/dscn5325.jpg/1/w640.png (http://g.imageshack.us/img689/dscn5325.jpg/1/)
Grease around the sides, making sure (unlike in this pic) that the grease is only sealing and not going into the chamber.
http://img263.imageshack.us/img263/5812/dscn5326zs.jpg (http://img263.imageshack.us/i/dscn5326zs.jpg/)http://img263.imageshack.us/img263/dscn5326zs.jpg/1/w640.png (http://g.imageshack.us/img263/dscn5326zs.jpg/1/)
Then went to play with the engine too, and cc it all together.
http://img685.imageshack.us/img685/9097/dscn5328.jpg (http://img685.imageshack.us/i/dscn5328.jpg/)http://img685.imageshack.us/img685/dscn5328.jpg/1/w640.png (http://g.imageshack.us/img685/dscn5328.jpg/1/)
Then I had a quick play with the rest of the engine.
When you fit zLET pumps you MUST use the cXE/LET oil seal.
Got a pic but not much to see really!
I then positioned the oil cooler, got to get a fan so I can see how much space I have.
http://img341.imageshack.us/img341/4687/dscn5332y.jpg (http://img341.imageshack.us/i/dscn5332y.jpg/)http://img341.imageshack.us/img341/dscn5332y.jpg/1/w640.png (http://g.imageshack.us/img341/dscn5332y.jpg/1/)

[burgo]

those pics are fooooooooking huge

[spanishfly]

those pics were fooooooooking huge:thumb:

[tony k]

good work there mr spanishfly keep it up,aint been near mine for a while,waiting for this baby to come out anytime now,how you been

[spanishfly]

good work there mr spanishfly keep it up,aint been near mine for a while,waiting for this baby to come out anytime now,how you been

Still not here yet? Bout time isn't it?

I been good matey:) You?

[tony k]

Still not here yet? Bout time isn't it?

I been good matey:) You?

yeah i know mate should be here,dont think the baby wants to come out lol,yeah am all good thanks:thumb:

[spanishfly]

keep on building your enginge as proper as it's shown
Will try:)

[GSI-TOMMY]

good woork mate
keep it up

[spanishfly]

So after a morning wasted with sorting a bench grinder (first one had bits missing) I had to get some valve stem seals for the exhaust. For some reason it has non standard bronze guides that are different than the inlet ones. Turns out they may be vw ones (don't ask me why they were used? For future reference for myself they are 9mm o/d)
So with these sourced I re-assembled the head, lovely job.
http://img51.imageshack.us/img51/8895/dscn5746p.jpg (http://img51.imageshack.us/i/dscn5746p.jpg/)
So with this done it was time for the fun (read boring) job of shimming the lifters. With a quote of between £70-100 I thought rather than be lazy lets do it myself.
So out with the feeler gauges, micrometer, grinder and patience. The shims I got were 6.4mm big, after doing my first one I found I would need them to start at around 4.5mm and work down. So the inlet side down I only have the exhaust to go. Need to order a couple extra shims as I was a bit keen on one, and the other dropped into the black hole.
http://img513.imageshack.us/img513/8695/dscn5748f.jpg (http://img513.imageshack.us/i/dscn5748f.jpg/)
http://img442.imageshack.us/img442/7245/dscn5747.jpg (http://img442.imageshack.us/i/dscn5747.jpg/)
Measuring and noting
http://img534.imageshack.us/img534/7439/dscn5750.jpg (http://img534.imageshack.us/i/dscn5750.jpg/)
http://img205.imageshack.us/img205/7476/dscn5752.jpg (http://img205.imageshack.us/i/dscn5752.jpg/)

[spanishfly]

Due to the cold and snow I've not been able to do much today, however I didn't let that defeat me.
I went and played with the head, i've shimmed the exhaust side now too, well bar two valves as i'm waiting on some more shims. I took the ones from the inlet which were gapped excessively (0.4mm) and used them on the exhaust side. Going to have to hear how it sounds as some of the gaps are a tight 0.3. If it's too fiesta like and I like these cams, i'll just reshim.
Anyway with that done, I decided to get some Ring practice in on Forza 3, as I was playing it I felt I should really be cracking on.
So bones warmed up I went up to the garage armed with my sump, pick up pipe and baffle.
Took some measurements and proceeded to modify and fit the baffle.
Due to using a zLET pump and pick up I had to modify the baffle to accept the pick up. Out with the nibbler and 5 minutes later it was done. Not hard like some would lead you to believe.

Pick up and WINDAGE PLATE fitted in correct position.
http://img704.imageshack.us/img704/4537/dscn5799.jpg (http://img704.imageshack.us/i/dscn5799.jpg/)
Marked out then duck taped in place
http://img213.imageshack.us/img213/5179/dscn5802.jpg (http://img213.imageshack.us/i/dscn5802.jpg/)
Baffle measured modified and then lined up using the sump. Marked up and tack welded on in various places to stop it moving. (notice bare metal marks...)
http://img213.imageshack.us/img213/5179/dscn5802.jpg (http://img213.imageshack.us/i/dscn5802.jpg/)
No pics of baffle as it breaches national security. ;)
Tomorrow I will get some sillicon and start fitting the sump. Hopefully my postman brings me some shims too which will mean engine assembly!!!!!

[peester]

you going to just silicone the sump to the block?

[spanishfly]

Will put a fine bead just don't want it to leak.

[craig green]

Are you still pishing about with this? lol

:thumb:

[spanishfly]

Are you still pishing about with this? lol

:thumb:

Unfortunetly. lol

[spanishfly]

So todays update.
Still waiting on shims, I decided to go to the nova and bolt some bits on. Quite exciting really!
Bolted one of my wheels on, they are team Dynamics Pro Race 1's. My god they are light, I took them to get balenced and the guy even commented when he picked them up. I guess they must weigh around 6kg each with tyres. There wearing Yoko A048R's in a M compound.
They look great too!
http://img193.imageshack.us/img193/6162/dscn5805.jpg (http://img193.imageshack.us/i/dscn5805.jpg/)
http://img193.imageshack.us/img193/5022/dscn5807.jpg (http://img193.imageshack.us/i/dscn5807.jpg/)
http://img193.imageshack.us/img193/892/dscn5813x.jpg (http://img193.imageshack.us/i/dscn5813x.jpg/)
I also fitted the sump and baffle. I used the 8v windage tray and a bit of loctite high performace sillicon, I smeared the sillicon smooth and used m6x20mm allen cap bolts.
I painted it hammerite silver. For some reason it looks as though it has run...
http://img109.imageshack.us/img109/843/dscn5809.jpg (http://img109.imageshack.us/i/dscn5809.jpg/)
http://img109.imageshack.us/img109/1737/dscn5810z.jpg (http://img109.imageshack.us/i/dscn5810z.jpg/)
As you can see I've used the allen head bolts in most places. I'm hoping to be able to rebuild the engine one day using just an allen key set lmao
Water pump is on.
http://img251.imageshack.us/img251/9837/dscn5811.jpg (http://img251.imageshack.us/i/dscn5811.jpg/)
I then fitted the cam belt backplate and crank pulley. I got a new bolt and washer for the crank pulley.. best part of £30 gone there!
http://img109.imageshack.us/img109/4324/dscn5815p.jpg (http://img109.imageshack.us/i/dscn5815p.jpg/)
http://img251.imageshack.us/img251/3662/dscn5814.jpg (http://img251.imageshack.us/i/dscn5814.jpg/)
I'm now wanting to wash the coupe, it hasn't been done for like 5 months! Still looks shiny but it's filthy!

[craig green]

Wheels look good dude, can we pretend they are anything but Team dynamics?

[MK999]

Wheels look good dude, can we pretend they are anything but Team dynamics?

No labels on them, sparco multispokes? lol

[spanishfly]

Wheels look good dude, can we pretend they are anything but Team dynamics?

These are the 'race series' wheels, so not as bad as getting some of the other stuff! We can pretend there sparco, Braid or something else cool if ya like! lol

[spanishfly]

Oh and cheers lol

[spanishfly]

Designed to be the lightest heat-treated cast alloy 7.0 x 15 wheel on the market today, this wheel is some 25% lighter than a comparative conventional cast alloy road wheel. This is achieved through developments in Computer Aided Design and Finite Element Analysis, complete with full impact and fatigue testing. All conducted in house.

See sounds so cool!

[steveboyslim]

Due to the cold and snow I've not been able to do much today, however I didn't let that defeat me.
I went and played with the head, i've shimmed the exhaust side now too, well bar two valves as i'm waiting on some more shims. I took the ones from the inlet which were gapped excessively (0.4mm) and used them on the exhaust side. Going to have to hear how it sounds as some of the gaps are a tight 0.3. If it's too fiesta like and I like these cams, i'll just reshim.
Anyway with that done, I decided to get some Ring practice in on Forza 3, as I was playing it I felt I should really be cracking on.
So bones warmed up I went up to the garage armed with my sump, pick up pipe and baffle.
Took some measurements and proceeded to modify and fit the baffle.
Due to using a zLET pump and pick up I had to modify the baffle to accept the pick up. Out with the nibbler and 5 minutes later it was done. Not hard like some would lead you to believe.

Pick up and WINDAGE PLATE fitted in correct position.
http://img704.imageshack.us/img704/4537/dscn5799.jpg (http://img704.imageshack.us/i/dscn5799.jpg/)
Marked out then duck taped in place
http://img213.imageshack.us/img213/5179/dscn5802.jpg (http://img213.imageshack.us/i/dscn5802.jpg/)
Baffle measured modified and then lined up using the sump. Marked up and tack welded on in various places to stop it moving. (notice bare metal marks...)
http://img213.imageshack.us/img213/5179/dscn5802.jpg (http://img213.imageshack.us/i/dscn5802.jpg/)
No pics of baffle as it breaches national security. ;)
Tomorrow I will get some sillicon and start fitting the sump. Hopefully my postman brings me some shims too which will mean engine assembly!!!!!

The postman would have brought some shims, if I had remembered to post them. lol (oops)

Steve

PS Hey that is a nice ZLET oil pick up pipe.;)

[Graeme]

Are the baffle plate mods to stop the Arp's catching? or for something else?

[spanishfly]

The postman would have brought some shims, if I had remembered to post them. lol (oops)

Steve

PS Hey that is a nice ZLET oil pick up pipe.;)

It is a well constructed pick up mate, you know who supplies them;)

[spanishfly]

Are the baffle plate mods to stop the Arp's catching? or for something else?
The only mod I had to do was bend the tag closest the oil pump. The brown thing is a windage tray. The other mods I did was tack weld my baffle to the windage tray. I haven't put pics up due to the sensitive nature of the finished article and the prospect of people copying it. I bought it from Hellier performance if anyone wants one.

[Benn]

What the funk is a windage try?

[scott.parker]

What the funk is a windage try?

sump baffle plate.

[Benn]

Oh, so its nothing special and new mod like...

[scott.parker]

Well im guessing that anyway? lol

[spanishfly]

Yes the bit that people regard as a baffle plate is a windage tray. I thought I would try make it public so not everyone goes around saying 'I got a baffled sump'. I have a real baffled sump now, so in the pub I can score extra spec points. lol

[The Simps]

Yes the bit that people regard as a baffle plate is a windage tray. I thought I would try make it public so not everyone goes around saying 'I got a baffled sump'. I have a real baffled sump now, so in the pub I can score extra spec points. lol


Having a REAL baffled sump is hardly shonky tho is it?!

[spanishfly]

Having a REAL baffled sump is hardly shonky tho is it?!
That's the beauty of shonky opels... the specs still there mate!lol

[spanishfly]

An update and a few pics thrown in that I like!
Progressed quite well today.
P clipped the nearside brakepipe to keep it safe.
http://img203.imageshack.us/img203/7821/img5515f.jpg (http://img203.imageshack.us/i/img5515f.jpg/)
I then fitted a new clutch cable, I now have a clutch and have a rough idea where I need to cut and modify the brake pedal.
http://img16.imageshack.us/img16/8216/img5516g.jpg (http://img16.imageshack.us/i/img5516g.jpg/)
New thermostat on, all the pipes I don't have, have been measured. I fitted some one already:)
http://img707.imageshack.us/img707/8983/img5517i.jpg (http://img707.imageshack.us/i/img5517i.jpg/)
I then took the suspension apart to fit new poly sport bump stops, the other ones melted in the fire. I also replace the passenger sperical bearing in the top mount as I had already done drivers one. I fitted the long driveshaft, but couldn't fit the short one as I'm missing an inner CV, I think I threw it away as I can't find it. So will get a new one and a boot.
http://img64.imageshack.us/img64/7264/img5519t.jpg (http://img64.imageshack.us/i/img5519t.jpg/)
I made a bracket to hold the rad. Then mounted my new fan, I was going to mount it on the front. Luckily for me they sent a rear mounted one to pull through. This meant I was able to mount it in the standard place...
http://img502.imageshack.us/img502/8610/img5522k.jpg (http://img502.imageshack.us/i/img5522k.jpg/)
http://img23.imageshack.us/img23/674/img5523j.jpg (http://img23.imageshack.us/i/img5523j.jpg/)
...and as I have loads of space there it meant the oil cooler could go here...
http://img683.imageshack.us/img683/7573/img5524.jpg (http://img683.imageshack.us/i/img5524.jpg/)
Now need to get Lee866 to make me some hoses up when he can.

I tightened all suspension joints and bolts. While I was doing the suspension stuff I decided to play with the height settings, I wanted to achieve a 'Low that Benn likes'. I won't be sticking with this but it looks cool, I also still have suspension travel and could go down some more lol
http://img94.imageshack.us/img94/5236/img5520a.jpg (http://img94.imageshack.us/i/img5520a.jpg/)

I adjusted the DZUS fasteners using washers so it holds the bumper right. It'll never be 100% but it holds it on and i'm happy with it.
So now I'll let you see a few pics, took them as I used my SLR today:)
http://img691.imageshack.us/img691/1402/img5528q.jpg (http://img691.imageshack.us/i/img5528q.jpg/)
http://img694.imageshack.us/img694/4531/img5526q.jpg (http://img694.imageshack.us/i/img5526q.jpg/)
http://img203.imageshack.us/img203/1525/img5534c.jpg (http://img203.imageshack.us/i/img5534c.jpg/)

[spanishfly]

Oh and the engine is in :)

[Adam]

Sweeet! Its going look even better than it did before the fire incident!!
When you hoping have it done by?? Combe in April a possibility???

[craig green]

SLR.... I thought the pics looked good. It's really coming along nicely now Rob, all those little jobs & fiddly bits to do.

[spanishfly]

Sweeet! Its going look even better than it did before the fire incident!!
When you hoping have it done by?? Combe in April a possibility???

Want it done by may mate, still a fair bit to do. If it's ready for coombe i'll prob give it a shakedown and re learn to drive it. It's changed so much it's not even near the same car! lol

I agree it looks better in photoslol The paint ain't great there's typical outdoor paint defects, think I caught a fly too. The engine bay have two shades as we used home mixxed hammerite to try much the Hurricane grey lol

[craig green]

Nova's always seem incredibly odd when you back into one. Shakedown or not it'll be like whacky racers.
Looks like I may have another very soon as a daily, uhoh!!

[spanishfly]

SLR.... I thought the pics looked good. It's really coming along nicely now Rob, all those little jobs & fiddly bits to do.

Yeah as you say it's the small fiddly jobs left, which seem to take longer than the big bits!
Yeah you can see the colour compared to the missis Nikon I usually use. I really should use my 400D more often, had it like 4 years now.:eek:

[spanishfly]

Nova's always seem incredibly odd when you back into one. Shakedown or not it'll be like whacky racers.
Looks like I may have another very soon as a daily, uhoh!!

What you getting?

Yeah even sitting in it stationary makes you realise how offset the steering is etc

[Adam]

Yeah, driving my astra and then sitting in a stripped out nova makes you realise how shonky novas are, but you still love them lol lol lol

[spanishfly]

Yeah, driving my astra and then sitting in a stripped out nova makes you realise how shonky novas are, but you still love them lol lol lol

Yeah it's a strange thing. I had a LET mk3 astra and my Coupe T yet still have more love for the nova.

27 and own a Nova:thumb: lol

[tony k]

looking good mate so the engines in ay,look at you getting stuck in lol,love them wheels i wnat white ones,might do my comp mo`s white,still aint done the fiesta yet bloody thing,gonna try do it tomorrow in work if we aint busy

[spanishfly]

looking good mate so the engines in ay,look at you getting stuck in lol,love them wheels i wnat white ones,might do my comp mo`s white,still aint done the fiesta yet bloody thing,gonna try do it tomorrow in work if we aint busy

YEah I do like red with White, wasn't gonna do it because Lee303 owns the rights to that:( But i stole them!

[blue_peg_16v]

Yeah it's a strange thing. I had a LET mk3 astra and my Coupe T yet still have more love for the nova.

27 and own a Nova:thumb: lol

im 30 and still have one the addictive little feckers lol

[spanishfly]

im 30 and still have one the addictive little feckers lol

:thumb:

[dj_wudgey]

looks well good matey!!

[MARTIN KELSON]

27 and own a Nova:thumb: lol

Try 37 & still own a Nova then lol

Martin

[bazil]

em 32 and have 3 lol

good rebuild thread mate:thumb:

[Benn]

You know the fan will work either way by swapping the wiring around yeah...?

Pics look good, the last 3 are awesome and the car looks sweet as funk!



Yeah, driving my astra and then sitting in a stripped out nova makes you realise how shonky novas are, but you still love them lol lol lol

Trying going from my 07 plate work van that has great brakes, really light pas perfect wipers and a really up right driving seating to driving my Nova..lol

[peester]

DZUS fasteners using washers so it holds the bumper right. It'll never be 100% but it holds it on and i'm happy with it.

http://img694.imageshack.us/img694/4531/img5526q.jpg (http://img694.imageshack.us/i/img5526q.jpg/)
http://img203.imageshack.us/img203/1525/img5534c.jpg (http://img203.imageshack.us/i/img5534c.jpg/)

christ thats hard as nails.. suffice to say itll have the grunt to back those looks up..
these dzus fasteners mean u rid of the old bumper bracket /iron?
and it sits that well?
idea pinchingly nice work..

[auzzy-b]

Looking good!! interesting project:thumb:

[novacabrio]

Try 37 & still own a Nova then lol

Martin

And still loving it!! :thumb: I think Joff, Royston or Offplot win?

[peester]

C.p..?

[spanishfly]

Try 37 & still own a Nova then lol

Martin

Your 37, don't look it mate!:thumb:

[spanishfly]

lmao @ the how old are you -ness?

Peester, yeah basically using the the standard side screw things but instead of screws I have 1/4turn dzus things. Then on the front I have the bonnet pins. No bumper bar front or rear, weigh too much.

Cheers for the nice comments everyone:)

[Mazz]

Do like!

http://img691.imageshack.us/img691/1402/img5528q.jpg

[The Simps]

Lovin it Rob, proper shonky! :cool:

[spanishfly]

Big update:)
Got both driveshafts now on and working. I ordered myself 10 cv boot clips so I could do the job properly.:)
http://img715.imageshack.us/img715/3277/dscn5908c.jpg (http://img715.imageshack.us/i/dscn5908c.jpg/)

I then sprayed my previously prep'd camcover. I've gone for hammerite smooth yellow to match my brakes!
http://img59.imageshack.us/img59/2194/dscn5909.jpg (http://img59.imageshack.us/i/dscn5909.jpg/)

My Camshaft also arrived, gonna try keep it in one expensive piece this time! I put the ball bearing in the end, and also the nice little cap they sent me!
http://img709.imageshack.us/img709/6632/dscn5912.jpg (http://img709.imageshack.us/i/dscn5912.jpg/)

http://img171.imageshack.us/img171/7810/dscn5913.jpg (http://img171.imageshack.us/i/dscn5913.jpg/)

Didn't have my feeler gauges so have just left it there. Need to check clearances again now!
http://img97.imageshack.us/img97/8969/dscn5914y.jpg (http://img97.imageshack.us/i/dscn5914y.jpg/)

Tried putting the small alternator on, this is a temp measure till the bottom pulley is on:)
http://img63.imageshack.us/img63/6816/dscn5915.jpg (http://img63.imageshack.us/i/dscn5915.jpg/)

As the shafts were fitted, I filled the gearbox up with Fuchs finest oil. Retails at around £15 a litre! It has a cool easy pour device too!
http://img689.imageshack.us/img689/3243/dscn5916e.jpg (http://img689.imageshack.us/i/dscn5916e.jpg/)
http://img718.imageshack.us/img718/8171/dscn5917d.jpg (http://img718.imageshack.us/i/dscn5917d.jpg/)

I then Rivited on the bulkhead fuel panel
http://img19.imageshack.us/img19/315/dscn5918s.jpg (http://img19.imageshack.us/i/dscn5918s.jpg/)

And then mounted my fuel reg.
http://img202.imageshack.us/img202/4738/dscn5920o.jpg (http://img202.imageshack.us/i/dscn5920o.jpg/)

I then decided to fit my TBs. I was leaving them off for easy access underneath, but with them on I could do my loom.
http://img202.imageshack.us/img202/7710/dscn5921.jpg (http://img202.imageshack.us/i/dscn5921.jpg/)

[spanishfly]

Which led to me 'trying' this- I LOVE IT!
http://img714.imageshack.us/img714/1522/dscn5927x.jpg (http://img714.imageshack.us/i/dscn5927x.jpg/)

http://img718.imageshack.us/img718/7514/dscn5936.jpg (http://img718.imageshack.us/i/dscn5936.jpg/)

I then started with the loom. I used all the correct bits.
http://img196.imageshack.us/img196/3476/dscn5930n.jpg (http://img196.imageshack.us/i/dscn5930n.jpg/)

Injectors and coil loom
http://img695.imageshack.us/img695/1094/dscn5931.jpg (http://img695.imageshack.us/i/dscn5931.jpg/)

http://img687.imageshack.us/img687/4479/dscn5932s.jpg (http://img687.imageshack.us/i/dscn5932s.jpg/)

[Benn]

Love the work, not a huge fan of the sbd sticker tho. Loom looks nice and neat.

[krobinson]

Cars looking great, loving the yellow rocker!

[mikeycc2009]

Good work mate!!

Mikey

[Graeme]

Good work, i think the burnt cam cover should stay

[spanishfly]

Benn kindof agree on SBD sticker tbh, would prob look nicer plain. Will see how it goes. May remove it to put a shonky one on instead:D

[Adam]

Top work Rob!!!!

Cam cover looks awesome, goes with the carbon spark plug cover perfectly!!!

Good to see the bodies cleaned up so well too! :)

[spanishfly]

Top work Rob!!!!

Cam cover looks awesome, goes with the carbon spark plug cover perfectly!!!

Good to see the bodies cleaned up so well too! :)

Sandblasting FTW. :thumb:

Cheers mate, i'm re getting the love, just can't wait till I drive it!