PNG Car Of The Year 2008

[Shaun_O'Donnell]

Congratulations to Shaun O'Donnell who's yellow Nova Saloon has been voted by PNG members as the official PNG Car Of The Year for 2008.

His saloon was entered into a poll along with the ten other cars from the previous featured Car Of The Month threads that were all hosted in 2008. In December, all eleven feature cars were assembled into one poll for the overall Car Of The Year, in which Shaun won over stiff competion after one third of members voted for his car.

At Shaun's request, and for your viewing pleasure, here follows the extracts of his WIP thread to form a diary of the rebuild work on his saloon.

Again, on behalf of myself and the PNG club membership, congratulations Shaun on your achievement.

- Razorjack
January 15th, 2009



- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -



With the Insurance of the written off P1 paid out..

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/P1%20Crash/Image023.jpg

..the Nova now moved into the garage............

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/Saloon%20Early%20Pics/STA60091.jpg

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/Saloon%20Early%20Pics/STA60092.jpg

..a new everyday car bought and some of the mortgage paid off.....

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/My%20Other%20Cars/STA60094-2.jpg

I have decided to re-build the Nova over the winter in preperation of a re-spray in the early New Year. Managed to find a decent reliable painter who is willing to do it after being knocked back by 2 others. With my confidence restored I began stripping the car of it's interior today. Taking things nice and easy and storing everything up the loft as I go so as not to cause clutter and end up loosing the plot and now with a TV with SKY fitted in the garage it's going to be even more pleasant.

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/inside1.jpg

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/inside2.jpg

Keeping the car driveable until the end of September when I will SORN it and put a hold on the insurance.

So far my plans include:

Doing away with the SR grille and bumper and replace with early 1 piece grille and bumper.
Doing away with the deep mk2 rear bumper and re-fitting the skinny original.
Have ordered new front wings and a passenger door skin as these are slightly damaged, but no rust, car has just covered 12k and been garaged all it's life.
Side skirts are going.
Wheels will be changed.
Engine at this stage will remain.

I am unsure about the new colour and what to do with the interior. I still have the original seats up the loft, but I love the comfort of the GTE seats, plus the original doorcards were sold.

I am on the lookout for the mk1 SR early bumper valance trim if anyone knows of such kicking about.

[Shaun_O'Donnell]

Oh and the wife and I are expecting a Baby in Spring, so this keeps me out her hair whilst she's all hormonal and stuff.......

[Shaun_O'Donnell]

Cool little car you have there. wheres all the sound deading tho? I just taking mine out - what a pain that is!

I quite like the colour atm, but what did you have in mind?


Cheers ash. There was no sound deadening, I can only assume poverty models lacked this luxury. When I got the car it had one wing mirror, no radio, no clock and no door card pockets. Here it is when I got it.

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/Saloon%20Early%20Pics/STA60022.jpg

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/Saloon%20Early%20Pics/STA60023.jpg

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/Saloon%20Early%20Pics/STA60024.jpg

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/Saloon%20Early%20Pics/STA60025.jpg

[Shaun_O'Donnell]

Work carried out today involved removing the ICE, the seat belts and any other interior trim that's surplus to the car being driveable. Hoovering as I went along to keep things nice and clean. Just got to put all the stuff up the loft out the way.

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/STA600881.jpg

Some pics taken of inside the boot.

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/STA60091-1.jpg

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/STA60092-1.jpg

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/STA60090-1.jpg

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/STA60093.jpg

Been thinking about colours and quite keen on the mk1 SR Mustard Yellow or Platinum Metalic. Looking for a colour that will match the car's age.

Also decided, the number plate panel is going which means the holes I drilled for it will need patching up.

[Shaun_O'Donnell]

Managed to get hold of an unused and immaculate zender front valance. So tonight removed the SR bumper, re-fitted my old skinny bumper along with the zender valance and was really chuffed with the results. That bumper and grille are not staying though. Got a one piece bumper and grille from an early mk1 SR on it's way along with new wings and a new door skin. Also removed the mk2 rear bumper and fitted the original skinny. Removed the rear number plate panel all together.

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/STA60092-2.jpg

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/STA60088-2.jpg

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/STA60089-2.jpg

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/STA60090-2.jpg

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/STA60091-2.jpg

Some pics of the underside at the rear.

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/STA60093-1.jpg

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/STA60094-3.jpg

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/STA60095-1.jpg

[Shaun_O'Donnell]

Cleaned behind the old bumper revealing very nice bodywork as expected.

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/STA60096.jpg

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/STA60097.jpg

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/STA60098.jpg

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/STA60099.jpg

The old rear bumper and number plate don't half look daft.

[Shaun_O'Donnell]

Today my new bumper, wings and door skin arrived so test fitted all except the door skin, will leave that to the bodyshop to sort out. Ordered these parts from http://www.beeversautopanels.co.uk (http://javascript<b></b>:ol('http://www.beeversautopanels.co.uk');) and was very happy with the service provided. Would recommend.

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/STA600881-1.jpg

Here's the bumper fitted, not fully bolted up though..

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/STA600891.jpg

And wings fitted, which must be the best aftermarket parts I have come across. I am well chuffed.

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/STA600911.jpg

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/STA600921.jpg

Here's a pic of the front near side sill under the wing, all it still solid.

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/STA600901.jpg

Also removed the front suspension and cleaned it up as it'll be up for sale as a set of Avo Coilovers from Chris Astley Motorsport are on their way. Stuck the old suspension back on, which even though it's 20 years old is still in immaculate condition.

Will get the rears off tomorrow and compile a for sale thread with all the bits I no longer require.

Comments would be appreciated.

Cheers,

Shaun.

[Shaun_O'Donnell]

Recieved a set of early SR clocks yesterday that I bought on eBay. Swapped over my tachometer and plugged in. All is working, just have to run a wire from the coil for the rev-counter, but will do this when the loom is out the car for a neater job.

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/clocks.jpg

Also removed the rear suspension and fitted the standard stuff. I have listed parts for sale that I will no longer require.

Thanks,

Shaun.

[Shaun_O'Donnell]

Was struggling to find decent fixings to secure the top of the bumper grill to the front panel. Figured out that I could use the rear number plate fixing, however there are only 2 and needed 3, so fitted the 2 and trawled the scrappies for another. As expected, very few Novas, in fact just the one and it had these fixings removed, but I did score a rear number plate light assembly. Searched around for an hour to see if any other models has these fixings, no luck there. Then came accross the Frontera, unscrewed the rear plate and woo hoo!! The tailgate was locked so a brick through the window and off with the rear panel to release the fixing. Well chuffed. Also managed to get the side repeater rubbers as mine were badly perished and was going to just get aftermarket repeaters, but now that I have these the originals, albeit clear, will be staying.
http://i73.photobucket.com/albums/i203/Shaun_ODonnell/fixing1.jpg
http://i73.photobucket.com/albums/i203/Shaun_ODonnell/fixing2.jpg
These screws are off a Nova, but I can't remember where.
http://i73.photobucket.com/albums/i203/Shaun_ODonnell/fixing3.jpg
http://i73.photobucket.com/albums/i203/Shaun_ODonnell/scrappyfind.jpg

[Shaun_O'Donnell]

Now that I am missing the rear number plate fixings, I'm thinking of re-locating the number plate and smoothing and filling the rear panel.
What do you think?
Before:
http://i73.photobucket.com/albums/i203/Shaun_ODonnell/rearphotoshop.jpg
After:
http://i73.photobucket.com/albums/i203/Shaun_ODonnell/Copyofrearphotoshop.jpg
Please let me know what you think?
Thanks,
Shaun.

[Shaun_O'Donnell]

Decided to smooth the rear panel anyway, can always stick the plate back there if I don't like it and it won't make any difference. Just have to make the decision before I go cutting the bumper to fit the number plate light to it's underneath. Anyway, got cracking today. Backed the car into the garage so I was closer to the TV and stripped it down.
http://i73.photobucket.com/albums/i203/Shaun_ODonnell/beforerubbing.jpg
Got myself one of these from B & Q. Did have a wire wheel in my hand until I came accross this.
http://i73.photobucket.com/albums/i203/Shaun_ODonnell/whatiused.jpg
It takes the paint off a treat with minimum mess and damage to the metal. Well chuffed with the results after a few minutes.
http://i73.photobucket.com/albums/i203/Shaun_ODonnell/paintrubbedaway.jpg
I only have to fill a couple of millimeters, plus the 2 holes and since the panel is reinforced from behind I am happy to go with just fibreglass matting.
http://i73.photobucket.com/albums/i203/Shaun_ODonnell/leaveovernight.jpg
Will leave that to go off before rubbing down, applying some filler and smoothing over. The 4 previously drilled holes where the plastic panel was fixed will just be welded up.

[Shaun_O'Donnell]

The boot lid will also be smoothed so that involves removing the lock. Something I have not seen done very often on a saloon so here goes. Decided to go for a manually operated mechanism, so set about creating the lever for the lock mechanism.
http://i73.photobucket.com/albums/i203/Shaun_ODonnell/lock1.jpg
Had to widen the slot where the key barrel goes in to make way for 2 thin screws. Note the 2 holes drilled in the angled bracket and the buffed down screw heads and washers.
http://i73.photobucket.com/albums/i203/Shaun_ODonnell/lock2.jpg
Screws installed with washers added. Pics very blurry, sorry...
http://i73.photobucket.com/albums/i203/Shaun_ODonnell/lock3.jpg
Bracket added. I had previously worked out the rotational action required to open the lock and the position the cable would pull on it, hence the offset angle of the bracket.
http://i73.photobucket.com/albums/i203/Shaun_ODonnell/lock4.jpg
http://i73.photobucket.com/albums/i203/Shaun_ODonnell/lock5.jpg
Bolted down with the smallest nyloc nuts I could find.
http://i73.photobucket.com/albums/i203/Shaun_ODonnell/lock6.jpg
Lock installed with barrell still removed. I can still open the lock from the outside via a philips screwdriver at this point.
http://i73.photobucket.com/albums/i203/Shaun_ODonnell/lock7.jpg
This is the position of the lever when the lock is open.
Climbed inside the boot and shut the boot to check everything was ok.
http://i73.photobucket.com/albums/i203/Shaun_ODonnell/lock8.jpg
A flick of the lever and the boot opens. Not a lot of force required to operate this so will have to spring it quite heavily to counteract the resistance on the cable.
http://i73.photobucket.com/albums/i203/Shaun_ODonnell/lock9.jpg
Now, as this will be opened from inside the car the boot will just fly open as the boot springs are not dampened. So rather than fit gas struts I have just made a spacer for the LH boot spring.
http://i73.photobucket.com/albums/i203/Shaun_ODonnell/springmod.jpg
It's perfect just now to open the boot gracefully, but could need adjusting once the weight of the cable and plating over the lock is added.
Job tomorrow is to fit the cable and route it into the car. Will probably dig about at the scrappies again for a release handle from a Civic or Impreza or something.
Cheers,
Shaun.

[Shaun_O'Donnell]

Today, sourced the bits and pieces I'd need to complete the first part of the boot release. Having to do this in 2 halves as I'd struggle to find a long enough cable and want to have a spring return halfway.

So after the weekly shop stopped in at Halfords for some gear cables and brake accessories. Having worked as a cycle mechanic for many years and being a keen cyclist, I knew exactly what I was after. The cables are teflon coated to reduce friction and are also pre-stretched, any left overs will be kept for my bike. Stopped by B&Q again for a load of washers and repair strips, oh and a plate holder.

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/parts.jpg

Started by fixing the cable stop at the lock. And also a return spring which is from the plate holder.

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/cable1.jpg

Then routing the cable.

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/cable2.jpg

Drilling and cable tying as I go, being careful not to damage the outer skin with the drill bits as the two skins are very close.

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/cable3.jpg

I have to overcome the fact that the cable needs to be loose as it will travel with the hinge but be secured to the inner panel. So have coiled it up as loosley as possible to reduce friction on the cable.

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/cable4.jpg

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/cable5.jpg

Adjusted the cable as required, the lock opens with only 40mm pull on the cable. I do not know how much pull the lever I will use will give, but the way I have done it, it won't matter as the front cable can be fixed to the lever anywhere. Have also formed a stop and sprung this lever to. With the rear light removed, I can reach in, push the lever and the boot opens slowly.

[Shaun_O'Donnell]

Also finished off the smoothing of the rear panel and the boot lid.

Prepared the fibreglass for filler with that thing I got from B&Q yesterday. Then applied the filler. Whilst that was going off I cleaned the lock hole down to bare metal using a combination of that thing I got from B&Q, sandpaper and a sharpened small flat screwdriver.

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/boot1.jpg

My loving wife kindly took the bootlid round to a mates to weld a plate over the hole, whilst I rubbed down the filler for another thin coat, then rubbed down and a quick coat of primer.
With the bootlid back, applied a thin layer of filler over the plate.

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/boot2.jpg

Again, same process as before.

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/boot3.jpg

[Shaun_O'Donnell]

Cheers for the comments guys. Will update this thread with regards to suspension hopefully tomorrow when I get tyres that fit. Should also be completing the boot release and the rear panel smoothing.

Arrived today:

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/Newplate.jpg

Very chuffed with these!

Shaun.

[Shaun_O'Donnell]

A few updates:

1st - Boot Lock.

Forgot I had old Nova door handles lying around so decided to keep things GM.

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/Handle1.jpg

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/Handle2.jpg

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/Handle4.jpg

And completed the rest of it and all is working beautifully.

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/cable6.jpg

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/cable7.jpg

[Shaun_O'Donnell]

2nd - Boot smoothing.

Was a really nice day today so finished the boot and put all back together. Going to be using the car as much as I can this week to empty the fuel tank. So wanted it looking a bit presentable.

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/Finishedboot.jpg

[Shaun_O'Donnell]

3rd - Coilovers.

These arrived earlier in the week.

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/Coiloverparts.jpg

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/chassis2.jpg

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/oldsuspension.jpg

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/rearfitting.jpg

Fitted the rears, no problems there, but the tyres slightly rubbed on the springs. So fitted 5mm wheel spacers and thought all my problems were over.

The fronts went on ok after a bit of confusion about the correct assembly, but my tyres rubbed by miles.

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/OSstrut.jpg

Decided the cheapest option would be to try and fit the Avons that are on my Volvo. Swapped over and still rub.

Removed the tyre to see what clearance I had and it's not much.

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/rimclearance.jpg

Went down this morning to try 185 wide tyres, but again they still do not clear.
So ventured home and decided to fit the original wheels.
But in having to do so, the brakes need to be changed.

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/soliddiscs.jpg

And on with the old wheels and wheel trims. And I must say. I love the look of this now........

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/slammed1.jpg

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/slammed2.jpg

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/slammed3.jpg

What do you think???

[Shaun_O'Donnell]

Weekends progress was as follows:

First job was to remove the coilovers and driveshafts and fit the original suspension back in.....again.....

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/Driveshaftsout.jpg

Went to the scrappies and bought strut tops so I didn't have to keep taking the struts apart. These, along with the rears are now stored out of harms way.

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/coiloversout.jpg

Removed the front end and stored parts as I went along.
http://i73.photobucket.com/albums/i203/Shaun_ODonnell/wingsoff.jpg

Dashboard was next to come out.

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/dashout1.jpg

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/dashout2.jpg

And to round off Saturday disconnected the interior wiring loom, pulled it round to the front of the car so I could check that the rev counter worked. Earthed the loom to the slam panel, connected a wire from the coil to the rev counter.

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/revcountertest1.jpg

Started the engine with a screwdriver and hey presto a working rev counter.

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/revcountertest2.jpg

Well Chuffed...

[Shaun_O'Donnell]

Meanwhile, my cat was enjoying himself.

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/catenjoyinghimself.jpg

[Shaun_O'Donnell]

Because it won't be long before I can only work on the car in the garage due to the scottish weather, thought I'd best wash the crud off the inner wings to keep things clean.

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/innerwingswashed1.jpg

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/innerwingswashed2.jpg

Tonight, removed the loom from the car and set about making my rev counter wire.

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/revcounterwiring1.jpg

Positioned the wire where it would connect to the rev counter and ran it into the loom to a redundant wire that would normally feed the bonnet lamp. Where it comes out the other end, cut back into the loom to splice with the green coil wire. All taped up and tested the curcuit.

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/revcounterwiring3.jpg

Job done.

Coiled up the loom to store away.

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/wiringcoiledup.jpg

Thoroughly enjoying this.

[Shaun_O'Donnell]

:thumb:

You're welcome mate.

Update from yesterday, but no pics.

Removed the exhaust, had to cut it off in the end, was hoping too much that it would come apart even after being on the car 20 years.

Un-done the handbrake cable which did come apart like it was brand new, and removed the fuel tank and fuel line.

Re-connected the handbrake cable.

Next job will be to drain the coolant and remove the radiator and pipes, then the engine's coming out.

Shaun.

[Shaun_O'Donnell]

Tonight, removed all the coolant pipes and radiator, plastic panel around the radiator and heater matrix. Managed to catch all the coollant in a basin, purely down to the long hose along the bottom of the radiator.

Just a few up close pics of how it's looking.

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/STA60050.jpg

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/STA60051.jpg

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/STA60052.jpg

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/STA60053.jpg

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/STA60054.jpg

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/STA60055.jpg

To free up my overflowing magnetic trays, bought this from B&Q earlier today and sorted all the bits and bobs out.

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/STA60056-1.jpg

Will have the engine out at the weekend.

[Shaun_O'Donnell]

Well after a very unproductive day at work I thought I'd make my evening as productive as possible, so the engine's now out.

Used a method that's served me well whilst doing it on my own (ahem) and without an engine crane.

Drop the car on the deck, unbolt the engine, jack the car back up, pull the engine out from under the car. Start to finish, took just over an hour with no problems.

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/STA60049-2.jpg

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/STA60050-1.jpg

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/STA60051-1.jpg

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/STA60052-1.jpg

Also went down again to discuss prices for the respray with my painter and I am looking at around ?1200 which I am chuffed with. He is quite excited about doing the job as the majority of his day to day work is newer car and just body repairs.

I am looking forward to this very much when it goes off to paint.

Shaun.

[Shaun_O'Donnell]

Today, glorious weather, ideal for getting to the final stripping stages.

Came out to the garage this morning to find my engine bleeding after it's removal yesterday.

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/STA60049-3.jpg

Removed the steering rack, steering column, pedal assembly, brake master cylinder, front brakes in their entirity, all the glass (which is the first time I've removed a windscreen without braking it so I'm pretty chuffed) and loosened all the front suspension arms so they can all be removed when the bay is being painted.

Pic of the brake pipes before they are removed.

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/STA60050-2.jpg

My loft is full, so having to store parts in the garage until I find somewhere else. Might keep stuff under my desk at work. hmmmmmmmmmm

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/STA60051-2.jpg

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/STA60052-2.jpg

All the glass out, just got the black sealant to remove.

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/STA60053-1.jpg

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/STA60054-1.jpg

The inside with everything out now.

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/STA60055-1.jpg

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/STA60056-2.jpg

Just the roof gutter trim to remove, then it's body prepping.

Cheers,
Shaun.

[Shaun_O'Donnell]

Yesterday, removed the roof lining and "A" & "B" pillar trims and got stuck (literally) into removing the black sealant for the front windscreen.

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/STA60049-4.jpg

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/STA60050-3.jpg

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/STA60052-3.jpg

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/STA60053-2.jpg

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/STA60054-2.jpg

Also made a start on de-greasing the engine bay, messy, messy job, but the worst is off now.

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/STA60055-2.jpg

With the black sealant gone...

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/STA60056-3.jpg

Final pics of the day.

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/STA60057.jpg

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/STA60058.jpg

The car is so light now, was able to lift it right over hard against the garage wall.

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/STA60059.jpg

Cheers,

Shaun.

[Shaun_O'Donnell]

Today, removed the last of the windscreen sealant, the gutter trims and sealant, then moved the car out onto the driveway, rolled it up onto ramps and removed the rear brake pipes.

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/STA60049-5.jpg

Where can you store intact brake pipes? hmmmmmmmmm












Nail them to the wall!!!!!!

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/STA60050-4.jpg

Power washed the underside of the car and the engine bay and now it's gleaming. Well, almost...

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/STA60051-4.jpg

Next job is body preperation.

Cheers,

Shaun.

[Shaun_O'Donnell]

Progress this week seems slow and un-rewarding.

So far I have rubbed down the roof, A & C pillars, scuttle panel, front panel and inner wings. The engine bay work is killing me at the moment, but want to get it over and done with as soon as. Just got the Bulkhead to do then it's back to flat panel preperation. All areas with any sign of surface rust or cracks in the paint are being taken back to bare metal.

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/STA60052-4.jpg

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/STA60051-5.jpg

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/STA60050-5.jpg

I knew the car had some front end damage, but only once I dug out quite a lot of filler on the front panel did I realise the extent of it. All areas on the front panel which have now had 5 coats of red-oxide were stripped back to bare metal. The damage was more over a large area than to an excessive depth. But as I am fitting the lower valance this will be unseen, so I'm not going to smooth it all back over.

[Shaun_O'Donnell]

Today, tackled the battery tray. Removed the tar like sound deadening stuff along with some of the seam sealer revealing no rust as hoped.

Before:

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/STA60051.jpg

After:

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/STA60049-6.jpg

Then a couple of coats of red oxide:

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/STA60050-6.jpg

Next job was to sort the small patches of rust on the offside, a few bubbles on the bottom edge of the door, thankfully nothing serious, but a few on the sill which concerned me before I starting digging. I knew that the car had had a few accidents, but my findings today showed the extent of this. The full off-side quarter panel has been replaced at once stage of it's life.

The C-pillar:

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/STA60051-6.jpg

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/STA60052-5.jpg

The sill where the rust was:

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/STA60053-3.jpg

Then on to the quarter panel:

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/STA60054-3.jpg

Arch lip returned to bare metal, no rust:

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/STA60055-3.jpg

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/STA60056-4.jpg

And a coat of red-oxide:

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/STA60057-1.jpg

Near side is next....

[Shaun_O'Donnell]

Update tonight is, well as my last post said the near side and I thought I'd blitz it.

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/STA60049-7.jpg

Few spots of rust on the sill, nothing major.

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/STA60050-7.jpg

No issues with this quarter panel at all.

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/STA60051-7.jpg

Arch cleaned up really well.

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/STA60052-6.jpg

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/STA60053-4.jpg

Just got the front half of the sill to do and then it's the bulkhead next.

Don't have to do the near side door as it's getting a new skin.

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/STA60054-4.jpg

Cheers,

Shaun.

[Shaun_O'Donnell]

Finally got all the body prepped and wiped clean with panel wipe.

I took this to work with me on Friday and polished it. (quite quiet at work at the moment so thought i'd keep myself busy)

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/STA60049-8.jpg

Have painted my brake servo a nice shade of metallic gold.

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/STA60050-8.jpg

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/STA60051-8.jpg

Along with the blanking plate.

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/STA60052-7.jpg

Then it was off with the front suspension arms for a clean up and a wee touch up at the bolted ends.

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/STA60053-5.jpg

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/STA60054-5.jpg

Today, dropped the rear beam out to clean it up and give the drums a paint.

Before:

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/STA60055-4.jpg

After cleaning:

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/STA60056-5.jpg

Just found one wee spot on the body needing a rub down and am going to re-skim the bootlid lock hole with filler as I'm not 100% happy with my 3rd attempt last night.

I have re-done the back panel and am happy with that.

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/STA60057-2.jpg

Got the garage all cleaned up, floor washed etc etc. Car goes away in 2 weeks for paint.

[Shaun_O'Donnell]

Not done anything to the car all week as there was nothing really to do and I was on my bike every night.

An idea sprung to mind at the start of the week whilst at work and that was to build myself a workbench which would fit in the garage along with the car. So designed it on the computer (I'm a draughtsman BTW), ordered the timber and fixings on Friday and started building yesterday.

Moved the Nova out onto the driveway and covered it up as rain was expected

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/STA60051-9.jpg

Bolts all ready and washered up

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/STA60049-9.jpg

Timber arrived, so lets get going

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/STA60052-8.jpg

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/STA60053-6.jpg

Castors I bought off eBay earlier in the week

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/STA60054-6.jpg

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/STA60055-5.jpg

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/STA60057-3.jpg

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/STA60056-6.jpg

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/STA60058-1.jpg

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/STA60059-1.jpg

Just enough room to drive the car under. Will be easier when the car is back on coilovers.

[Shaun_O'Donnell]

Car related work carried out was:

Exhaust cleaned up ready to be used again.

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/STA60060.jpg

Gearbox removed from the engine and drained the transmission fluid out

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/STA60061.jpg

Clutch & starter out, starter needs new electrical connections

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/STA60062.jpg

Some transmission fluid did leak out

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/STA60063.jpg

My other cat was curious about what was going on

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/STA60064.jpg

New connections on the starter

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/STA60065.jpg

Timing chain cover removed for clean up

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/STA60067.jpg

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/STA60066-1.jpg

The cork seal around the altenator belt pulley is perished so will need re-newing. Wonder how hard that is going to be to find

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/STA60068.jpg

As I left things tonight

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/STA60069.jpg

[Shaun_O'Donnell]

Update from the last few days.

New clutch arrived

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/STA60049-10.jpg

On with it

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/STA60054-7.jpg

Wire brushed the gearbox to get off the corrosion ready for painting

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/STA60051-10.jpg

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/STA60052-9.jpg

Timing Chain cover painted

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/STA60053-7.jpg

Various bits and pieces cleaned and painted

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/STA60056-7.jpg

Gear linkage cleaned and painted

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/STA60059-2.jpg

Decided to re-position the cable assembly for the boot lock, mounted it on the back side of the panel so that I can trim this out easier.

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/STA60057-4.jpg

Had to bring the bootlid back to check it all still worked

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/STA60058-2.jpg

Will get paint for the gearbox today and hopefully my timing chain kit arrives so I can get started on cleaning up the engine.

Shaun

[Shaun_O'Donnell]

This arrived today, but am stumped as to how to fit the cork ring seal into the timing chain cover.

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/STA60049-11.jpg

As you can see I have had an attempt at it with a hold punch and hammer, but nothing seems to be budging, not that I know how it comes apart, if it comes apart.

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/STA60052-10.jpg

Decided to leave it for now until I find out how to do it properly so the gearbox got a lick of paint.

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/STA60050-11.jpg

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/STA60051-11.jpg

Am kind of stuck for things to do now until I get the timing chain cover back on the engine.

[Shaun_O'Donnell]

Yesterday, lifted the engine up onto the bench to fit the new timing chain kit and give it a clean up. Will replace the water pump, inlet, exhaust and rocker cover gaskets.

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/STA60051-12.jpg

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/STA60053-8.jpg

The gearbox got another lick of paint and removed the inlet and exhaust manifold and rocker cover for clean up and paint. The water pump seems ok, but will replace it as they're not expensive.

Exhaust manifold will get another coat of High temp paint today.

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/STA60055-6.jpg

Test fitted my exhaust on the car and all is well. Sourced the front pipe from ebay ?10 and the centre section from a Tyre & Exhaust fitter ?35. The rear box is the original off the car.

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/STA60052-11.jpg

[Shaun_O'Donnell]

Assembled the gearbox back together.

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/STA60055-7.jpg

Exhaust manifold got another coat, inlet manifold got 2 coats (silver), rocker cover (black) and cleaned up the hot air feed.

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/STA60058-3.jpg

Managed to get my hands on a heavy duty bench vice

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/STA60056-8.jpg

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/STA60057-5.jpg

[Shaun_O'Donnell]

Tonight's progress is 24 hours behind for 2 reasons.

There was a delay getting my gaskets and water pump and the radiator let go in the Astra, so had to get stuck in to that last night. Still no where forward as the radiator I got today isn't the correct one.

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/STA60063-1.jpg

So this lies abandoned on the driveway and the wife is having to use my car as she works further away than me.

Also, check the condition of this, pretty fooked.

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/STA60062-1.jpg

?212 for a new one from vauxhall, needless to say this will be repaired closer to the time when the Air-Con will be required.

So tonight, got the engine off the bench and put back together. Was easier getting it down than lifting it up, funny that!

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/STA60055-8.jpg

New bits

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/STA60056-9.jpg

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/STA60057-6.jpg

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/STA60058-4.jpg

Great Idea to compress the clutch in order to remove the clips.

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/STA60059-3.jpg

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/STA60060-1.jpg

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/STA60061-1.jpg

Very little left to do now, but I'm sure I'll find bits here and there.

[Shaun_O'Donnell]

Progress has dwindled to nothing now as the car is now in the paint shop and everything else has been done.

The last few jobs I had to do were, grind off all the rust from the anti-roll bars and paint them, clean up the steering rack and paint and remove all the windscreen sealant from the rubber seal.

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/STA60065-1.jpg

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/STA60064-1.jpg

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/STA60066-2.jpg

Shaun.

[Shaun_O'Donnell]

Had to dig this out and give it a clean and paint.

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/wipermotor.jpg

Have now run out of things to do, will have to do Christmas shopping now........

[Shaun_O'Donnell]

Not a huge amount has happened, went down this morning to see the car and take a few pics.

The car now takes pride of place within the paint booth as the TR7 that was in front of it in the queue is almost finished.

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/Other%20Cars/STA60011-1.jpg

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/STA60010-1.jpg

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/STA60009.jpg

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/STA60008.jpg

Also got the first glimpse of the paint.

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/STA60012-1.jpg

My GTE front seats are now at the upholsterers to get re-trimmed in the grey tweed to match the back seats. The headrest holes are being covered over as I'm ditching the headrests. The seats should be ready by the end of January.

[Shaun_O'Donnell]

I am re-fitting the stereo blanking plate that you can see in this photo.

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/Saloon%20Early%20Pics/STA60036.jpg

So will be re-locating the head unit to the glove box, so a little trimming in MDF is required.

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/STA60010-3.jpg

Have cut the back off the glove box for access.

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/STA60009-2.jpg

Still have a little space for gloves on the left of the head unit.

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/STA60008-2.jpg

Just have to take apart and cover in accoustic felt and that's another job done.

[Shaun_O'Donnell]

Forgot to mention, can't wait to put this back together so I can use my Christmas presents.

The wife got me these:

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/Home/STA60012-2.jpg

And this:

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/Home/STA60014-1.jpg

My Mum got me these:

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/Home/STA60013.jpg

I'm well chuffed.

[Shaun_O'Donnell]

Dismantled ready for re-trim.

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/STA60014-2.jpg

Apologies for not taking photos along the way, hands were a bit gummed up.

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/STA60015.jpg

Was a tight fit getting this all back in there with the additional thickness of the carpet. Pretty chuffed with the results.

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/STA60016.jpg

As I was in a trimming mood, the parcel shelf thingy got the same treatment.

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/STA60017.jpg

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/STA60018.jpg

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/STA60019.jpg

The 6x9's with be mounted below and not protrude at all.

[Shaun_O'Donnell]

"Finally" I hear you cry, there's paint on the car.

Ok, it's just the engine bay and boot lip, but it's a start. Hopefully have the shell painted this time next week.

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/STA60015-1.jpg

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/STA60016-1.jpg

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/STA60017-1.jpg

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/STA60020.jpg

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/STA60019-1.jpg

The valance has just had a guide coat to highlight any imperfections, but all is ok so it'll get flatted and painted again.

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/Other%20Cars/STA60018-1.jpg

The inside isn't being painted as apart from the doors, there will be not metal exposed.

I am chuffed as a chuffed thing.

Shaun.

[Shaun_O'Donnell]

Went to collect the car at 10am on Saturday, was home with it and ready to work on it by 11am, engine was in by 12pm. Then in went the rear brake pipes & brake master cylinder, fuel tank, exhaust, pedal box, steering rack. Wiring loom went in this morning at 5am along with the radiator. Had to go shopping but got ?5's worth of fuel, back at 10am, engine was running at 11.40am after having to suck the fuel through the lines as the pump was taking forever and draining the battery due to cranking over for ages. Then onto the A & B pillar trims which is accoustic cloth, then on with the roof lining which is only fixed on the passenger side, waiting for this to dry before tensioning across to the drivers side. Will fit the passenger door rubber and rear passenger window first before doing so. Rear bumper is on along with the rear lights (cheers Steve for the Euro-Fog). Pretty much that's it so far.

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/STA60009-4.jpg

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/STA60010-5.jpg

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/STA60011-2.jpg

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/STA60012-3.jpg

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/STA60013-1.jpg

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/STA60014-3.jpg

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/STA60015-2.jpg

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/STA60016-2.jpg

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/STA60017-2.jpg

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/STA60018-2.jpg

[Shaun_O'Donnell]

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/STA60019-2.jpg

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/STA60020-1.jpg

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/STA60021.jpg

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/STA60022-1.jpg

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/STA60023-1.jpg

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/STA60024-1.jpg

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/STA60025-1.jpg

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/STA60026-1.jpg

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/STA60027-1.jpg

[Shaun_O'Donnell]

Got a new thermostat, alternator (& water pump) belt and new jubilee clips today so I could get some coolant in there and get the engine running for good. Started first time, then started smoking like a chimney. As expected, the paint on the manifold was not up to the job and is starting to blister. Anyhoo, got up to temp and all the air is out the coolant system now.

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/STA60011-3.jpg

Got the carpets in and trimmed around my boot release handle.

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/STA60009-5.jpg

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/STA60010-6.jpg

Then in went the passenger door seal and rear side window to keep the roof cloth in place.

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/STA60012-4.jpg

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/STA60013-2.jpg

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/STA60014-4.jpg

Happy so far with how the roof cloth is looking.

Have glued the drivers side roof cloth down around the windscreen and fitted the drivers door seal. The windscreen is going in tomorrow. Then the rest of the roof cloth will get glued down.

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/STA60015-3.jpg

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/STA60017-3.jpg

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/STA60016-3.jpg

Getting there......

[Shaun_O'Donnell]

Been a little disheartened last week as on Tuesday, broke the windscreen whilst fitting it. Also had a few electrical gremlins that took unexpected time to sort.

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/STA60010-7.jpg

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/STA60011-4.jpg

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/STA60012-5.jpg

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/STA60013-3.jpg

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/STA60014-5.jpg

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/STA60015-4.jpg

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/STA60016-4.jpg

New windscreen supplied, fitted and guaranteed by Autoglass:

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/STA60018-3.jpg

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/STA60019-3.jpg

[Shaun_O'Donnell]

Got a nice little pair of speakers for the dash - Blaupunkt BGx 402 HP, very nice speakers.

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/STA60020-2.jpg

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/STA60021-1.jpg

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/STA60022-2.jpg

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/STA60024-2.jpg

Got the rest of my panels home on Saturday, stored them inside out the way "Yeah Right!" said the wife!

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/STA60025-2.jpg

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/STA60026-2.jpg

Will probably get a stainless exhaust made up, but this'll do in the meantime.

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/STA60027-2.jpg

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/STA60028.jpg

[Shaun_O'Donnell]

Start puting the panels on:

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/STA60029.jpg

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/STA60030.jpg

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/STA60031.jpg

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/STA60032-2.jpg

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/STA60033-1.jpg

New Headlamps, cheers Matt2107

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/STA60034-2.jpg

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/STA60035-1.jpg

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/STA60036-1.jpg

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/STA60037-2.jpg

Seats in, they are a little lighter than the rears, so will probably have the rears done to match.

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/STA60038-2.jpg

[Shaun_O'Donnell]

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/STA60039.jpg

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/STA60040.jpg

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/STA60041-2.jpg

Just got the drivers door left to fit, drill a hole for the drivers side-repeater, then I can start on the boot.

Cheers again for all the comments.

[Shaun_O'Donnell]

Well, not got a lot left to do now.

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/STA60015-5.jpg

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/STA60016-5.jpg

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/STA60017-4.jpg

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/STA60022-3.jpg

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/STA60023-2.jpg

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/STA60024-3.jpg

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/STA60025-3.jpg

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/STA60026-3.jpg

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/STA60027-3.jpg

[Shaun_O'Donnell]

Took a half day off work today since it was decent weather. Finished up the last few little jobs that I would struggle to do in the garage due to lack of space. Washed the car down, hoovered inside and cleaned all the glass.
Took it for a wee test drive (just up the street and back), brakes needed bleeding slightly, then got some almost finished pics.

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/STA60028-1.jpg

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/STA60029-1.jpg

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/STA60030-1.jpg

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/STA60031-1.jpg

The last 2 jobs to do are:
1) Sort out my boot install (will start it this weekend)
2) Finish re-furbing my Cav GSI Alloys, which will need spacers to clear the coilovers.

Once again, thanks very much for all the comments.

Shaun.

[Shaun_O'Donnell]

Finished up the boot this weekend.

Started by making a timber frame for the side panels.

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/STA60001-2.jpg

Then made up some cardboard templates

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/STA60002-2.jpg

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/STA60003-1.jpg

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/STA60004-1.jpg

Transferred the outines onto 18mm MDF along the back of the seats and 4mm Hardboard for the sides.

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/STA60005.jpg

Carpeted it up and fitted the subs and amp.

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/STA60006.jpg

Carpeted the arches then fitted it all in.

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/STA60007-1.jpg

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/STA60008-4.jpg

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/STA60009-6.jpg

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/STA60010-8.jpg

The side panels are held in place with velcro to so visible fixings are seen. You can still see a little blue behind the hinges, so next time I have nothing to do, going to take the sides back out and carpet behind there.

Cheers for all the comments,

Shaun.

I'm away for a sleep now. zzzzzzzzzzzzzzz

[Shaun_O'Donnell]

Since last update, I have went round the car touching up (oooeer) any imperfections in the paint, I have fitted a red stripe to the bumpers and the most noticeable is the wheels.

Thanks to Vaughan, they fit a treat, no spacers on the rear and only 3mm on the front. I will probably space out the rears 5mm to increase the track width, still plenty of room under those arches.

I'm chuffed with how it looks.

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/STA60006-1.jpg

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/STA60005-1.jpg

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/STA60004-2.jpg

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/STA60003-2.jpg

Almost finished........

[Shaun_O'Donnell]

Puting the car on the road next week so need to finish up the last few jobs so:

16v brakes fitted back on...

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/STA60003-3.jpg

My early SR steering wheel which arrived yesterday..

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/STA60004-3.jpg

Is now fitted.....

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/STA60005-2.jpg

Which just leaves me to sort the slight blow from the exhaust centre join tomorrow evening. Then it's insurance to sort, MOT to book then get Tax and it's back on the road.

[Shaun_O'Donnell]

M.O.T. at 10am today. Taking it to my local Vauxhall dealer to see if I get any comments, ha ha.

[Shaun_O'Donnell]

Cheers Guys,

Well, the car passed with flying colours and generated a lot of interest.

Only down side is, it was pi$$ing with rain on the way home so had to wash it, move it into the garage and then dry it before it made a mess of my floor.

Also, insurance certificate hasn't arrived so can't tax it, hoping it falls through the letter box tomorrow morning.

Cheers again,

Shaun.

[Shaun_O'Donnell]

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/STA60005-3.jpg

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/STA60006-2.jpg

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/STA60007-2.jpg

Still got the other 2 to do........

[Shaun_O'Donnell]

Huge thanks to NOVABIKECARBED who Photoshopped out the camera boom from the photoshoot pics:

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/Finished%20Saloon%20Pics/0147NOBOOM.jpg

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/Finished%20Saloon%20Pics/0143NOBOOM.jpg

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/Finished%20Saloon%20Pics/0135NOBOOM.jpg

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/Finished%20Saloon%20Pics/0133NOBOOM.jpg

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/Finished%20Saloon%20Pics/0132NOBOOM.jpg

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/Finished%20Saloon%20Pics/0149NOBOOM.jpg

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/Finished%20Saloon%20Pics/0152NOBOOM.jpg

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/Finished%20Saloon%20Pics/0156NOBOOM.jpg

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/Finished%20Saloon%20Pics/0157NOBOOM.jpg

http://i73.photobucket.com/albums/i203/Shaun_ODonnell/Finished%20Saloon%20Pics/0158NOBOOM.jpg