Iain's 20XE Trackday Nova

[Iain]

Fly back on with ARPs, and since the whole reason of pulling the engine was to do the clutch after it popped at Oulton Park, on goes a new old stock GM clutch:

http://iainel.co.uk/images/forums/NovaWIP2b/048.JPG

Rready to go home:


http://iainel.co.uk/images/forums/NovaWIP2b/049.JPG

Now this annoyed me after painting my crossmember and bolting on the tiebars the 50mm 3mm wall box started to crush under the bolts. Not good. So 10mm ID 16mm OD tube was cut to length:

http://iainel.co.uk/images/forums/NovaWIP2b/050.JPG

And holes on the underside opened up to 16mm:


http://iainel.co.uk/images/forums/NovaWIP2b/051.JPG

And welded in the tubes:


http://iainel.co.uk/images/forums/NovaWIP2b/052.JPG

The crush tubes are visible from the top, sitting flush with the top of the box to be clamped down by the bolt head:

http://iainel.co.uk/images/forums/NovaWIP2b/053.JPG

[Iain]

On with some engine goodies now the engine's back in, I did buy some Jenvey DTH ITBS but the seller messed me about with a couple of hundred quids worth of missing parts. They had to go back for a refund :(

However I'd got my heart set on binning the standard injection system at this point, so I went down a cheaper route (that I have always professed to hate lol) but still satisfies my tinkering side. Bike carbs!

So I bought an R1 setup off eBay, with new C20XE H&H dizzy/coil/module/leads, and an inlet manifold that was unfortunately fit for the bin :(

Cut down a new H&H dizzy to work with dispack cams in a dizzy engine:


http://iainel.co.uk/images/forums/NovaWIP2b/054.JPG

Replacement inlet manifold from Bogg Bros:

http://iainel.co.uk/images/forums/NovaWIP2b/055.JPG

Looking good:


http://iainel.co.uk/images/forums/NovaWIP2b/056.JPG

Mmmm nicely finished:

http://iainel.co.uk/images/forums/NovaWIP2b/057.JPG

They even have machined ends to suit the standard R1 rubbers which give a lovely positive fit compared to silicone hoses:


http://iainel.co.uk/images/forums/NovaWIP2b/058.JPG

Trial fit of it all:

http://iainel.co.uk/images/forums/NovaWIP2b/059.JPG

I wanted to retain the original water ways, so I needed to find a way of mating up these two:


http://iainel.co.uk/images/forums/NovaWIP2b/060.JPG

Got some steel reinforced 22mm silicone hose and joiners, cut down the 3 way hose and joined them all up (had to crush the bottom hose a bit to go down to 22mm so might do something else here yet, got a 28mm-22mm reducer and joiner to try out)

http://iainel.co.uk/images/forums/NovaWIP2b/061.JPG

Decided to do away with the original wobbly smaller water hose in favour of this, and neatened up the oil cooler pipework, and shortened the radiator bottom hose as the rad has moved over:


http://iainel.co.uk/images/forums/NovaWIP2b/062.JPG

Manual choke goodness lol

http://iainel.co.uk/images/forums/NovaWIP2b/063.JPG

Connected to the carbs with a little 6mm solderless nipple:


http://iainel.co.uk/images/forums/NovaWIP2b/064.JPG

[Scottcooper85]

Excellent!!!

im glad you connected that waterway up before I got round to mine so I can see how you've done it lol
will you be posting up some videos of it running up?

[Andy]

Cracking stuff

[ben doodar]

excellent work mate carbs look cool and the crossmember is really nicely done.

give that man a blue peter badge!

[Benn]

Looking very good dude.

[BRoadGhost]

I used a piston stop & took the reading from the crank to find TDC; spent hours getting the cams dialed in to kent AST1612 figures only to find on the rollers the inlet can was advanced quite a bit each time for more power ~ to the point where it was still going up but on standard pistons valves were going to be touching advancing much more.

[Iain]

Did your exhaust cam end up advanced too? Just checking I've not totally done it wrong.

My autosprint pistons have slightly larger valve pockets :) I wasn't planning on touching them again just setting them better than before. It ran fine before and I'm sure it was quite a way out from their figures.


Cheers all videos will be made. Just wondering what initial settings to put the carbs at to get it running safely. Total Vauxhall suggest drilling the jets to 1.8

[josh-sri]

Cracking progress Iain, I love that front crossmember, I really should do something similar but haven't plucked up the courage to start cutting mine out yet.

[Adam]

Inlet looks top notch.


Should be fitting bodies tho!!!!!

[brucer]

top work iain, have been enjoying you updates recently so keep it up.

[turbojolt]

easy for everyone to say you need throttle bodies when it isn't their bank account 3/3.5k is coming out of lol

[BRoadGhost]

Just the inlet cam; with the 6 bolts undone on the pulley undone everything else stays where it is (crank exhaust) with the belt in place.

If I'm honest I can't wait to have the money to put 12.5:1 pistons in it, but I can't see the hydraulic lifters liking 8500 that often lol

I'm on webers so can't comment on bike carbs.

[Iain]

Know what you're talking about the inlet cam but figured you'd set up the exhaust cam as per Kent's recommendations too...

[Will F]

I always used to hate bike carbs, just thought it was a pikey way of the engine just making a better sound... Then I bought a Corsa b to break with some that had been set up properly and it was an absolute hoot to drive, totally changed my opinion.
Ok, they aren't going to get the best figures, but pound per horse it's worth doing.

[BRoadGhost]

Everything seemed to go out the window with 40MM chokes & knife edged venturi lol

[Iain]

Done some bits recently, fitted the fuel pump, ripped apart all the wiring, removed unecessary loom plugs from behind the dash and the headlight area, rewired the spotlights, wired up the new H&H coil, modified and tidied up loads of bits...

R1 fuel pump

http://iainel.co.uk/images/forums/NovaWIP2b/065.JPG

Mounted up in the original fuel filter location, fits quite nicely there:

http://iainel.co.uk/images/forums/NovaWIP2b/066.JPG

Since I use an SPI tank and in-tank pump, I've taken out the (now MPI) pump:

http://iainel.co.uk/images/forums/NovaWIP2b/067.JPG

And collected a bunch of bits:

http://iainel.co.uk/images/forums/NovaWIP2b/068.JPG

And made this wonderful bypass piece up, from a spare pump top, 10mm ID hose joined to 13mm hose joined to a 12mm OD steel tube pressed into the filter lol And welded the fuel clip to the hanging bracket for some support, top bodging lol

http://iainel.co.uk/images/forums/NovaWIP2b/069.JPG

My old equal shafts had lots of play on the splines, I don't think they were machined very well, so I've made up a new set of non equal ones:

http://iainel.co.uk/images/forums/NovaWIP2b/070.JPG

All painted and built up:

http://iainel.co.uk/images/forums/NovaWIP2b/071.JPG

Engine bay is loads neater now, H&H coil all wired up neatly and engine bay sensors/starter loom is much neater now too without the XE loom:

http://iainel.co.uk/images/forums/NovaWIP2b/072.JPG

Gauges moved location slightly with lots of M14x1.5 to 1/8 NPT adaptors:

http://iainel.co.uk/images/forums/NovaWIP2b/073.JPG

Universal throttle cable ordered and is a perfect fit to bolt into the standard throttle location:

http://iainel.co.uk/images/forums/NovaWIP2b/074.JPG

Butchered an old cable and relieve it of it's bulkhead union and sprung loaded clip so it can still be removed quickly:

http://iainel.co.uk/images/forums/NovaWIP2b/075.JPG

Engine bay as it stands:

http://iainel.co.uk/images/forums/NovaWIP2b/076.JPG

And behold, it starts and revs nicely, happy days. Going to book it in for set-up now.


https://www.youtube.com/watch?v=BL5YCzqtrdA&feature=youtu.be

[Scottcooper85]

It sounds great! Good job on the tank feed too.

Are you taking it to bogg's for set up or somewhere else?

[Iain]

Thats on standard carbs and random ignition timing too. :)

Its going to torque tune in Ollerton. The guy seems to know his stuff and is very reasonable.

[mowgli]

iain, what did you do with the old electrical connector from the loom to the the spi pump? I need one to fit my new pump/tank

[Iain]

Oh man you did say that didn't you, should have remembered while you were over, let me see if I've got it lying around somewhere

[Balley]

Very nice work!

[Connor]

Nice work Iain as per,
Haven't been on here in ages, but it's come on well since I last look, loving the addition of the R1's!

[Adam]

Nice work Iain.

Have to say runs pretty well saying its not even been setup properly yet. :)

[kevster]

As everyone else has said well done bud

[Benn]

Why are you not gonna run equal lenght shafts?

[BRoadGhost]

The difference is pretty imeadiate

[Iain]

Theyre just some temporary shafts I've built up. My equal shafts suffered wear on the splines and excessive CV play from this. Put some non equal ones on cos that's what I could get hold of and my new equal one is in the process of being made...

[Benn]

Ah i get ya.

[Iain]

Few snaps of what I've been up to, it's now ready for it's R1 setup at the end of the week all going well

I think the Bogg Bros manifold thread for the alternator was in slightly the wrong place so the bracket didn't sit nicely and the belt rubbed the belt cover, so I made up this bad boy:

http://iainel.co.uk/images/forums/NovaWIP2b/077.JPG

Fitted:

http://iainel.co.uk/images/forums/NovaWIP2b/078.JPG

Also plumbed up the vacuum takeoff for the brake servo:

http://iainel.co.uk/images/forums/NovaWIP2b/079.JPG

Plumbed in extinguisher mounted up behind passenger seat:

http://iainel.co.uk/images/forums/NovaWIP2b/080.JPG

Pull cables on the outside with proper stickers:

http://iainel.co.uk/images/forums/NovaWIP2b/081.JPG

Pull cable mounted inside for the electric cut off (sneaks out under the gauges, which unfortunately was necessary due to the angle I've mounted the killswitch:

http://iainel.co.uk/images/forums/NovaWIP2b/082.JPG

Turns out you can open a mudflap bracket slightly with a step drill and the extinguisher nozzle fits in snug:

http://iainel.co.uk/images/forums/NovaWIP2b/083.JPG

Only got the one nozzle for now until I get more pipe and another pull cable to mount the second nozzle:

http://iainel.co.uk/images/forums/NovaWIP2b/084.JPG

All done, back on the floor, ran upto temperature, great oil pressure, fixed one oil leak on a gauge sensor, fixed one water leak on the radiator, runs sweet as a nut so good to go:

http://iainel.co.uk/images/forums/NovaWIP2b/085.JPG

[Scottcooper85]

Looks great, really enjoyed your build thread recently.

need to get my carbs fitted but might leave them while winter, I hope my alternator bracket works now lol another thing I'm now worried about is fitting a filter in as I have the firewall in still and space looks tight.

cant wait to watch/hear a video of you rattle it around blyton:)

[Iain]

Thanks, been doing some interesting stuff recently out my comfort zone which is nice.... Coming up soon, window nets and rear window vents for trackday driver temperature control!

I don't know where my rollcage bar sits in relation to the firewall but I have plenty of room happily.

At Donington first in April, but no doubt be at Blyton at some point in the year.

[8valve-craig]

Blyton 10th May.

[ben doodar]

Great work Iain bet you can't wait to feel the difference in the performance.

Cracking progress mate, its inspiring to read others peoples projects threads.

[Benn]

Love what you've done. LIfeline fire thing looks great. Very good safty add on.

Your alt bracket. i'd move the ground off the bolt in to the head, i dont think it gives enough of a ground. Which is why mine caught fire i think.

Love the rose joints tho.

[TOZNOVA81]

Looking good mate :D

[Gibbo]

looking good mate . were do you plum up the vacuum takeoff for the brake servo.

[Iain]

Benn I think I'll leave it on the top, only because I had a solid alternator bracket on my 1.6 and it sheared off, so don't want to give it any opportunity to 'rock' on the bolt.

Gibbo the vacuum is on a purpose welded union on the Bogg Bros manifold coming off #1.

Well lots happened over Easter weekend, got the carbs and ignition set up on the rollers on Good Friday:

http://iainel.co.uk/images/forums/NovaWIP2b/086.JPG

Unfortunately it was making really poor power and he wasn't sure why. We ended up reverting the cam timing I'd done for a small increase, so I must have ballsed that up. It was still making poor power though.

Half way through the setup it started running on three and found a completely burnt out spark plug:

http://iainel.co.uk/images/forums/NovaWIP2b/087.JPG

However that was that, it was safe fueling and ignition so I drove it home.

Took it for a spin on Sunday and it started running on three again, towed it home and pulled the plugs and found one of the plug gaps had totally closed up (#1):

http://iainel.co.uk/images/forums/NovaWIP2b/088.JPG

Hmmm something funny going on... Fitted some new plugs and still sounded like crap, so maybe it's time for a compression test... Had poor compression on all cylinders and none on #1, great. Maybe it's just the headgasket though?

http://iainel.co.uk/images/forums/NovaWIP2b/094.JPG

Off came the head this evening:

http://iainel.co.uk/images/forums/NovaWIP2b/089.JPG

Looks like it's been leaking between #2 and #3, but not the obvious leak to the oilway on #1 like I'd hoped for:

http://iainel.co.uk/images/forums/NovaWIP2b/090.JPG

...Oh, maybe this relatively minor piston damage could be to blame then!

http://iainel.co.uk/images/forums/NovaWIP2b/091.JPG

http://iainel.co.uk/images/forums/NovaWIP2b/092.JPG

http://iainel.co.uk/images/forums/NovaWIP2b/093.JPG

#1 and #2 are missing a chunk each, #3 is undamaged and #4 is missing two chunks.

I can only assume I've knackered up the cam timing and it's been touching the piston slightly at high RPM. Properly ruined the pistons. Head on initial visual inspection doesn't look damaged but I'll investigate further, may be the difference between a new bottom end or new tall engine, as I'm not sure I can be arsed to get it honed and bed in some new rings.

[brucer]

Jesus iain! Thats a shxtter!

Good lad for cracking on though

[bazzap8389]

Gutted to hear about your misfortunes this weekend mate! Hopefully you get it sorted it problem free.

[burgo]

If it helps with the decision making I've got a set of standard pistons you can have for a cuddle lol

[Iain]

Thanks but unfortunately not Burgo, this was a +1mm block

[Will F]

I would say (at a guess) that the damage could have been caused by the pistons getting really hot and cracking (wrong timing/lean) and then breaking up under load.... (or is that what you suggested earlier? lol)

[scott.parker]

Not been on in ages, just looked through the last few pages, nice Mods with the carbs and extinguisher (everyone forgets these) then I flicked to the last page, mate I'm gutted for you, these things always kick you in the balls when you think your doing well..
Your too far in to stop, so get the engine sorted, get them carbs set and sling up a video of you kicking in its Teath!

[Benn]

I've never seen that happen before. Impressed and gutted for you.

[House]

Keep on it mate.

How much cam timing are you talking about? Do the Verniers allow that much of an adjustment? It's only about half a tooth in both directions isn't it?? Are the valves showing and signs of damage?

I've got 2 spare blocks and 2 spare heads if you need any hardware mate

[turbojolt]

just think about it if you replace the bottom end or the pistons you may have solved the low power gain issue aswell, cant believe this happened seems to be working well when we was out in it :(

[nova_stee]

Never seen a piston break apart like that, if it was lean ad expect it to melt a bit first but that looks brittle

[Edd]

Oh :(

Sure with your skills you'll have it sorted tho

[burgo]

There you go sorted. Block off House, pistons off me and your well away

[House]

One block is +.5 but the other is standard, would be good enough with Mr Burgo's pistons to atleast get it back rolling while you decide what to do with the engine you have, got a standard head here aswell with valves in, could do with a clean but if you need it I'll get that done for you and bring it up, get you back rolling for the summer season!!

[8valve-craig]

Seeing as we are all being charitable il throw in a once used (few hours) Cometic 1.3mm gasket, if you think you can use it.

[House]

And now I think about it I'm sure ive got a water pump and tensioners but I'm guessing you can borrow these bits off the existing engine!!

look at that, between us we've built an XE!! The bugger will probably make 160 horses and last 10 years!!!

[ben doodar]

look at that, between us we've built an XE!! The bugger will probably make 160 horses and last 10 years!!!


Good effort lads team spirit. Ha ha.

[Iain]

Ha ha thanks guys very charitable. I'll give you all a shout what I need when I need bits!

Amazingly it doesn't look like its damaged my block so if I could source some 87mm pistons I could be back running with minimal parts. Was toying with a new bottom end purely to avoid the faff of running in period and bedding in rings.

[House]

Good work mate!!

[turbojolt]

https://fbcdn-sphotos-g-a.akamaihd.net/hphotos-ak-xpa1/v/t1.0-9/1926852_10153180515582118_1595252611207831714_n.jp g?oh=3296461f9f0ce6e2587e0590c0659b6d&oe=55AFE4D4&__gda__=1435993790_52c20585005af06f89f62c032876b90 d

ive got all this that's never going to be used....yours for a soapy tit ****

[nova_stee]

Get some high comp pistons and steel rods and rev the ****er

[Mieran]

I would use a steel head gasket too, from a zlet.

[tom reid]

Any witness marks on the valves or head?

[8valve-craig]

I would use a steel head gasket too, from a zlet.

Zlet are open deck, so not a great idea to use their gasket on a closed deck XE. Just stick with a std one or upgrade to the right Cometic.

[burgo]

Zlet are open deck, so not a great idea to use their gasket on a closed deck XE. Just stick with a std one or upgrade to the right Cometic.
You talk wet!

Almost all high powered zlets run a clet or xe block and still use a zlet head gasket. Using a zlet gasket on anew xe is almost as common these days as using the 8v baffle plate

[8valve-craig]

You talk wet!

Almost all high powered zlets run a clet or xe block and still use a zlet head gasket. Using a zlet gasket on anew xe is almost as common these days as using the 8v baffle plate

I have seen how they can rapidly cause an XE head to corrode, so no thanks.

Use a gasket which matches the alloy heads waterways Ian, just as Vauxhall intended.

[Iain]

Any witness marks on the valves or head?

I've not cleaned them up to check for damage yet, however at least one of the exhaust valves is bent (probably more). It's also on it's last skim and is warped so I'm building a new head, and using my good bits in a new bottom end also.

I have a thicker Cometic for when I found my head was below tolerance, but I'm happy with a standard gasket for now. Going to build a relatively standard engine back up.

[Benn]

How do you know it's warped?

[Iain]

Steel rule over the head and look for light, head gasket has blown between #2 and #3 and I can see why.

[burgo]

I have seen how they can rapidly cause an XE head to corrode, so no thanks.

Use a gasket which matches the alloy heads waterways Ian, just as Vauxhall intended.

If you use anti freeze mixed to the correct ratio it doesn't corrode!

[8valve-craig]

You may be right, but not everyone has just a £50 cylinder head, so for the sake of a few extra pounds lets just use the right gasket shall we.

[Harvey]

I would have to agree with Craig on this one as I run an N/A 220bhp XE and having had the head off a few times with a stock OE gasket installed I've been able to slap it all back together with no corrosion of the water ways at all and the gasket left no residue. I much prefer a £30 gasket to blow than the head get damaged as I know it would cost me around £1K to get the head to the same spec as I have now. Just to add I run the pink longlife coolant which is not recommend for older engines such as the XE but after a flush when it last had a full rebuild in 2008 it's been fine with no coolant related issues.

Anyway back over to Iain as this is his build diary...updates please sir as we all like pretty pictures?

[Iain]

Only update is it's all apart lol

http://iainel.co.uk/images/forums/Misc/rps20150415_153436_999.jpg

Head is being replaced (updates on that when it arrives) and rebuilt with the good bits from my current head (valve springs, lifters, cams).

Bottom end is being replaced with an OE 86mm one (just leave the pistons/rings well alone and hope they're OK), probably with my current balanced crank/new shells/lightened flywheel in & my ZLET pump swapped over.

[Benn]

Is like one of them pics with a rally car stripped to bits. Like it.

Good luck on the new build up, sure it will be much better after.

[bazzap8389]

I like how you don't mess about and just get **** done!

I hope it works as it should after it's built mate.

[kevster]

Looks like your getting stuck in mate , hope you get its sorted

[Andy]

wounded.kept the faith proper though mate,sterling effort.tis the only way mind

[Adam]

S**t news that Iain. Good to see youve cracked on with it though.

[Mazz]

awww man...

just thought i'd check in and i find this :(

Still my favourite thread!

[Iain]

Thanks for the kind words chaps, no point in getting down over these things is there! The only frustration nowa days is having enough time to work on it.

First things first, a bit of a non-update lol Picked up this 20XE bottom end cheapish:

http://iainel.co.uk/images/forums/NovaWIP2b/095.JPG


Good crank, early pistons, but I couldn't clean the rusty bores up to satisfaction:


http://iainel.co.uk/images/forums/NovaWIP2b/096.JPG


So that one is for scrap...



And at the other end of the used engine parts scale, House1983 off here kindly said he'd sort me out a new head, figured I'd have some cleaning and rebuilding to do when a 'free head to help out' arrived.... Maybe not!

http://iainel.co.uk/images/forums/NovaWIP2b/097.JPG


http://iainel.co.uk/images/forums/NovaWIP2b/098.JPG


http://iainel.co.uk/images/forums/NovaWIP2b/099.JPG


Fully cleaned, stripped, pressure tested, skimmed and valves cut/lapped in ready for assembly. Thanks mate I owe you an incredibly large pint, will make it up to you!


So cracked on with building it up:


http://iainel.co.uk/images/forums/NovaWIP2b/100.JPG


Finished and wrapped up ready for a bottom end, with my old lifters and Kent cams:


http://iainel.co.uk/images/forums/NovaWIP2b/101.JPG

[Iain]

Got some gaskets, so a big thanks to Leigh for them!

http://iainel.co.uk/images/forums/NovaWIP2b/102.JPG


Was on holiday down south a few weeks ago and happened to message 8v-Craig to say hi on WhatsApp, ended up dropping in on the way home and stripping an XE for it's bottom end! Good plan until it tipped over on the way home and emptied several litres of used oil in my missus's mum's Corsa D lol Fail!


http://iainel.co.uk/images/forums/NovaWIP2b/103.JPG


Back in the garage and the bottom end got stripped down, Craig was nice enough to sell me one with an early crank and forged pistons, thanks sir!


http://iainel.co.uk/images/forums/NovaWIP2b/104.JPG


Blocked got cleaned inside and out, never removed the pistons and rods so not to disturb their seal with the bores:


http://iainel.co.uk/images/forums/NovaWIP2b/105.JPG


And then painted up:


http://iainel.co.uk/images/forums/NovaWIP2b/106.JPG

[Iain]

All this dawdling about took me until Saturday (2 days ago), when I picked up my original early balanced crank from the machine shop after a polish:


http://iainel.co.uk/images/forums/NovaWIP2b/107.JPG


Saturday afternoon, the bottom end got assembled...


http://iainel.co.uk/images/forums/NovaWIP2b/108.JPG


http://iainel.co.uk/images/forums/NovaWIP2b/109.JPG


http://iainel.co.uk/images/forums/NovaWIP2b/110.JPG


And the head went back on, complete with standard pulleys so I can't mess up the timing again lol


http://iainel.co.uk/images/forums/NovaWIP2b/111.JPG


Late Saturday night, the engine was complete and mated up to the 'box:


http://iainel.co.uk/images/forums/NovaWIP2b/112.JPG


First thing Sunday morning (yesterday), I cracked on boshing it in:


http://iainel.co.uk/images/forums/NovaWIP2b/113.JPG


Plumbed up, fluids in, carbs on...


http://iainel.co.uk/images/forums/NovaWIP2b/114.JPG


And Sunday lunchtime I ran it up to temperature and took it for a spin. Feels good driving it again!


http://iainel.co.uk/images/forums/NovaWIP2b/115.JPG


MOT booked for Thursday, so job jobbed.

[House]

Tidy!!

[brucer]

No messing, well done iain.

[Scottcooper85]

Excellent! I bet driving it again boosted your enthusiasm back up :)

how ow do the cams feel on standard marks? As that's how mine are going in at the weekend for the time being too.

[8valve-craig]

Crikey that all happened quickly. Good on you, It beats my 13-month and counting engine build hands down.

[Iain]

Excellent! I bet driving it again boosted your enthusiasm back up :)

how ow do the cams feel on standard marks? As that's how mine are going in at the weekend for the time being too.

I ran the verniers on standard marks all the time I was injection and the engine felt nice and strong, so I wasn't overly fussed on binning the verniers in favour of standard pulleys. Will be out in it at the weekend for some more testing!


Cheers Craig, yours is in a different league to bolting together some standard parts though!

[Benn]

Hang on. You can down my way and didn't stop in and see me?

Loving the work, you've cracked on well! Why didn't you get the block honed? Rust doesn't look that bad.

[Iain]

Sorry sir, was genuinely supposed to be a holiday with the missus and her parents and not car related at all!

A hone would probably want new rings and I didn't want the hassle of running it in basically, especially with it not having an MOT anymore. Also I've tried honing an old block with a lip at the top before and it didn't work too well. The rust looks OK but even after a wet+dry, scrub etc it was still pitted and I'd feel like a numpty if I built it all up and it smoked when I knew there was a potential problem at the beginning.

[Benn]

Ah thats fair enough and ah. I thought you could get anyway reusing rings if it wasnt that bad. But pictures tell lies so its worse than it looks.

[Iain]

Well good and bad times, compression test came back good but the engine seems quite flat and unresponsive so going to go back to get it set up again...

A bit of tinkering today saw me get a longer fifth gear which should make the drive to PV a little more tolerable...

It's a 0.744 from an F18 on a 1.7 diesel Astra mk3 to replace the 0.886 from the F20. Should drop RPM from about 4000rpm at 70mph to about 3250 or there abouts.

Plenty of room for access thanks to my tickled chassis leg for this very task:

http://iainel.co.uk/images/forums/NovaWIP2b/116.JPG

End cover off:

http://iainel.co.uk/images/forums/NovaWIP2b/117.JPG

Gears and selector off:

http://iainel.co.uk/images/forums/NovaWIP2b/118.JPG

Old one on right, new ones on the left:

http://iainel.co.uk/images/forums/NovaWIP2b/119.JPG

Difference in gear sizes (new one left):

http://iainel.co.uk/images/forums/NovaWIP2b/120.JPG

Oh and I got my nice new rubber fitted too!

http://iainel.co.uk/images/forums/NovaWIP2b/121.JPG

Although it's causing some arch scrubbage issues so looking at ways of widening the front arches more...

[mowgli]

On one of those hotrod shows on cable tv, I saw a pretty neat trick. They stuck a baseball bat in the arch and pressed it to the wheel. Tgen someone drove it forward slowly, bending the arch out. God knows if it would work on a nova though.

[Iain]

Seen similar in jap drifters but with scaff pole. Tbh my front arches are already flared out!

http://iainel.co.uk/images/forums/Misc/rps20150529_213528_373.jpg

[House]

Hmmmm chassis leg space for gear ratio adjustments. I must get more inventive!!

What new johnies you rolling on?? They look rather tasty!!!

[Iain]

Toyo R1R 195/50/15

[BRoadGhost]

Just cut the arches higher

[8valve-craig]

I do love how neat your workshop is compared to mine. I must paint my floors.

Oh and as always good work Sir.

[Benn]

Great gearbox mod. Which i had done it over fitting a F28.

Can you not lightly widen your front arches? Add in 20mm in for so. Give a bit more clearance, but keeping the std look.

[Rob H]

With regards to widening the arches search the phone book trick, we use it all the time in the jap scene. Basically just jack the car up, put phone book/yellow pages or similar in between arch and wheel and lower the jack, works a treat and you can't really **** it up. rolling them with a pipe or bat is alot more prone to **** ups.

[scott.parker]

Nice job on the engine rebuild! House deserves a free years membership for that top end he gave you!.. (did want to say free head) lol
The scrap block looks similar to what that let one was like that I had, simply not worth the hassle..
All looking awesome dude, as for arches, could you cut them at the bumper line, and at the bottom where it bolts to sill, then extend it out with a small amount of steel? Might work with minimal bodywork effort?.

[burgo]

Needs saloon arches ;)

[M Sutton]

Great work :)

[BRoadGhost]

You might say it's using every book in the trick

[Iain]

1/10 for that joke BRoad lol I've watched videos of that phonebook trick, I cringe at it tbh! lol There's already a skim of filler from the rolling that's already happened so I'm a bit reluctant to mess with the current arches, got a spare arch I can tinker with if I need to.

Tried my new fifth last night and I can drive between 70 and 80 on the clocks at roughly 3500rpm, a vast improvement and you don't really notice the RPM drop too much for general driving.

[House]

Free head?!?

Where do I sign??

[Iain]

Well made it to PV Show 2015 and back, good day out on the PNG stand.

http://iainel.co.uk/images/forums/NovaWIP2b/122.JPG

However it still wasn't running all that well, so I've just got back from Torque Tune in Ollerton (again):

http://iainel.co.uk/images/forums/NovaWIP2b/123.JPG

Familiar scene to last time:

http://iainel.co.uk/images/forums/NovaWIP2b/124.JPG

Bit of tweaking on the needles, fueling was fine but this helped midrange driving. Ignition timing set up properly (I'd got it 10 degrees out! Surprised it didn't melt on way to PV!!)

http://iainel.co.uk/images/forums/NovaWIP2b/125.JPG

After the tune up it's an absolute monster, old school dyno with a basic dial gauge but looking at around 160BHP at the wheels, and it drives fantastically now.

[Southie]

Good power, I love the sound of bike carbs at full throttle. The cars looking well now ;)

[turbojolt]

you cant hear the carbs over his ridiculous gearbox lol

[Benn]

No videos? What is this the dark ages?

[Iain]

No videos? What is this the dark ages?

Yeah for the dyno runs I was in the passenger seat checking gauges and writing down the measurements for him lol

[Benn]

Ah well that's ok, as long as you where involved.

[Iain]

PART 1/3

Couple of recent mods and improvements to report. First off, the poor thing gets really hot when sitting stationary, so I've upgraded my old fan:


http://iainel.co.uk/images/forums/NovaWIP2b/126.JPG


With a monster 13" SPAL fan, which barely fits on the radiator lol


http://iainel.co.uk/images/forums/NovaWIP2b/127.JPG


Fitted:


http://iainel.co.uk/images/forums/NovaWIP2b/128.JPG


Funky waterproof connector:


http://iainel.co.uk/images/forums/NovaWIP2b/129.JPG


Finished off my extinguisher plumbing, by making up a new bracket:


http://iainel.co.uk/images/forums/NovaWIP2b/130.JPG


And fitting the second nozzle next to the oil catch tank (original nozzle on the drivers turret focusing on the fuel system):


http://iainel.co.uk/images/forums/NovaWIP2b/131.JPG

[Iain]

PART 2/3

Now bit of a sore point, I've had 2 sets of shafts now that have worn away on the splines, I blame companies not hardening them after machning. So bazzap off here was nice enough to step in and make these beauties for me machined from EN24T. I then got the splines hardened locally via induction heating/quenching.


http://iainel.co.uk/images/forums/NovaWIP2b/132.JPG


Things of beauty they are lol


http://iainel.co.uk/images/forums/NovaWIP2b/133.JPG


Got some proper jobby GKN Lobro CV joints too, which are OE Vauxhall fitment ones:


http://iainel.co.uk/images/forums/NovaWIP2b/134.JPG


Painted up and outers shortened to clear wheel centre caps:


http://iainel.co.uk/images/forums/NovaWIP2b/135.JPG


Built up:


http://iainel.co.uk/images/forums/NovaWIP2b/136.JPG


One for Benn to think about in bed tonight:


http://iainel.co.uk/images/forums/NovaWIP2b/137.JPG


These bad boys were fitted earlier and have drastically reduced the free play in the wheels and it feels a lot better on the whole now, so thanks to bazzap for sorting them out.

[Iain]

PART 3/3

Something I've had a for a while and just got round to fitting, I wanted some window nets so I can crack my windows open on trackdays. The proper way to fit these is round the cage, but my massive seats don't allow that, so I've welded some bracketry to the top of the door frame:


http://iainel.co.uk/images/forums/NovaWIP2b/138.JPG


http://iainel.co.uk/images/forums/NovaWIP2b/139.JPG


This allows a top rail to be clipped in:


http://iainel.co.uk/images/forums/NovaWIP2b/140.JPG


Window net with top and bottom rail:


http://iainel.co.uk/images/forums/NovaWIP2b/141.JPG


It was slightly too tall to fit on the door so I hired a Hayley to stitch the bottom hoops to reduce the total height (on pic above):


http://iainel.co.uk/images/forums/NovaWIP2b/142.JPG


Rivnuts on bottom of door frame:


http://iainel.co.uk/images/forums/NovaWIP2b/143.JPG


Window net in place:


http://iainel.co.uk/images/forums/NovaWIP2b/144.JPG


Drivers side done too:


http://iainel.co.uk/images/forums/NovaWIP2b/145.JPG


http://iainel.co.uk/images/forums/NovaWIP2b/146.JPG


Nice big red button visible on passenger side for quick removal:


http://iainel.co.uk/images/forums/NovaWIP2b/147.JPG


All done:


http://iainel.co.uk/images/forums/NovaWIP2b/148.JPG

[BRoadGhost]

Erm I might need to double check this on my images (not on right computer atm) but those shaft ends look to come to too sharp a point; this would explain your play woes.

[Iain]

There's still a tiny bit of movement on the splines on the new shafts, however I tried an OE CV on an OE Vauxhall shaft and they had a similar amount of movement. Hoping the hardening on these stops them wearing down and becoming extremely sloppy like the last ones.

[bazzap8389]

Hopefully the shafts do the job and don't snap/wear. Broadghost, the ones I made are an exact (within .001") of a set of equal length shafts I had.

[Benn]

Shafts are shiney, i approve. Like the window nets too.

[Iain]

Some niggly jobs sorted now, I can finally use the car.

Unfortunately didn't make it to Billing as diagnosed a fairly bad gearbox fault, so cracked on with fixing it.

Whilst the box is off, I ran the engine up on 1 mount and 2 axle stands:

http://iainel.co.uk/images/forums/NovaWIP2b/149.JPG

Oil leaks, sponsored by Imperial Leather lol Talcum powder clearly showed the problem leak, the end cap! You can see it on the right join here:

http://iainel.co.uk/images/forums/NovaWIP2b/150.JPG

So sump, pickup, gasket etc off, then end cap off and resealed properly with RTV:

http://iainel.co.uk/images/forums/NovaWIP2b/151.JPG

Now onto the good stuff, the gearbox. It had been having really bad feedback through the selector turret and up the stick for a while, and something was amiss. I ran it up on axle stands without the selector turret on and noticed a hell of a lot of movement through the output shaft, so unfortunately it had to be stripped.

So box off:

http://iainel.co.uk/images/forums/NovaWIP2b/152.JPG

End cap and fifth coming off:

http://iainel.co.uk/images/forums/NovaWIP2b/153.JPG

Cluster out:

http://iainel.co.uk/images/forums/NovaWIP2b/154.JPG

Cluster stripped, which involved removing all the selector arms, circlips, etc, got a pile of bits at this point lol

http://iainel.co.uk/images/forums/NovaWIP2b/155.JPG

The culprit, the large circlip holding the output shaft into the end plate wasn't actually seated at all, so it was just bouncing between the end casing and the gears and the other shaft gears, eek. The circlip is damaged as is the needle bearing spacer pictured here. The spacer was actually fitted the wrong way round which meant the circlip would never seat properly...

http://iainel.co.uk/images/forums/NovaWIP2b/156.JPG

Luckily I have a spare cluster (well, 2), so I've used the end casing, circlip, spacer and needle bearing from the spare cluster, and re-used both shafts and casing from the current box. Bit sparse on pictures, but it's all built up again all clean:

http://iainel.co.uk/images/forums/NovaWIP2b/157.JPG

Refitted an there's a tiny bit of movement but very happy with it now. No more leak from the gearbox end, so one happy Iain.

Thanks to Stuart for the explanation for stripping the box and Harvey for lending a hand with the sump sealing.

[House]

Top work old chum!!

[Harvey]

It was very satisfying hitting your shaft very hard.

Just glad the box is sorted, strange it never did it when I had it fitted but I do drive like Miss Daisy. I'll get my engine drip sorted one day.

[House]

It's not a real Vauxhall if it doesn't drip oil Harvey!!!

[Iain]

I've only fixed all the bloody leaks took it out for a few hours last night and the garage floor is bone dry today!

[conza123]

I've only fixed all the bloody leaks took it out for a few hours last night and the garage floor is bone dry today!
I give it a couple of days and something will be leaking again lol lol lol

#vauxhall life

[House]

I've only fixed all the bloody leaks took it out for a few hours last night and the garage floor is bone dry today!

This is a deceptive facade, it'll leak, they always do!!!!

[Benn]

Christ you havent hung about. Good work.

[Iain]

Bit of prep done over the last few weeks for Cadwell. Swapped out the TX Autosport radiator for a standard Valeo item. Strip down:

http://iainel.co.uk/images/forums/NovaWIP2b/158.JPG

New one installed:

http://iainel.co.uk/images/forums/NovaWIP2b/159.JPG

Short (standard) F20 fifth installed:

http://iainel.co.uk/images/forums/NovaWIP2b/160.JPG

Front ride height raised, slicks trial fitted, tracked up 1mm toe out:

http://iainel.co.uk/images/forums/NovaWIP2b/161.JPG

Window nets bolted into place:

http://iainel.co.uk/images/forums/NovaWIP2b/162.JPG

Careful measuring of window:

http://iainel.co.uk/images/forums/NovaWIP2b/163.JPG

Rear ventilation holes drilled to aid airflow out the car since I'll be driving with my windows open:

http://iainel.co.uk/images/forums/NovaWIP2b/164.JPG

Rain was forecast, so had Hayley paint up my wet rims:

http://iainel.co.uk/images/forums/NovaWIP2b/165.JPG

[Iain]

Cadwell today with a team of sleep deprived grumpy people lol

Team mascot pigeon:

http://iainel.co.uk/images/forums/NovaWIP2b/166.JPG

Did some fairly poor and inconsistent laps struggling with the track complexity, then on a lap out with House this happened:


https://www.youtube.com/watch?v=H8D13JK1TbY&feature=youtu.be

Uh oh, so after a red flag and tow off the track this is the failure:

http://iainel.co.uk/images/forums/NovaWIP2b/167.JPG

http://iainel.co.uk/images/forums/NovaWIP2b/168.JPG

http://iainel.co.uk/images/forums/NovaWIP2b/169.JPG

Brand new GKN inner CV joint, now fit for scrap, boooo. Not to worry though! I had chucked my old welded shafts in the boot, so fitted the replacement with the aid of a new castle nut from Harveys spares, and went back out after lunch to carry on! Happy days.

Pic of the trio:

http://iainel.co.uk/images/forums/NovaWIP2b/170.JPG

[Iain]

And a small mishap on the last session lol


https://www.youtube.com/watch?v=9L7XFv2V3N8&feature=youtu.be

Just sorting out footage of my best clear laps :)

[House]

The best 2 lines of the day........

"That doesn't sound good?!?!"

"I broke it"

[Edd]

Why have you got a 5cm diameter steering wheel?

[Iain]

Always had it, had no real reason to change it to a bigger one to be honest?

Couple of clear laps on video.


https://www.youtube.com/watch?v=yeFizRIGZDI&feature=youtu.be


Car handles really well, slicks still have some life left in them, brakes are sharp on DS3000s and oil temps and pressure stay good. Open windows up front makes for a nice cool drive on hot days, so I'm not sure what I'm going to do with the thing to improve it now!

[bazzap8389]

Nice bit of driving Iain. Handling looks very good! :thumb:

[House]

Why have you got a 5cm diameter steering wheel?

Bigger steering wheel also means that when turning in to a corner or correcting over steer or under steer mid corner you hands have to go further to apply lock or opposite lock.

Yes, the steering is harder to turn but you don't have to turn the wheel as far, also I've found on track that heavier steering is a plus as it feels more direct and engaged with the surface. Just my take on it.

[Iain]

No steering is hard with EPAS lol

[House]

No steering is hard with EPAS lol

Only girls use EPAS.

[ben doodar]

So the car seems pretty complete now then Iain?
any other plans for it? Seems to go well and handle nicely on track.
Can I ask why you swapped the tx radiator for a standard one? Looking at getting a tx one for mine. A few people seem to have problems with them tho.

[Iain]

Yeah bizarrely nothing to really improve on, other than the broken CV joint. Probably find some other track/race inspired tweaks but nothing major.

I had my TX one welded once, and noticed when up to temperature it 'steamed' slightly from the top. Held pressure mostly and ran cool enough, just wasn't properly sealed. I do regret having to go back to a standard radiator, the fins are too delicate and get damaged easily. In my fact my Valeo one picked up a whole load of damage just fitting it. lol

[Pistol Pete]

Really like your car and the work you have done. This thread makes for interesting reading. I think i may go towards this route of mods once i get bored with how mine is. I have already starting drafting a wish list for next winter lol

[HouseAtreides]

Awesome! Awesome! Awesome! :thumb: Car shifts, sounds epic, and looks the part. Quality bit of driving, too ... You look familiar with getting round Cadwell Park lol.

[Harvey]

Only girls use EPAS.

We are all female as heart....moobs :d

[House]

We are all female as heart....moobs :d

To be fair Harv the girl dealt quite well with his mullered CV joint, I was expecting tears and toys being thrown out the pram!!!!

[Iain]

Thanks chaps, glad you like it.


To be fair Harv the girl dealt quite well with his mullered CV joint, I was expecting tears and toys being thrown out the pram!!!!

Getting used to this kind of thing happening lol

[Benn]

Love all the vids. Love the first video, the cv die and the "Oh crap" feeling.. I know that one all to well. Spin was handled well too.
Holding speed and the track very well, impressive driving as always.

[House]

Thanks chaps, glad you like it.



Getting used to this kind of thing happening lol

mainly cos you drive it like you stole it!!

[scott.parker]

Love the "I broke it" lol
Last video is brilliant, it's flying dude!..

[House]

Love the "I broke it" lol
Last video is brilliant, it's flying dude!..

It was flying...... Flying over the kerb on the inside of the mountain, that's what blew the CV as we landed!! That and my 107kg in the passenger seat!!!!!

[Adam]

Theres no such thing as finished lol

Impressive btw, got a pretty much perfect track weapon!
Good to see you actually give it some boot as well and not treat it nicely.

[Iain]

Adam was correct (for once), found something else to tinker with.

Good guide with info in on the SBD website with bolt sizes: http://www.sbdev.co.uk/Info_sheets/Alternators/2.0L%20XE%20ALT-SM2-B%20fitting%20of%20SBD%20alternator%20brackets.pdf

Denso 40a compact alternator vs standard XE alt

http://iainel.co.uk/images/forums/NovaWIP2b/171.JPG

Vauxhall bracket part number for anyone who wants to know. I used a 9.5mm spacer instead of SBD's suggested 14.5mm spacer which has placed the alternator in the right place

http://iainel.co.uk/images/forums/NovaWIP2b/172.JPG

Alternator part number, marking on the right is the wiring plug instructions too:
S = sense, a perm 12v source away from the alternator, which I haven't bothered connecting,
IG = Ignition live
L = Light

http://iainel.co.uk/images/forums/NovaWIP2b/173.JPG

Adjuster bracket needed lengthening to suit it further down

http://iainel.co.uk/images/forums/NovaWIP2b/174.JPG

Alt even came with a lovely splashproof crimped plug

http://iainel.co.uk/images/forums/NovaWIP2b/175.JPG

Alternator bracket in place (the large stud on the top is the perm +ve connection)

http://iainel.co.uk/images/forums/NovaWIP2b/176.JPG

Teeny weeny

http://iainel.co.uk/images/forums/NovaWIP2b/177.JPG

Belt is a temporary one I found that fits, it's 10x875 V velt.


I've also put the radiator fan on a switch inside the car and tidied up loads of wiring, yipee.


Snetterton on 21st, so car's pretty much ready for that.

[Mazz]

Great little alternators, I found mine in an Axiam thing at a scrappy for 20 quid! And while there a liberated a mk3 Astra mount too

[Iain]

Happy days Mazz, well chuffed seems to charge fine even with most things on.

I've done this all with brand new parts but on a budget with bargains over the last few months... Alternator was about £40, bracket £8, then just misc rosejoints and spacers and stuff!

[Mazz]

I'm sure the same on sbd site is over £200!

[House]

Tasty!! I'm guessing the alternator doesn't move left to right at all? I noticed when using a rose joint tensioner that the alternator could wiggle about a few mm, it wasn't rock solid like it is on the standard mount.

[Harvey]

The alternator with be Iain tight and will never move.

[Iain]

Everything's he-manned up lol I guess the rubber on an OE alternator allows a bit of movement, whereas this has an M10 bolt through the alt, spacer and bracket and no rubber anywhere. This, along with the RJs, act as an earth so no extra earth cable required too.

[Benn]

Why the alt swap? good info. I enjoy it.

[Iain]

Saves a few kilos, lots of space, and I like tinkering.

[Benn]

Sounds good.

[Dar]

Nice little mode that. The car is looking nice as well :)

[House]

Err I thought the rose joint would earth my standard alt bit was getting arc'ing across the rose joint.

You will probably be ok because as you say th bottom mount is a bolt not rubbers as on the standard one!!!

[Iain]

I've changed my front bumper bolts into R clips, I'm thinking of having them blackodized but until then this is what they look like.

Two M12 bolts, heads cut off and holes drilled.

http://iainel.co.uk/images/forums/NovaWIP2b/178.JPG

Two M6 bolts (old XE rocker bolts), heads cut off and holes drilled.

http://iainel.co.uk/images/forums/NovaWIP2b/179.JPG

Fitted:

http://iainel.co.uk/images/forums/NovaWIP2b/180.JPG

http://iainel.co.uk/images/forums/NovaWIP2b/181.JPG

Bit of impact protection should I have a 70mph crash lol lol lol

http://iainel.co.uk/images/forums/NovaWIP2b/182.JPG




Last Monday I took it to Snetterton 300 circuit. Good day out, no breakages, but turned very wet from 11am onwards so made it difficult driving. No real pics as I was left to attend alone by someone I shall not name.

http://iainel.co.uk/images/forums/NovaWIP2b/183.JPG


Some dry laps where I was still learning the circuit:


https://www.youtube.com/watch?v=x-juhX0hGJ8&feature=youtu.be

[Iain]

And some very wet laps at the end of the day. watch the first half lap for a mega slidey moment lol


https://www.youtube.com/watch?v=vSB5lzTW02c&feature=youtu.be

[Iain]

Random evasive action clip where I thought this guy was on my line lol


https://www.youtube.com/watch?v=2EB0JOsMbUo&feature=youtu.be

[RallyMarshal]

The wet looks more fun :-)

Paul..

[Will F]

Youre getting quite a bit of movement in your gear shifter when on/off throttle? What mounts are using?

Nice vids btw!

[Iain]

The wet was actually pretty fun Paul, just I prefer to lose control at high speed rather than low speed!

Will it's on solid TAS mounts, a few pages ago in my WIP I rebuilt the gearbox because a circlip wasn't seated properly causing movement in the gear shaft and therefore shifter movement, unfortunately it appears to still do it a little bit.... Might be a job for winter to try and rebuild it again.

[Benn]

I'm not a fan of the pins, but thy are a good job.

That wet lap looks like scarey fun. I was always told if you start to spin, use really light movement on the steering to correct, dont panic and over turn it... Just a random tip i was told.

[total_vauxhall]

That alternator looks the biz mate were can i get one
Im looking at changing mine after it turning the belt over twice at the weekend . Cheers dan

[Iain]

Mine used to invert the belt when it wasn't aligned properly. Slotting the bracket allowed me go line it up properly with the standard gear.

Alternator was from eBay and Vauxhall bracket was off genuine parts search on the net. Rosejoints and turn buckle were from McGill Motorsport.

[total_vauxhall]

;) cheers bud

[RallyMarshal]

Ready for next weekend?

[Iain]

My Ferrodo DS3000s are getting a bit low so will probably chuck on my Mintex M1144s for the day, but apart from that it's ready to roll.

No repairs, mods or improvements since the last trackday, it's a weird feeling.

[RallyMarshal]

You will notice a difference between those if its dry...

Paul..

[8valve-craig]

What front brakes are on this Iain? If its new pad time I can't recommend Carbone Lorraine RC6 enough. They are expensive, but you wont regret buying them.

[Iain]

Wilwood Dynalites. Having discussed further with Paul, I may regret going with 1144s (which is what I use for road, in the hope I wouldn't have to swap pads before a trackday).

I will probably order some further DS3000s as they're cheap and I know they work well for me, I can probably squeeze another day out my current pads but they're quite worn now haha.

[Iain]

This is gonna be short and sweet as barely had any time to get pics together!

I added some more stickers, I bolted my slicks on, and I took it to Blyton Park last Sunday 11th Oct. Proper laugh, with the mk2 Astra donor car bunch:

http://iainel.co.uk/images/forums/NovaWIP2b/184.JPG

Representin' PNG:

http://iainel.co.uk/images/forums/NovaWIP2b/185.JPG

http://iainel.co.uk/images/forums/NovaWIP2b/186.JPG

And ended the day with this happening to my clutch lol

http://iainel.co.uk/images/forums/NovaWIP2b/187.JPG

Helix 4 paddle in the post.

After a passenger lap in Paul's epic rally car (red and white Coconut court car), I realised I have loads more tweaking to do on my suspension as that thing handles better than I thought any FWD Vauxhall ever could, so look forwad to starting to tweak more to do with springs, damping and rollbars.

[Iain]

Video of a clear lap, won't upload one of it breaking as they're getting boring lol


https://www.youtube.com/watch?v=e4TwHhiVUZk&feature=youtu.be

[Harvey]

Tidy lapage laddo. Now stop breaking the darn thing.

[Benn]

Liking the stickers give it a more track look. Very impressed with the clutch, not seen that before.

[Iain]

Didn't think you'd like the stickers Benn you never do!

Forgot a track photo courtesy of Amanda!

http://img.photobucket.com/albums/v214/harvey.emsley/GTE%2016v/Blyton_Oct_2015/IMG_0664%20Small.jpg

[Dar]

Nice job on the clutch!
Keep replacing the broken parts with better bits ;)

[BRoadGhost]

Amen to that

[RallyMarshal]

Nice lap considering you had a fatty in the passenger seat :-)

Glad you got the Helix - expensive but pretty much fit and forget I hope

Thanks for the compliments on the car. The proof will be how we do this weekend at Donington. See you Sunday.

Paul..

[Benn]

Christ your holding some speed on that vid, good work.

[Iain]

Weeny update, Helix clutch in

http://iainel.co.uk/images/forums/NovaWIP2b/188.JPG

http://iainel.co.uk/images/forums/NovaWIP2b/189.JPG

Remade my gear linkage with new rosejoints

http://iainel.co.uk/images/forums/NovaWIP2b/190.JPG

http://iainel.co.uk/images/forums/NovaWIP2b/191.JPG

Modified to clear rack, you can see where it's been hitting

http://iainel.co.uk/images/forums/NovaWIP2b/192.JPG

Also raised shifter so the ball is bang in the middle of the rod

http://iainel.co.uk/images/forums/NovaWIP2b/193.JPG

Result? The clutch feels amazing, and the gearstick doesn't kick when I let off in gear anymore. Feels amazing now.

[Benn]

Nice mods.

[House]

I'm running the Helix centre aswell, like the feel with the standard cover plate.

[Iain]

Went to Snetterton on the 9th, good fun although wet for most of the day. That's 2 wet Snetterton days this year, grrr.

Myself and House off this very forum

http://iainel.co.uk/images/forums/NovaWIP2b/195.JPG

Even got some humorous team stickers made up for a few days we're doing with eachother this year lol

http://iainel.co.uk/images/forums/NovaWIP2b/194.JPG

Few videos but nothing too wild, followed House for a bit:


https://www.youtube.com/watch?v=jtDIbfLDpAA

[Iain]

And a fails compilation as it was full of them that day


https://www.youtube.com/watch?v=knKYkW9Ckwg

[Iain]

Oh almost forgot, somehow. Since the slip slideyness of Monday and trying out House's Nova on a similar tyre setup, I've upgraded my wet tyre setup to a spanking new set of powdercoated Cesaros

http://iainel.co.uk/images/forums/NovaWIP2b/196.JPG

And some swanky new Uniroyal Rainsport 3s in 195/50/15

http://iainel.co.uk/images/forums/NovaWIP2b/197.JPG

Booked onto Donington on 21st November so don't mind if it's a wet one now!

[toymex]

Looked like fun ,I'm sure you will learn plenty about car control on a day like that

[House]

Brilliant!!

Was a lot of fun sliding around. I can't believe the save at the end of the back straight didn't make the compilation? It was possibly one of the best displays of over limit car control I've ever witnessed!!!

[Iain]

Forgot that one! Just created a new compilation with that one included and edited post above!

[bazzap8389]

Looks like good fun tbh! That rainsports should help out big time.

[Iain]

Hope so, they have an A wet rating! If they don't help I'll park up and look badass with my shiny new rims.

http://iainel.co.uk/images/forums/NovaWIP2b/198.JPG

[8valve-craig]

Car looks great Iain. I have a lovely engine here for sale if you feel it needs to be a little faster.

[House]

Hmmm he's cray enough without needing anymore power Craig!!

[Iain]

I'll need more power to keep up with your new engine, hmmmmmmmmmm :d

[bazzap8389]

C20let you know you want to.

[House]

C20let you know you want to.

Can't beat NA instantaneousness!!!!!

I think mine will be a handful when it's done Iain, murder in the wet!!!!!!

[Mike]

And some swanky new Uniroyal Rainsport 3s in 195/50/15

Not a bad price them, certainly cheaper then DMack W3's.

Still cant figure out why some of you trackdayers blast money on 888's and the like when you can get E marked inters for £100 a corner tho lol lol

[Iain]

Worked out at £140 the set after postage, they performed very well on standing water on the road the other night so hopefully up to the job.

My cheap Michelin S9C slicks have lasted a couple of years now and still got 2 I've never fitted!

At Donington this Saturday so fingers crossed the weather holds off for a bit longer.

[Mike]

£140 for a set is nowt to be fair, from camskill or something?

[Iain]

Yep Camskill, £32 a tyre plus postage

[RallyMarshal]

Worked out at £140 the set after postage, they performed very well on standing water on the road the other night so hopefully up to the job.

My cheap Michelin S9C slicks have lasted a couple of years now and still got 2 I've never fitted!

At Donington this Saturday so fingers crossed the weather holds off for a bit longer.

Got your snow tyres fitted?

Paul..

[Iain]

I plan to order some snow socks, although I think you can only do 30mph on them. House has his chains at the ready.

[RallyMarshal]

I plan to order some snow socks, although I think you can only do 30mph on them. House has his chains at the ready.

30mph is plenty fast enough for you if its not dry! lol

Paul

[House]

Not a bad price them, certainly cheaper then DMack W3's.

Still cant figure out why some of you trackdayers blast money on 888's and the like when you can get E marked inters for £100 a corner tho lol lol

I only paid I think £330 for 4 888's. Would be very interested in some proper inters thouhg if there's a link?!?

[Mike]

I only paid I think £330 for 4 888's. Would be very interested in some proper inters thouhg if there's a link?!?

http://www.dmacktyres.com/asphalt-tyres

http://www.dmacktyres.com/trackday-tyre

You'll have to find a supplier, but plenty motorsport parts places stock them. They good enough for WRC then they good enough for a track car.

[House]

Agreed, thanks Mike!!

I'd love to get hold of some of the Michellin slick inters that the Le Mans guys use. Many drivers have said they're amazing!!!

http://ears.co.uk/tyres/dmack-tarmac-rally-tyres/5519-19550-15-dmack-dmt-rc-tarmac-rally-tyre.html

http://www.demon-tweeks.co.uk/motorsport/competition-tyres/dmack-dmt-rc-tarmac-asphalt-rally-tyre-e-approved

These look decent, obvioulsy no rating for wet but from the description, designed specifically for wet and greasy surfaces. Might give these a go instead of more rainsports next time!!!

R888's available here for £83 rated C in the wet

http://www.mytyres.co.uk/cgi-bin/rshop.pl?dsco=110&cart_id=27379053.110.19797&Cookie=froogle&Breite=195&Quer=50&Felge=15&Speed=&Load=&kategorie=&Marke=Toyo&ranzahl=4&tyre_for=&x_tyre_for=&Herst=Toyo&weiter=10&rsmFahrzeugart=ALL&filter_preis_bis=&filter_preis_von=&homologation=&Label=F-C-69-2&details=Ordern&typ=R-156525

and the new R888R for £90 Rated E in the wet though

http://www.mytyres.co.uk/cgi-bin/rshop.pl?dsco=110&cart_id=27379053.110.19797&Cookie=froogle&Breite=195&Quer=50&Felge=15&Speed=&Load=&kategorie=&Marke=Toyo&ranzahl=4&tyre_for=&x_tyre_for=&Herst=Toyo&weiter=10&rsmFahrzeugart=ALL&filter_preis_bis=&filter_preis_von=&homologation=&Label=F-E-70-2&details=Ordern&typ=R-283554

[Mike]

Ah yea you guys run 15s dont you!

For big rims like 17 an 18 inch (Impreza & Evos etc) DMacks work out cheaper. 15 and 16 inch, popular sizes, there not cheaper then 888's lol

[House]

That's cool Mike, we've been searching for some decent inters, or I have atleast, not sure what the Elf is doing!!

[Mike]

Dont get me wrong there not the best money can buy but there far from shit!

For a relativly inexpensive outright track tyre there incredibly good. A lot of guys I know that do tarmac rallies swear by them based on cost vs performance.

[House]

Thanks mate, the rainsports are amazing in the wet wet but in the damp the 888's wont be any good and a decent inter is something i've been looking for for a while!!

#hijackedelf'sthread!!!

[Harvey]

Popped to Donington Park today as House and Iain were doing their thing.

http://img.photobucket.com/albums/v214/harvey.emsley/General/20151121_121344%20Small.jpg

http://img.photobucket.com/albums/v214/harvey.emsley/General/20151121_121749%20Small.jpg

http://img.photobucket.com/albums/v214/harvey.emsley/General/BestPhoto_20151121_181538_7%20Small.jpg

http://img.photobucket.com/albums/v214/harvey.emsley/General/BestPhoto_20151121_181036_4%20Small.jpg

They seemed to be enjoying the man loving with each other so I left them to it.

[House]

Can't believe you managed a day without breaking it!! That's gotta be a record, 2 track days, 0 failures!!!

I heard you were going down through Craner at 110?!? Not sure where I heard it from though?!?

[Iain]

Thanks for the pics Harvey. It was a good outing for Team Shonky Vauxhall yesterday!

Donington, 21st November. Booked when lovely and mild, and first snow the night before. Oh well what can you do.

It's a local circuit so I took plenty of spares, CVs for House, and three sets of wheels. The day started wet, so I did a few warm up laps on my new Rainsport 3s. Very impressed with them.

It started to dry up so I first tried slicks on the front and Toyo R1Rs (my road tyres) on the back. It was oversteering all over the place and the R1Rs started to peel badly so I knew it was getting enough heat in, so I swapped to slicks all round by late morning.

Got some more good laps in, with Josh as a passenger. Took House's friend out for a session and proceeded to come as close as I've never come to writing the beasty off. Whoops. Good job it didn't roll, that's all I'll say.

Here's a video of the carnage of car control:


https://www.youtube.com/watch?v=hkNjEskDCwk

And the result:

http://iainel.co.uk/images/forums/NovaWIP2b/200.JPG

And scooping out gravel out of every nook and cranny after lol

http://iainel.co.uk/images/forums/NovaWIP2b/201.JPG

It survived with some minor bumper damage, some paint loss in the arches and skirts and a driver with a battered ego so not too bad.

http://iainel.co.uk/images/forums/NovaWIP2b/202.JPG

[Iain]

Later in the day I refitted the front ARB that I had removed at Snetterton a few weeks ago in the wet...

http://iainel.co.uk/images/forums/NovaWIP2b/199.JPG

..,and my God the car felt so much more stable. Here's a few laps on a clear track with the ARB fitted and I gained a bit of confidence back.


https://www.youtube.com/watch?v=rCo4Q_HkUU4&feature=youtu.be

[House]

WOW!!!

Mike said it was a good one!!!! That was close!!!

[Dar]

Lol, I did exactly the same thing in exactly the same place :D. That gravel gets everywhere doesn't it!

[Iain]

All the cool kids fall off there.

[BRoadGhost]

Very fortunate not to roll there; that side ways rocking can make it dig in.

[brucer]

Nice vids and good driving, are you using a quaife rack or corsa rack iain?

[Iain]

BRoad - felt like it was going to, think I got lucky.

brucer, Quaife quickrack and EPAS on the steering. If I was building it again or on a budget I'd consider trying the Corsa one first though.

[bazzap8389]

Ooooh scary moment there! Fairly chapping on too.

[Benn]

Christ that was a nice close one. I've got a pic of 3 cars all sliding off on that same bit.

As always very impressed with your driving. Car looks flat in the corners and fast too. The ARB looks like it works very well on your car.

[toymex]

That looked like a brown trouser moment ,carrying a fair bit of speed at the time ,was it a lift off oversteer or just the rear tyres crying enough ?

[House]

BRoad - felt like it was going to, think I got lucky.

brucer, Quaife quickrack and EPAS on the steering. If I was building it again or on a budget I'd consider trying the Corsa one first though.

I'm running the corsa rack with no EPAS and it's really good!!

[Iain]

That looked like a brown trouser moment ,carrying a fair bit of speed at the time ,was it a lift off oversteer or just the rear tyres crying enough ?
Not sure. The drivers rear tyre did have issues keeping the heat in (any tripod meant instant sideways) so maybe cooled off and leant on it a bit too much.

[turbojolt]

He is just over doing it now as he wants a kit car that's all that happened lol

[brucer]

I'm running the corsa rack with no EPAS and it's really good!!

Good to hear as i was planning on getting the corsa one for mine and not fitting epas. Whats it like at slow speeds?

Is there a part number for the corsa rack?

[Iain]

Winter upgrades have begun, started with some better quality bushes, SuperFlex/SuperPro one piece poly bushes:

http://iainel.co.uk/images/forums/NovaWIP2b/203.JPG

Easier with the beam off, so now is a good time for a brake fluid chang, so bled it all through with air. It was very dirty and discoloured so in need of a change despite it not being that old:

http://iainel.co.uk/images/forums/NovaWIP2b/204.JPG

I set my pet Harvey to work removing the rear beam:

http://iainel.co.uk/images/forums/NovaWIP2b/205.JPG

While I stripped the front and pulled the arms off:

http://iainel.co.uk/images/forums/NovaWIP2b/206.JPG

Old RallyDesign bushes:

http://iainel.co.uk/images/forums/NovaWIP2b/207.JPG

Grubby beam:

http://iainel.co.uk/images/forums/NovaWIP2b/208.JPG

Even grubbier car:

http://iainel.co.uk/images/forums/NovaWIP2b/209.JPG

On with the fitting, beam cleaned with a wire wheel:

http://iainel.co.uk/images/forums/NovaWIP2b/210.JPG

Bush fitting toolage with lots of grease, but were still a pain to fit:

http://iainel.co.uk/images/forums/NovaWIP2b/211.JPG

Even the steel insert was tight:

http://iainel.co.uk/images/forums/NovaWIP2b/212.JPG

Front arms were even harder:

http://iainel.co.uk/images/forums/NovaWIP2b/213.JPG

But this weirdo made it easier than tackling it alone:

http://iainel.co.uk/images/forums/NovaWIP2b/214.JPG

Next up is touch up some paintwork from the gravel trap:

http://iainel.co.uk/images/forums/NovaWIP2b/215.JPG

And refurb the calipers as stones got wedged between the wheel and calipers and ruined them:

http://iainel.co.uk/images/forums/NovaWIP2b/216.JPG

Also on the list is Corsa bias pedal box, new fluid, and looking at the pedal ratio to suit.

[Novasport]

Should have said, I have a full car set of them one piece bushes. I fitted the ones to the rear beam and had a right job getting them in. Was even more of a b@stard to get out when I decided to fit Powerflex ones instead!

[Iain]

Well that's annoying. :)

[Iain]

So toying with the brake pas box, I figured it's worth checking if my set up will really support it.

Current pedal setup:

http://iainel.co.uk/images/forums/NovaWIP2b/217.JPG

http://iainel.co.uk/images/forums/NovaWIP2b/218.JPG

Yoinked out:

http://iainel.co.uk/images/forums/NovaWIP2b/219.JPG

And what I was interested in, some measurements of the brake pedal:

http://iainel.co.uk/images/forums/NovaWIP2b/220.JPG

http://iainel.co.uk/images/forums/NovaWIP2b/221.JPG

Now i've followed this tech advice on the Wilwood website: http://www.wilwood.com/TechTip/TechPedalTip.aspx

If my understanding is correct, 19cm between pivot and pedal and 4.5cm between pivot and connecting bar gives a pedal ratio of 4.2:1.

On the last pic, if I drill where the white dot is (approx 3.1-3.2cm) that'll give the ideal non-servo-assisted brake pedal ratio of 6:1. So assuming that'll operate the set up properly, who know; I'll have to get a bias box and see how it goes.

[Peredur]

I think (might have imagined it though lol ) Ben Spencer (boffer8) might have altered the pivot on his when installing a bias box, might be worth a shout?

[Benn]

I like the the bushes apage back are 1peice.

[boffer8]

I have a nova pedal box fitted in mine not the corsa one so its a little bit different to be honest due to the how the standard pedal bar works.

You could redrill it there giving the correct pedal ratio but it also means that the pedal position will change (in relation to other pedals) so you might need to be wary. Worth a go though as it wont weaken the pedal vastly drilling where you are thinking looking at your pics and it would help the feel massively as mine is like pushing a brick wall but im now used to how it is so like the feel of it.

If i was you, whist it was out re-drill it, put it back in and they you can try the standard position back to back with the new one and choose which you prefer...

[Iain]

Thanks Boffer, I received some good advice regarding pedal ratios on PistonHeads actually, my basic measurements may well not be as accurate as I hoped: http://www.pistonheads.com/gassing/topic.asp?h=0&f=135&t=1560935&mid=0&nmt=Brake+pedal+ratio+modifications

End of the day it's a hacked about Corsa set up against an OE clutch and accelerator pedal, both with their on pivot points, so I just get used to how they feel against eachother as it'll never be as good as a proper pedal box which I just don't have the room for without redesigning my steering, seating and shifter arrangement.

I think redrill and fit is the way forward yeah, hopefully have some updates over xmas when I come to fit my bias pedal box.

[Harvey]

I never heard a murmur from you when I was touching your bushes, they felt so good and you seemed to enjoy yourself. It was all a bit tight but with lots of lube and the correct toys they all slipped in eventually which left you with a huge smile and feeling of satisfaction.

You got that pedalbox in yet?

[House]

You got that pedalbox in yet?

He's not hardcore enough for a real man's pedal box mate!! lollollol

[Iain]

So with the bushes fitted, I went about refitting the suspension. Rear beam slotted in lovely

http://iainel.co.uk/images/forums/NovaWIP2b/222.JPG

Front bushes posed a problem as the original ones were only 50mm wide, which is actually 2mm too narrow:

http://iainel.co.uk/images/forums/NovaWIP2b/223.JPG

The new bushes are the correct 52mm:

http://iainel.co.uk/images/forums/NovaWIP2b/224.JPG

The chassis had been pinched in by doing up the old bushes, meaning the new ones were miles away from fitting (well, 2mm to be precise):

http://iainel.co.uk/images/forums/NovaWIP2b/225.JPG

This was opened up with a large threaded rod and nuts, wound out from the inside to bring the chassis back into shape:

http://iainel.co.uk/images/forums/NovaWIP2b/226.JPG

Easy job, new 280mm discs for the Wilwoods

http://iainel.co.uk/images/forums/NovaWIP2b/227.JPG

Or so I thought, even those were a faff and had to take the spigot rings from the old discs...

http://iainel.co.uk/images/forums/NovaWIP2b/228.JPG

...And press them into the new ones

http://iainel.co.uk/images/forums/NovaWIP2b/229.JPG

[Iain]

Calipers got tarted up, purely cosmetic refurb as in full working order

http://iainel.co.uk/images/forums/NovaWIP2b/230.JPG

Stripped

http://iainel.co.uk/images/forums/NovaWIP2b/231.JPG

High temp red from Halfords, isn't very red, so a few layers of that

http://iainel.co.uk/images/forums/NovaWIP2b/232.JPG

Then a coat of Vauxhall flame red, hopefully it won't burn off

http://iainel.co.uk/images/forums/NovaWIP2b/233.JPG

Fitted

http://iainel.co.uk/images/forums/NovaWIP2b/234.JPG

Onto some new shiny bits, I purchased a Corsa brake bias assembly from Harry Hockly

http://iainel.co.uk/images/forums/NovaWIP2b/235.JPG

First problem to overcome, the drop on the original Corsa set up was about 10-11cm

http://iainel.co.uk/images/forums/NovaWIP2b/236.JPG

The Hockly item was about 6cm so needed a threaded extension piece and extra rod to reach the pedal

http://iainel.co.uk/images/forums/NovaWIP2b/237.JPG

Using Wilwood master cylinders, the push rods were far too long to actually bolt together

http://iainel.co.uk/images/forums/NovaWIP2b/238.JPG

So both of these got cut down

http://iainel.co.uk/images/forums/NovaWIP2b/239.JPG

All built up on the bench, with 0.625 and 0.7 cylinders for front and rear respectively

http://iainel.co.uk/images/forums/NovaWIP2b/240.JPG

Slightly quirky sideways fitment, luckily the clevis have enough free play to operate this way (as the pedal pivots at 90 degrees to the assembly pivot)

http://iainel.co.uk/images/forums/NovaWIP2b/241.JPG

2 new braided lines to mate up to the original braided lines

http://iainel.co.uk/images/forums/NovaWIP2b/242.JPG

[Iain]

Couldn't be bothered with the manual brake bleeding so took one of the reservoir caps and popped off the internal splash guard

http://iainel.co.uk/images/forums/NovaWIP2b/243.JPG

Drilled a 10mm hole

http://iainel.co.uk/images/forums/NovaWIP2b/244.JPG

Which allowed me to use the Eezibleed pressure bleeder

http://iainel.co.uk/images/forums/NovaWIP2b/245.JPG

Finished

http://iainel.co.uk/images/forums/NovaWIP2b/246.JPG

A quick test drive up the garden proves it works although braking was incredibly poor.. Hopefully due to the new discs so will bed it all in and see where I'm at.

[RallyMarshal]

A quick test drive up the garden proves it works although braking was incredibly poor.. Hopefully due to the new discs so will bed it all in and see where I'm at.

Bigger legs needed :-)

Paul..

[Will F]

Ha - I did exactly the same to bleed mine - worked a treat.

And initially, the bias box will feel like nothing's happening - especially if you've got pads that need heat in them to work... I regularly get into the Nova out of a normal car and nearly sail through junctions, read-faced and sweating! lol

[Iain]

I drove at probably less than 10mph and struggled to stop within a 3 metres, need to bed stuff in properly and see where I'm at. Got Mintex 1144s in at the mo.

[Benn]

Wont the pressure just blow the tape off?

[Iain]

I have a new cap on order, however the reservoir isn't pressurised, the master cylinder just draws in what it needs.

[Benn]

Oh ok, i thought the bottles would be too. Thank you.

[Iain]

Well my issue was pressure bleeding from a dry system, there must have been tonnes of air in the master cylinder (between the push rod and outlet I imagine).

What you're supposed to do is something called 'bench bleed' the new cylinders; plenty of resources online about doing this.

So instead of removing them from the car, I got them level and looped my new lines back into the reservoirs:

http://iainel.co.uk/images/forums/NovaWIP2b/247.JPG

Then topped the brake fluid up to create a looped system

http://iainel.co.uk/images/forums/NovaWIP2b/248.JPG

Lots and lots of pumps of the pedal later, I've reconnected up the system and pressure bled as before. The cylinders now travel a hell of a lot less and the pedal moves lots less too, much more like I was expecting it to.

Test drive later to bed in the front pads and find out if my pedal ratio is usable...

[Southie]

Glad I asked if you'd bled them up okay ;)

[Iain]

Southie wins a gold star.