Iain's 20XE Trackday Nova

[Iain]

What shows you taking it too... so we can prove the yellowy whitey greyness....
Probably billing. I must insist any photos are upload with the worst Instagram filter available though.

[NovalutionGSi]

I'll be bringing the sting over to prove the colour again!

[brainsnova]

I can scan it with the paint scanner probs 50 shades of grey

[Benn]

Yeah some bits you've got to wonder what they took the mould from

Prob is it's normally,a,mould,from,a,mould....

[Andy]

Yo dawg lol
nice work on making it right Iain

[turbojolt]

I can scan it with the paint scanner probs 50 shades of grey

Or cream

[Iain]

When I built the car several years ago, the car/stands/driveway must have been on an angle. This means all that hard work putting in my seat rails led to both seats leaning towards the right.

The height of the rails were restrictive and I would occasionally hit my helmet on the rollcage, which wasn't ideal. So they needed fixing.

New measurements were done with a spirit level, and importantly a spirit level across the door shuts. This should make them more level.

http://iainel.co.uk/images/forums/NovaWIP2b/363.JPG

I attempted the level the car off as well as possible, and you'd be surprised how wonky the rails are. They would run out 5-10mm across the width of each rail. lol

http://iainel.co.uk/images/forums/NovaWIP2b/364.JPG

Chop chop.

http://iainel.co.uk/images/forums/NovaWIP2b/365.JPG

Both sides shortened slightly, spreader plates on car cleaned and re-welded. The rails needed slightly fettling as did the floorpan (read: smash it with a hammer) to get the rails as low as physically possible:

http://iainel.co.uk/images/forums/NovaWIP2b/366.JPG

You can see how much it's lower on the spreader plate compared to orginal:

http://iainel.co.uk/images/forums/NovaWIP2b/367.JPG

I've also coupled this with going 1 bolt hole lower on the rear of my side mounts. To achieve this was a task in itself, and included:
1) Shortening the height of the bracket to clear the harness hole
2) Reversing one of the bolts, countersinking the metal and using a countersunk bolt (to clear the seat)
3) Using a shallow allen headed bolt on the sidemount-to-car just to clear the seat

http://iainel.co.uk/images/forums/NovaWIP2b/368.JPG

This was a lucky fluke, luckily the seat feels nice in front of the harness eye bolt lol

http://iainel.co.uk/images/forums/NovaWIP2b/369.JPG

New seating position is excellent, very low with good visibility still, and miles away from the rollcage

http://iainel.co.uk/images/forums/NovaWIP2b/370.JPG

http://iainel.co.uk/images/forums/NovaWIP2b/371.JPG

http://iainel.co.uk/images/forums/NovaWIP2b/372.JPG

[House]

I would occasionally hit my helmet on the rollcage, which wasn't ideal.

Don't lie, you told me you love smashing your helmet into things.

Proper job this.

[scott.parker]

Nice one on sorting out the seats, I had mine low as I could..


Probably billing. I must insist any photos are upload with the worst Instagram filter available though.

You'll be the only one there! Lol it's moved to the show ground at market Harborough, so it's also closer..

[prs]

nicely done!

[RallyMarshal]

Good progress though I think you might need to rename the team if you start doing things properly....

Team not quite as shonky as before..?

Paul..

[BRoadGhost]

Can't beat a low bucket lol - You make me wanna drop my seat rails down futher, think I could go as far as the tube onto the floorpan!

[Stuart]

Can't beat a low bucket lol - You make me wanna drop my seat rails down futher, think I could go as far as the tube onto the floorpan!

tube under the floor :D

[BRoadGhost]

The floor is about 4" from the ground, it couldn't happen; I guess if you were doing extremes you could half the tubes length ways & seam them to the floor!

[Benn]

They look better.

[House]

Good progress though I think you might need to rename the team if you start doing things properly....

Team not quite as shonky as before..?

Paul..

See my thread for restoration of the shonkiness Paul, keeping the TSV name alive!!!

[Mike]

That replica tailgate is amazing lol lol lol

When you take a mould of a re-mould of a re-mould, the end part actually ends up substantially smaller then the genuine original.

Thats why loads of replica grp panels never fit very well.

[Iain]

I think a lot of the tailgate fitment issues are due to the fibreglass skins bring thciker than the pressed steel. Then bolting on standard hinges pushes it out way too far.

It was evident everything was a bit thicker when the rear screen was going in. Was a bit of a pain.

It looks the part now I have tickled the hinges. You'd not notice it is fibreglass.

Thanks for the comments all. The rails could go lower with substantial floor modifications.

[Iain]

First outing of the year did not go well. The engine went all unbalanced and won't go into gear so suspect the clutch cover plate has eaten itself again.

http://iainel.co.uk/images/forums/Misc/rps20170312_185818_395.jpg

[House]

And the shonkiness returns

[Benn]

Oh :(

[Harvey]

I know you're finding less and less to do but breaking it (again) doesn't impress anyone, grow up.

[Iain]

I think I'll try a Helix cover plate.

http://iainel.co.uk/images/forums/NovaWIP2b/373.JPG

http://iainel.co.uk/images/forums/NovaWIP2b/374.JPG

http://iainel.co.uk/images/forums/NovaWIP2b/375.JPG

[turbojolt]

Like Harvey told you ages ago l

[Harvey]

Plus a TTV flywheel :)

[Iain]

The hilarious part is the LUK clutch problem diagnostics PDF and it's explanation for the problem.

http://iainel.co.uk/images/forums/Misc/rps20170313_221807_867.jpg

Basically I'm crap at changing gear!

[Stuart]

Or you've got a sloppy box

[Will F]

Strange. I've used a standard clutch on a 280lb/ft engine for 3 years without issue... How old is the clutch?

[Iain]

New LUK clutch in September 2014 I think, when it broke at Oulton with the same issue. So 2 years of trackdays.

[RallyMarshal]

Like Harvey told you ages ago l

Like I also told him.... pah.

Also agreed on the TTV flywheel..


Paul..

[Harvey]

Buy the top one part no.0559 click me (http://ttvracing.com/products/?manufacturers=opel-vauxhall&engine=opel-vauxhall-c20xe-let&type=flywheels). It actually weighs 3.9kg as the 4.2kg is for the pot type but TTV have never updated the details. They look almost too nice to fit and should ideally be used for wall art.

http://ttvracing.com/wp-content/uploads/Vaux-0559-xe-flat-4.21.jpg

[RallyMarshal]

https://www.part-box.com/index.php?route=product/product&path=81_167&product_id=49366&sort=p.price&order=DESC&limit=100

[Harvey]

Already sent Iain the details for them as that's the sales part of www.coordsport.co.uk

[Iain]

Too much wonga right now if I need to buy a Helix cover plate lol You lot are a bad influence.

[Benn]

I know you're finding less and less to do but breaking it (again) doesn't impress anyone, grow up.


You must spread some Reputation around before giving it to Harvey again.


If i could i would.

[Harvey]

So so so fast with only 4 gears the wife could only get a blury picture of the one and only Iain at Cadwell today...zoom clunk bang...where's 5th gone!!!

http://img.photobucket.com/albums/v214/harvey.emsley/General/img_3238%20Small.jpg

[bazzap8389]

Poor car. I'm sure he breaks it deliberately.

[Iain]

Alright so I took it to Cadwell yesterday, the above hints at a slight problem I had...

First off, some prep. New clutch cover plate:

http://iainel.co.uk/images/forums/NovaWIP2b/376.JPG

Lots beefier where it matters:

http://iainel.co.uk/images/forums/NovaWIP2b/377.JPG

Bleed out some new Motul RBF 660 with my new pressure bleeding toy:

http://iainel.co.uk/images/forums/NovaWIP2b/378.JPG

Tackled the exhaust blows which I believe are giving me stonking headaches when driving it. Turns out the front flexi was completely knackered, so this was bodged and a new one ordered:

http://iainel.co.uk/images/forums/NovaWIP2b/379.JPG

Some pictures may crop up, but I've swapped my wheels around. Road tyres are now on black powdercoated Cesaros, Rainsport wets are now on bright orange Cesaros and I had a few more new slicks fitted to some more matt black Cesaros.

So I took it to Cadwell yesterday. Managed about 4 laps when it crunched going into fifth and made a hell of a noise.

I initially thought it was the new clutch so pulled the cover plate off. That was fine. Investigated the box by removing the diff cover plate and turret to show no problems.

I'd had the input shaft out so checked that by removing the end cover, uh oh:

http://iainel.co.uk/images/forums/NovaWIP2b/380.JPG

http://iainel.co.uk/images/forums/NovaWIP2b/381.JPG

http://iainel.co.uk/images/forums/NovaWIP2b/382.JPG

I have no idea what has happened. Either a foreign item got in there when I had the cover off, or something has failed and taken out the gears. Looking at the picture it looks like it's missing a bit of circlip so maybe that has failed and jumped in?

I removed the fifth bits and took it out as an incredibly noisy 4 speed for a few sessions, so I think it's all pretty much toast now as it started making some horrendous noises. :)

[Harvey]

I have kept a chunk of tooth from one of those rather sad looking 5th gears as a reminder to myself to never ever ever ever let you drive one of my cars you ruthless car breaker.

[Benn]

Ouch!

[Harvey]

Ouch!

Said the 5th gear when he killed it.

[Benn]

Bet there was more screaming and pleading for more time...


HA

[Iain]

It's pretty much all scrap. The only saving grace is it looks like the diff survived.

Stripdown

http://iainel.co.uk/images/forums/NovaWIP2b/383.JPG

More bits have worked their way through

http://iainel.co.uk/images/forums/NovaWIP2b/384.JPG

Straight cut 4.2 final drive dead

http://iainel.co.uk/images/forums/NovaWIP2b/385.JPG

The good news is my ATB diff looks good, just need to clean it thoroughly to make sure there's no swarf in there.

http://iainel.co.uk/images/forums/NovaWIP2b/386.JPG

When I removed the gearbox, the input shaft stayed in the clutch and was dragged out of the gearbox. This means it had wound itself out of the little bolt that holds it in position - maybe I didn't tighten it up as much as it needed, but I didn't think it needed to be mega tight as it had nowhere to go. I think this means the input shaft has moved further towards the engine, and a sharp gear change has put pressure on the shaft. This may have snapped the circlip below, which has got wedged in the fifth gear and munched it. Makes sense in my head but who knows.

See the missing bit of circlip here:

http://iainel.co.uk/images/forums/NovaWIP2b/387.JPG

[totalnova]

Ouch, I'm sure you'll have it back on the road/ track in no time and with an even better spec then before.

[Stuart]

If you're gonna fuck it up you may as well do it right!

[House]

I love you

[Harvey]

click me and buy (http://dev.motorsport-tools.com/quaife-vauxhall-astra-kadett-f18-f20-gearbox-5-speed-synchromesh-gear-kit-cwp.html) Mr 5th gear eater.

[BRoadGhost]

Takes a big man to admit there could have been a fault on the build so fair play on that. January before last I mullered 3rd in my F16 with 4.18 FD (all o.e gears) just at part throttle 4.5K rpm.

If you are looking for gearbox parts I'll have a straight cut 4.85 crown wheel & pinion in a matter of a couple of weeks if you can hold out.

[Iain]

I think that'll be a little too short for me. Thanks though.

Funnily enough if it was that bolt on the input shaft that caused it - when building it back up I bolted the cover plate on, pondered removing it to check I'd tightened it up enough and thought 'hey where can it actually go or undo itself'. Epic fail.

[carls nova sri]

Ahh that's devastating hopefully you sort everything out

[House]

I think that'll be a little too short for me. Thanks though.

Funnily enough if it was that bolt on the input shaft that caused it - when building it back up I bolted the cover plate on, pondered removing it to check I'd tightened it up enough and thought 'hey where can it actually go or undo itself'. Epic fail.

The Shonky build technique has returned.

However this ethos shows you to be a true member of Team Shonky Vauxhall!! The "what's the worst that can happen" ideology is ingrained in our very core!!!

[Iain]

Fixed. Downgraded, but fixed.

Nice unmolested standard F20 3.55FD purchased, thanks Ben/Nemesis

http://iainel.co.uk/images/forums/NovaWIP2b/388.JPG

The box came running a hydraulic setup, which was very easy to swap over to cable. Remove the hydraulic release bearing, and wiggly pipe:

http://iainel.co.uk/images/forums/NovaWIP2b/389.JPG

And replace with a standard release bearing sleeve with new input shaft seal. Then the manual cable arm etc fits as normal.

http://iainel.co.uk/images/forums/NovaWIP2b/390.JPG

Holy moly was the castle nut tight. No sealant or funnies, just mega tight. Lots of WD40 and a professional tool built:

http://iainel.co.uk/images/forums/NovaWIP2b/391.JPG

Which fits like so:

http://iainel.co.uk/images/forums/NovaWIP2b/392.JPG

And the old diff was out.

The Quaife ATB was stripped down and thoroughly inspected and cleaned. All the worm gears were cleaned and some of the outer gear surfaces were dressed and cleaned:

http://iainel.co.uk/images/forums/NovaWIP2b/393.JPG

Cupped washers for the diff pre-load fit alternating in-out-in etc:

http://iainel.co.uk/images/forums/NovaWIP2b/394.JPG

And fitted up with the new boxes crownwheel:

http://iainel.co.uk/images/forums/NovaWIP2b/395.JPG

The rest of the box got cleaned up inside and out, taper bearings set and all fitted up:

http://iainel.co.uk/images/forums/NovaWIP2b/396.JPG

Box fitted, and a bonus replacement inner CV which was discovered knackered at Cadwell:

http://iainel.co.uk/images/forums/NovaWIP2b/397.JPG

Test drive success. And a bonus picture, R1Rs are now on powdercoat black Cesaros and 5mm spacers. Mmmmmmmmm I like it.

http://iainel.co.uk/images/forums/NovaWIP2b/398.JPG

Bought another set of Cesaros too (4 and a half sets now!), oops lol

[House]

Is this a road only car now?

[Iain]

Helical gears and not leaking exhaust fumes into the cabin, I think I'll use it as my daily driver now.

[8valve-craig]

Irresponsible place to stop. Or was it broken down again?

[Stuart]

I can only see yellow lines, werent you supposed to be photographing the car?

[tom reid]

Good to see this car still developing, well done Iaiain

[Benn]

Nice rebuild on the box. You've gone back to a cable change now?

[Iain]

The cable change was due to being a hydraulic clutch F20. I wasn't aware they even made one but it looked factory. The right lumps are on the casing to allow it to be converted back to the original release bearing and arm.

[Iain]

Good to see this car still developing, well done Iaiain

Bit of an step in the wrong direction this time, but it's still going. I'm aiming to make it cheaper this year lol For example I've just ordered some £70 DS3000 pads to replace the £180 CL6s!

[turbojolt]

1.7 td engine next for better fuel economy

[House]

The cable change was due to being a hydraulic clutch F20. I wasn't aware they even made one but it looked factory. The right lumps are on the casing to allow it to be converted back to the original release bearing and arm.

Next you'll be saying you're gonna use 95 ron to save money

[Iain]

Trackday prep.

New pads all round, trying out the DS3000's again as they are £100 cheaper than the Carbon Lorraines. GM rears.

http://iainel.co.uk/images/forums/NovaWIP2b/399.JPG

I needed to fit my new front exhaust flexi, so thought I'd tackle the exhaust situation while it's off. Removed and backbox cut open to inspect:

http://iainel.co.uk/images/forums/NovaWIP2b/400.JPG

Not much deadening left in there:

http://iainel.co.uk/images/forums/NovaWIP2b/401.JPG

The small centre silencer has also somehow collapsed on the perforated tube. No idea how this happens but looks to be creating quite an obstruction.

http://iainel.co.uk/images/forums/NovaWIP2b/402.JPG

So decision was made to remove it and replace with some straight pipe:

http://iainel.co.uk/images/forums/NovaWIP2b/403.JPG

Tacked in place:

http://iainel.co.uk/images/forums/NovaWIP2b/404.JPG

Access for re-packing the rear box was tight so the rest of the box outer was removed:

http://iainel.co.uk/images/forums/NovaWIP2b/405.JPG

Acousta-Fil wadding, 400mm wide 2 metres ordered. This is supposed to expand with heat and deaden very well.

http://iainel.co.uk/images/forums/NovaWIP2b/406.JPG

Used about 1.8 metres re-packing it around the perforated tube and tucking it in the box.

http://iainel.co.uk/images/forums/NovaWIP2b/407.JPG

Welded everything up and gave it a waft of VHT paint:

http://iainel.co.uk/images/forums/NovaWIP2b/408.JPG

While the welder was out I gave the centre box a little more support too, just cos.

http://iainel.co.uk/images/forums/NovaWIP2b/409.JPG

Sound meter testing will be formally done on the next trackday (Rockingham 13th) but my unofficial testing looks promising. It's a 105dB day next so should give me a bit of wiggle room.

[House]

Are we at a trackday? Did I not get an invite?

[Iain]

I've booked you on so be there or be square lol

[House]

Result!!

[BRoadGhost]

Top Wafting

[Benn]

I like it.

Any pics of the cable change set up?

[Iain]

It doesn't have cable change. I had to change the box to a cable clutch. Change to cable. Cable change. Gerrit?

[Benn]

Oh sorry! Cable clutch, not gears.. ha sorry.

[turbojolt]

Get with it Ben you div

[Benn]

*Picks up mod stick.....*

[Iain]

Rockingham international sports circuit today with House.

It looked like it was going to be wet, so I tickled the wet wheels with a bit more orange on the inside to tidy them up:

http://iainel.co.uk/images/forums/NovaWIP2b/410.JPG

But they weren't needed! After the sighting laps went straight to slicks and didn't look back.

The yellow sticker is my sound test pass, which amazingly was 82dB. That's down from 97dB and 3 silencers, that Acousta-Fil is great stuff. I had bought a 'Decibel Devil' just incase but didn't need it.

http://iainel.co.uk/images/forums/NovaWIP2b/411.JPG

I took an infra-red thermometer with me and got some good info after some quick laps. These are the tyre temps on all tyres, inside middle and outside. From this I am going to add some camber to the rear wheels. as the one I lean on was colder by a long way on the inside (9 degrees colder on inside at 38 degrees opposed to 47 on the outside edge)

http://iainel.co.uk/images/forums/NovaWIP2b/412.JPG

Fairly poor shot of the car in the pit garage lol

http://iainel.co.uk/images/forums/NovaWIP2b/413.JPG

[BRoadGhost]

You can actually go cable gear change straight on top of that box; you will need to make a mounting bracket however for the F20

[Iain]

Bit of in-car footage. I've upgraded my kit to a Hero 4 Silver, extra battery pack and official WiFi remote. Cracking bit of kit, now records in 1080p (although that hasn't appeared on YT for some reason), and can turn on the camera and start the recording from a button on the rollcage.

Only uploaded a lap, but it contains all the key points. Bit of sideways action, bit of braking wiggle that we both suffered from and shows how evenly matched the cars are.


https://www.youtube.com/watch?v=58y3VbyCtPQ

[darragh792]

going well, looks like good fun having two similar cars to go on a track day

[BRoadGhost]

I just wish I could be out there with some other XEs

[House]

going well, looks like good fun having two similar cars to go on a track day

All we do is have fun!! I was in complete stitches following Iain go sideways!!

We're reasonably evenly matched, sure Iain would have the edge in combat though!!

[8valve-craig]

I just wish I could be out there with some other XEs

What's stopping you?

[Benn]

Bullet points.

Great driving,
Nice looking track,
House's seem to lock that n/s/r wheel up well,
Looks alot of fun.

[House]

What's stopping you?

Yeah BG, what's stopping you?? We'll be at Brands 6th June, hopefully Mallory, Snet and Donny at some point soon too.

Benn, I was working on my trail braking, trying to brake at the 100 metre board and trail brake down into turn 2. Loads of fun!!

[toymex]

I will try to pop down to. Brands and get that passenger ride

[BRoadGhost]

Circumstance & perpetual development combined with frequent evictions

[NovalutionGSi]

Let us know when you're at Snetterton, I'll pop down if not busy.

[House]

All you boys are always welcome!!!!

[Iain]

OK so Rockingham's tyre temperature measurement was an eye opener. Front wasn't perfect, but rear was not good at all.

The jack picture on the previous page shows my temperature measurements - for the outside tyre that I was leaning on (Rockingham is an anticlockwise circuit so RH rear) the temperature was 38C inside, 47C middle and outside. I'm told the ideal is 10 degrees between inside and outside, with the inside hotter. e.g. 45 inside, 40 middle, 35 outside.

To combat this I've added some camber shims - totally guessed what I'll need but it's a starting point.

For those of you that have used these shims all the below will be obvious but for those that haven't, here's a few pics.

Current camber on the rear, a shade over 0 degrees. Slightly more on the passenger side but that'll be standard Nova geometry tolerances

http://iainel.co.uk/images/forums/NovaWIP2b/414.JPG

5.75200K is the part number we need, which contains one shim and instructions

http://iainel.co.uk/images/forums/NovaWIP2b/415.JPG

I've gone for maximum camber (1.5 degrees negative) and no toe adjustment, which according to the chart is '20-20' - this means we line up the inside and outside rings, with 20 facing upwards

http://iainel.co.uk/images/forums/NovaWIP2b/416.JPG

Camber adjustment demonstration

http://iainel.co.uk/images/forums/NovaWIP2b/417.JPG

Use the chart to cut out some sections to fit the stub axle - for some reason they have different diagrams for Corsa A and C despite them being the layout - I used the Corsa C pattern (Pattern B)

http://iainel.co.uk/images/forums/NovaWIP2b/418.JPG

Which fits perfectly on the Nova axle

http://iainel.co.uk/images/forums/NovaWIP2b/419.JPG

The rear is now approx 1.5 degrees negative. Again, little more on passenger side but that'll suit most clockwise circuits

http://iainel.co.uk/images/forums/NovaWIP2b/420.JPG

[toymex]

Just booked on for the 6th, my mate is there in his Audi TT spaceframe after a two year build ,first time on circuit if it goes as good as it looks it will be rapid

[Iain]

Yessssssssss. Good man.

[toymex]

I can't wait ,it was almost a year since the last outing at Bedford ,I will have to try to remind myself how to drive it

[Benn]

Skims look good. Nice way to correct the tyre temps.
Plus..... Camber YO.

[Harvey]

He loves fiddling with shimage...should handle superb at Brands. Don't break the gearbox or engine for that matter as you have more than enough 'repair' pictures in your diary.

[Iain]

Monday I ventured down to Brands Hatch and stayed with House, for a MSV-run trackday on the Tuesday. Superb accomodation, 5/5 would stay again.

Well, the trackday. My first time at Brands, nice little circuit, good facilities and pit garages. The weather wasn't ideal, but you can't win them all.

Got there in the pouring rain.

Sound test... Wet.

http://iainel.co.uk/images/forums/NovaWIP2b/421.JPG

Chucked it in the garage with Housy. The garage was wet.

http://iainel.co.uk/images/forums/NovaWIP2b/422.JPG

Caught up with Jezz on the day. Sneak shot of his car in the wet.

http://iainel.co.uk/images/forums/NovaWIP2b/423.JPG

Now incase you were wondering, it was very wet. Because of this my 1960s style ignition system had some damp ingress and caused some horrific misfires. Cap and leads off and dried out, coil module out and wired in a better earth - the blue wire was kindly cut out of House's car so I could extend it to the chassis leg earthing point. I cable tied it up behind the slam panel for some protection...

http://iainel.co.uk/images/forums/NovaWIP2b/424.JPG

...And thoroughly waterproofed that corner of the car with gaffa tape to stop water getting to it all lol

http://iainel.co.uk/images/forums/NovaWIP2b/425.JPG

Which only bloody worked! Ran perfectly for the rest of the day.

House found a weigh bridge, so I chucked mine on with half a tank of fuel in. About what I expected @ 822kg no driver.

http://iainel.co.uk/images/forums/NovaWIP2b/426.JPG

Track action was fun. Wet was a bit slow and slippy, but towards the end of the day we managed 2-3 dry sessions where I could actually try and learn the circuit.

Rear camber actually was spot on, the rear outside tyre is now seeing 38 degrees outside edge and middle and 45 degrees inside edge. That's a lot better than Rockingham and should give more contact, grip and better tyre war.

All in all a jolly day out, no records broken, I didn't really get much dry time to learn the circuit but it was an enjoyable drive while out there.

[Iain]

Mandatory video. With only a few dry sessions to try and learn the lines it's not the tidiest but it'll serve as a reference point for when I go back.


https://www.youtube.com/watch?v=-v8mqHWtt4s&t=30s

[Harvey]

822kg...fatty!!!

[brucer]

looks, awesome. I'd like to do the full circuit at brands.

[House]

looks, awesome. I'd like to do the full circuit at brands.

Good luck!! About 1-2 a year and they're always fully booked and bloody expensive!!!!

[brucer]

Good luck!! About 1-2 a year and they're always fully booked and bloody expensive!!!!


Thanks for the heads up, I want to do the full Silverstone track too, just to say i've done them really.

[Iain]

I've had enough breakdowns to put me off spending £450 booking onto a trackday lol It's not going to be better than three Cadwell days.

[Andy]

Damp start/ignition sealer is good for electrical connections.

[brucer]

I've had enough breakdowns to put me off spending £450 booking onto a trackday lol It's not going to be better than three Cadwell days.


I suppose you do give it death, compared to what i'd be like, tootling round like an old man in a sports car with a pipe and slippers.

[House]

I've had enough breakdowns to put me off spending £450 booking onto a trackday lol It's not going to be better than three Cadwell days.

Nothing on this planet is better than 3 days at Cadwell

[NovalutionGSi]

So that must have been where you were off to on Tuesday.. spotted a lovely off white Nova on the back of a trailer, however that was near Donnington so put 2 and 2 together and thought you'd been there!

[House]

spotted an off white Nova

I believe Mr GSI has just mugged you off like some fucking yank buying London Bridge.

Off white nova?!? it's yellow!!

[Iain]

I didn't notice the sly 'off' comment first time I read that. Not cool. Not cool.

[NovalutionGSi]

To be fair, it was getting dark and it still looked White... plus it wasn't parked next to my glacier white sting!
I'd of waved but as I only clocked the trailer you had past the rear of my Astra by then!

[8valve-craig]

Don't make excuses. Grey, cream, off white, piss yellow and hearing aid beige are all acceptable.

[RallyMarshal]

Any further developments Mr E?

[Iain]

Righto. A few improvements, a few repairs and a trackday.

First off, I robbed the electric fan for my daily so I've fitted a nice 9" Spal puller

http://iainel.co.uk/images/forums/NovaWIP2b/427.JPG

The throttle cable frayed and stuck, so a new cable and better direct routing:

http://iainel.co.uk/images/forums/NovaWIP2b/428.JPG

With a nicely cut and crimped end:

http://iainel.co.uk/images/forums/NovaWIP2b/429.JPG

Drivers chassis leg is getting worse for wear, I think rust has fatigued it:

http://iainel.co.uk/images/forums/NovaWIP2b/430.JPG

Repair section includes the dented area, might as well while I'm there:

http://iainel.co.uk/images/forums/NovaWIP2b/431.JPG

Repaired:

http://iainel.co.uk/images/forums/NovaWIP2b/432.JPG

Stonechipped:

http://iainel.co.uk/images/forums/NovaWIP2b/433.JPG

Took it to Blyton Park on 24th Sept, great day with the Mk2 Astra lads. There's some videos if I can be bothered but it was all fairly ueventful!

http://iainel.co.uk/images/forums/NovaWIP2b/434.JPG

[totalnova]

Great to see you updating this again, always enjoy your updates. :thumb:

[BRoadGhost]

such stronk!

[Iain]

Few improvements. I've ditched the electric windows and refitted the polycarbs I fitted when I first built it all those years ago. With the glass, motors and window nets I save 7kg.

http://iainel.co.uk/images/forums/NovaWIP2b/435.JPG

I've also bought a gizmo to check my fueling on the carbs, as I am considering going to mappable ignition. AEM X-Series UEGO 4.9 wideband:

http://iainel.co.uk/images/forums/NovaWIP2b/436.JPG

Nice bit of kit:

http://iainel.co.uk/images/forums/NovaWIP2b/437.JPG

Handily many years ago I welded in a bung, so the lambda fitting was easy. I'd even done it properly and angled it upwards a bit:

http://iainel.co.uk/images/forums/NovaWIP2b/438.JPG

It is only temporarily installed, the wiring comes through the bulkhead and the wiring sits on top of the dash.

The gauge is installed in a Stack roll bar pod mount which keeps it nice and secure:

http://iainel.co.uk/images/forums/NovaWIP2b/439.JPG

http://iainel.co.uk/images/forums/NovaWIP2b/440.JPG

I've also bought a new gearbox which I should be picking up at the end of the week - it's hybrid of F18 casing, F20 internals, Quaife 4.2 final drive and Quaife ATB diff. Just like my old one that nuked itself. lol

[total_vauxhall]

Wideband looks the bees knees mate.
Also just incase your intrested on ebay you can get alloy mount clamps ment for 4x4 spotlights ect but work mint on cages and they come with rubber shims for diffrent tubes I used them on my roof bar switch pannel about £6 from china and look spot on .

[Iain]

Nice idea with the spotlight brackets, the Stack mount is meant for 40mm tube so as you can see I've improvised with gaffa tape lol

[Iain]

Well the gearbox was a bit of a mixed bag. It is a 4.2 Quaife FD, Quaife ATB, F20 cluster and a long fifth in an F18 housing. When I bought it:

http://iainel.co.uk/images/forums/NovaWIP2b/441.JPG

The internals were known good but the build was unfortunately questionable so it ended up getting stripped and inspected, cleaned and fixed.

The F18 casing was binned as it doesn't have a clutch inspection hole. The speedo drive is blanked, but that is just a core plug that can be knocked out.

The gearset had a tight spot in one place which is very concerning.

The fifth gear was removed and replaced with a standard F20 one, which handily fixed the tight spot too. Upon removing the fifth I found the input shaft wasn't even fitted properly, missing the bolt and circlip that retains it. This was corrected.

Upon inspecting the rest of the box, it turns out the input shaft was absolutely full of metal swarf so the box would have eaten itself it used as-is anyway. And every bolt was tightened up unnecessarily tight, I'm surprised there's any threads left.

Stripped and cleaned parts ready for installation:

http://iainel.co.uk/images/forums/NovaWIP2b/442.JPG

I went a little unorthodox, instead of building it into a new box and swapping release bearing guide, clutch arm, mounts, etc etc I simply removed the gearset from my current box:

http://iainel.co.uk/images/forums/NovaWIP2b/443.JPG

Crownwheel was removed to set the preload on the taper bearings, so re-installed with loctite and torqued to 90nm

http://iainel.co.uk/images/forums/NovaWIP2b/444.JPG

Rubber-seal gaskets came with the box so re-used them, I've not seen an end plate one before so that was a nice touch:

http://iainel.co.uk/images/forums/NovaWIP2b/445.JPG

The original metal diff cover plate was heavily scored, so I made a new one using an M12x1.5 sump bolt, threaded insert and a welder:

http://iainel.co.uk/images/forums/NovaWIP2b/446.JPG

Finished article:

http://iainel.co.uk/images/forums/NovaWIP2b/447.JPG

[Iain]

Whilst I was in the area I've done a few more improvements. Pro-tec solid rack mounts:

http://iainel.co.uk/images/forums/NovaWIP2b/448.JPG

Fitted:

http://iainel.co.uk/images/forums/NovaWIP2b/449.JPG

Custom bottom brace, apparently this really helps tighten things up by stopping flex along the chassis legs. Whilst it was made for a Nova, with my custom crossmember and tolerances it was never going to just fit.

http://iainel.co.uk/images/forums/NovaWIP2b/450.JPG

So I hacked it up. The main difference was the bend on the drivers side was flipped - it was previously made for a smallblock but flipping it over nicely clears an XE sump as if it was designed for it.

http://iainel.co.uk/images/forums/NovaWIP2b/451.JPG

Rear part mounted to the car, then I tacked it all together and welded it off the car.

http://iainel.co.uk/images/forums/NovaWIP2b/452.JPG

Finished product, pretty pleased with it.

http://iainel.co.uk/images/forums/NovaWIP2b/453.JPG

[boffer8]

Looking good bud!

Where did you get the bottom brace from? :eek:

[Iain]

Hangar 30 who is doing heds drag car makes them. This was the one off his car I’ve butchered to fit mine but he would normally build it on your car for a perfect fit.

[Al1exx]

Nice work mate :thumb:

[bazzap8389]

Top work as always :thumb:

[boffer8]

Hangar 30 who is doing heds drag car makes them. This was the one off his car I’ve butchered to fit mine but he would normally build it on your car for a perfect fit.

Thought it looked very similar... lol

[Iain]

Thought it looked very similar... lol

It was very nicely finished, I did feel bad hacking it to pieces lol

[Harvey]

Love the new climbing frame, makes engine/box removal even more of a darn faff.

Can we all place bets on how long the new box will last, my first guess is 187.32miles exactly. Let's just hope it's longer than the last few!!!

[Benn]

Crownwheel was removed to set the preload on the taper bearings, so re-installed with loctite and torqued to 90nm

http://iainel.co.uk/images/forums/NovaWIP2b/444.JPG


Preload? Is that set able on all diffs?

[Iain]

I'm referring to setting up the taper bearings, like a rear wheel bearing. Not a configuration setting of the diff. With no crownwheel fitted, it's a lot easier to feel for movement in the bearings to set by feel.

[Benn]

Oh ok. Thank you.

[Iain]

First 2018 outing is Mallory Park this Saturday, 27th January.

I have some R888s on some Cesaros to try out if I get a dry session - the idea being I can move away from the slicks which mask any fault in skill, line and car setup and make things a little more fun.

I also have a rosejoint-linked rear beam to try on the car, however won't have time to get this on before the day.

[novarally]

I also have a rosejoint-linked rear beam to try on the car, however won't have time to get this on before the day.

I’d be keen to know more on this please Iain.

[Iain]

https://uploads.tapatalk-cdn.com/20180125/5a5174a5d2b14231feebbb884642f57d.jpg

Here’s a sneak preview Colin. It’s one of Ben’s (Hanger 30). Nylon bushes, beefed up coilover mounts and rose jointed link bars to ensure the geometry does not change due to flex. All nicely powder coated.

I plan to fit a Saab 93 rear anti roll bar, which handily can be bought in different thicknesses (22 & 25mm). I was going to have a bid on your bladed one on eBay as this beam has mounts welded to it for that style already!

[prs]

https://uploads.tapatalk-cdn.com/20180125/5a5174a5d2b14231feebbb884642f57d.jpg

Here’s a sneak preview Colin. It’s one of Ben’s (Hanger 30). Nylon bushes, beefed up coilover mounts and rose jointed link bars to ensure the geometry does not change due to flex. All nicely powder coated.

I plan to fit a Saab 93 rear anti roll bar, which handily can be bought in different thicknesses (22 & 25mm). I was going to have a bid on your bladed one on eBay as this beam has mounts welded to it for that style already!

nice looking rearbeam!



I was going to have a bid on your bladed one on eBay as this beam has mounts welded to it for that style already!

i had the same plan but the listing ended before the end of the action??

[8valve-craig]

I was going to bid on that too. Thought it was a safe bet that Colin wouldn't sell early, I'm sure he normally lets them run.

[prs]

it seems this might be interesting for some people on here: http://www.sellholmshop.se/chassiedelar-1/krangningshammare.html

a compete kit is about £280,-

[phil_tucker]

I was going to bid on that too. Thought it was a safe bet that Colin wouldn't sell early, I'm sure he normally lets them run.

As was I, we could've had a right bidding war.....

[Iain]

Well the car performed amazingly on Saturday. Not sure why, I did barely any prep other than some fluids.

Mallory was incredibly wet, rained all day, but the Rainsports were excellent. I could perfectly balance it between under and oversteer and didn't spin out all day.

Short video of a very wet morning lap:


https://www.youtube.com/watch?v=lSGdJI9dwuk

[Iain]

Longer video of chasing a Clio around, which was fun. I was faster in Gerrards, he was faster getting out of the hairpin.


https://www.youtube.com/watch?v=efAzEAXVlSc&t=6s

[RallyMarshal]

Nice Job :-)

[totalnova]

Always love your videos but it looked like that Clio was holding you up, what's your opinion would you prefer he moved over and let you past or do you like to have a little play?
Nick

[Iain]

He held me up at Gerrards but pulled away from me on the hairpin. I think I was catching him on a clear circuit so maybe move over but it was fun driving with a confident driver. I showed a headlight up the inside towards the hairpin on one lap and he immediately took the defensive line so I think he's a racer lol

[BRoadGhost]

Yours is faster through the bends no doubt! That steering wheel is too small; you shouldn't be taking hands off the wheel to counter steer - the diff & rack should mean you can get it back. You do still have to be fast though with a short wheelbase :D

[8valve-craig]

Good Video Iain, Glad to see you found some love for it.

Did your car have red wheels on? Someone mentioned that it was me at Mallory (even though i don't have red wheels).

[Iain]

I had the bright orange ones on (my wets)

[toymex]

Did you get the new rear beam on, if so how was it ? And where is House ,doesn’t seem right not following a red Nova

[Iain]

New beam isn't on yet - I need to source some handbrake cable guides and devise a roll bar setup. I did have the new chassis brace and solid rack mounts to test out.

Housie couldn't be bothered to come up to see me. The main purpose of the day was testing my mates new MX5 coilovers!

[BRoadGhost]

If the beam's with the rose joints you wont need the ARB

[prs]

If the beam's with the rose joints you wont need the ARB

:confused:
can you explain this statement..?

[BRoadGhost]

Isn't the new beam going to be this one? (or like it?)

https://uploads.tapatalk-cdn.com/20180125/5a5174a5d2b14231feebbb884642f57d.jpg

[prs]

Isn't the new beam going to be this one? (or like it?)

https://uploads.tapatalk-cdn.com/20180125/5a5174a5d2b14231feebbb884642f57d.jpg

it's going te be.. but why do you say you don't need an arb with these rosejoints...?

[BRoadGhost]

Fit it and find out ;O

[Iain]

That is the actual beam yes. My understanding is the link bars keep the geometry in check, but will not give the benefits of a roll bar reducing wheel-to-wheel roll.

[House]

It's obvious isn't it!!

The torsional stiffness of the additional bars secured to the beam using flexible rose joints add dynamic load spreading, meaning that the additional G-forces caused on conditional turn in translate through the flexible joint and into the centre of the beam, thereby fully dissipating any form of oversteer body roll or fluctuation. The only real way to work this out is to install a torsion/roll meter and assess if the car does indeed flex the tyres more, if it does then you'll know that the rear beam is indeed on solid mounts and the shocks are too stiff. The answer then would be to try 5 different sets of rear shocks and then after that install an absolute central roll limiter to prevent further discretional body roll around the Y axis.

However if you just wanna bolt on ARB's willy nilly then don't come crying to me when you're backwards in the gravel

[House]

:confused:
can you explain this statement..?

But PRS the question is, can you explain how a man may eat his own head?!?!?

[BRoadGhost]

Revel in the subversion.

All an arb does is (in part) add strength (you no longer need), unsprung weight (I expect you wouldn't like) & add effective spring rate (when it now can just be achieved through a change of springs should you even need it).

[Iain]

I'd prefer to limit roll with a roll bar rather than increase spring rate. It'll keep the rear end safer on the straights, and a roll bar is a lot more tunable at track side for wet days - none, standard, 22mm and 25mm are all available and changed with 4 bolts.

[BRoadGhost]

You'd be better off replacing the bushings for spherical bearings

[NOVANICK]

Wow, great work. Read the whole of this thread from start over past week whilst travelling for work. Now motivated to get mine back on track as its not been touched in years... Thanks!

[BRoadGhost]

Nick are you the guy that bought Nigels yellow atb / carbed / alpha ign nova like in your avatar?

[Iain]

Wow, great work. Read the whole of this thread from start over past week whilst travelling for work. Now motivated to get mine back on track as its not been touched in years... Thanks!

Cheers mate, I luckily hosted my own images so the threads not too broken! Glad it’s helped, see you on track this year.

[NOVANICK]

Nick are you the guy that bought Nigels yellow atb / carbed / alpha ign nova like in your avatar?

Yes thats right. Still got it but runs on mbe mgmt and throttle bodies now.

[NOVANICK]

Cheers mate, I luckily hosted my own images so the threads not too broken! Glad it’s helped, see you on track this year.

Yes, the images were a blessing! indeed, see you on track!

[Benn]

Yes thats right. Still got it but runs on mbe mgmt and throttle bodies now.

Sounds like you need a project thread!

[Iain]

I've finished the toe-linked beam, fitted it and tested it. It was eventful, that's for sure.

So I needed a roll bar on the new beam, so I fabricated some mounts out of 25mm box section with captive nuts to facilitate the fitting of a mk2 Astra GTE secondary ARB:

http://iainel.co.uk/images/forums/NovaWIP2b/454.JPG

http://iainel.co.uk/images/forums/NovaWIP2b/455.JPG

Fits nice and snug:

http://iainel.co.uk/images/forums/NovaWIP2b/456.JPG

Handbrake guides also re-attached as my Corsa C rear discs use this:

http://iainel.co.uk/images/forums/NovaWIP2b/457.JPG

Old one removed, new one fitted:

http://iainel.co.uk/images/forums/NovaWIP2b/458.JPG

All fitted:

http://iainel.co.uk/images/forums/NovaWIP2b/459.JPG

[sibzy]

is that a front or rear gte astra roll bar mate?

[Iain]

Took it to Donington yesterday for a test. First session went OK, the new beam was very oversteery but in a predictable sort of way. Second session it thew me off the track, made a horrible noise turning right and I went back to the pits to investigate.


https://www.youtube.com/watch?v=aXb5nX07SVY&feature=youtu.be

Upon further inspection the wheel had touched the tie link bolt and machined a big groove off it. Confused, I did some testing in the pits to try and replicate the issue before going on track and risking my life and a red flag only to get a right royal bollocking for doing "donuts" and almost sent home there and then. Apparently she "wasn't born yesterday it was obvious what I was doing". Riiiigggghhhtt.

Then we noticed the geo had changed to positive camber after my testing so it was loaded on the trailer and took home.

....to change the beam back to the original! Took me and Harvey about 30 mins with the use of a lot of cable ties.

Positive camber yo:

http://iainel.co.uk/images/forums/NovaWIP2b/460.JPG

Hmmm, it actually looks like the new beam is missing the strengthening here!

http://iainel.co.uk/images/forums/NovaWIP2b/461.JPG

Oh yeah, that'll do it!

http://iainel.co.uk/images/forums/NovaWIP2b/462.JPG

With the old beam on, I towed it back to Donington and got a session in before 1pm lunch!

This was entirely my own fault, I didn't twig the plates were missing when fitting, despite the tell-tale signs. The previous owner had a grp-A 2 pot set-up which does not require these parts - d'oh!

[Iain]

Back at the circuit, I did a full afternoon session ignoring some severe wheel wobble due to the unbalanced wheels. I was actually using some well worn R888s instead of the usual Michelin slicks as a test.

http://iainel.co.uk/images/forums/NovaWIP2b/463.JPG

I actually really rated the R888s over the slicks. They gave much more feedback by squeeling when you pushed them too hard, wore much more evenly and over-all were much more enjoyable to drive. I'm going to move to semi slicks instead of slicks from now on, despite more than likely slower laps.

Here's a session towards the end of the day:


https://www.youtube.com/watch?v=2qqVi6nuijc

[Iain]

is that a front or rear gte astra roll bar mate?

It's a mk2 Astra GTE 'secondary' rear ARB. Apparently they have two, one Nova-style one through the middle of the beam and this one attached externally. I believe it's the same as a mk3 Astra GSi and also Saab 900s and maybe 93s.

Thanks to our local lovable rally man Paul (rallymarshal) for the ARB xxx

[sibzy]

cheers, car looks planted in the 2nd video.

[JoeWak98]

What system is this please Iain ?
Cheers


Sent from my iPhone using Tapatalk

[Iain]

What system is this please Iain ?
Cheers


Sent from my iPhone using Tapatalk

It’s an Ashley 2.25” system however the larger squarer centre box is added in to make it a three box system (until I removed the damaged one in the quoted post).

I’ve also replaced he sleeve joint onto the manifold with a flexi due to fatigue causing it to fail.

[JoeWak98]

It’s an Ashley 2.25” system however the larger squarer centre box is added in to make it a three box system (until I removed the damaged one in the quoted post).

I’ve also replaced he sleeve joint onto the manifold with a flexi due to fatigue causing it to fail.

Cheers for that Iain [emoji1303] just getting a few ideas for a system for the rally car as it’s just a bodge which is on it now


Sent from my iPhone using Tapatalk

[brucer]

Love the videos, was your rear wheels not spaced in more without that plate fitted?

[Benn]

Whats the round bit above the D shaped hole in the end....

http://iainel.co.uk/images/forums/NovaWIP2b/461.JPG

[8valve-craig]

Good write up Iian. Kudos for getting back to the track.

Round bit looks like a mounting for a drop link Ben. Probably for a custom ARB.

[Iain]

Love the videos, was your rear wheels not spaced in more without that plate fitted?

It was indeed. Tyre was touching the spring slightly at full droop. Just didn’t twig at the time of fitting, doh.

[Iain]

Whats the round bit above the D shaped hole in the end....

http://iainel.co.uk/images/forums/NovaWIP2b/461.JPG

That’s a mount for a bladed ARB that sits behind the beam. I’m not using them just remnants of a proper car! Look like they could be useful eg droop stops so left them on!

[Iain]

Bit of an update.

The bent beam got fixed, Ben kindly made me some plates up and I managed to straighten it sufficiently and weld them up.

http://iainel.co.uk/images/forums/NovaWIP2b/464.JPG

http://iainel.co.uk/images/forums/NovaWIP2b/465.JPG

http://iainel.co.uk/images/forums/NovaWIP2b/466.JPG

Did a track day at Mallory on the new beam and everything was good. Unfortunately the car developed an intermittent misfire during the afternoon so retired.

http://iainel.co.uk/images/forums/NovaWIP2b/467.JPG

I've struggled to diagnose the misfire so I'm using the opportunity to upgrade. Out with the H&H dizzy, in with a Vauxhall coilpack, QED dizzy blank and bracket.

http://iainel.co.uk/images/forums/NovaWIP2b/468.JPG

Pretty happy with the set up. The leads feel secure, the bracket and coilpack feel sturdy and there should be some gains from having a 3D ignition map (by using the TPS on the carbs).

http://iainel.co.uk/images/forums/NovaWIP2b/469.JPG

http://iainel.co.uk/images/forums/NovaWIP2b/470.JPG

Regarding the management, I've got a DTA S40 ECU and just waiting on the custom loom to turn up. It'll do fuel and spark, but going to get up and running spark-only at first.

[Benn]

Looking good, just reread the beam issues. Did you weld the cut lines up in the beam end too? As they had gone right thru...

[Southie]

Nice to read your still enjoying this, even though it’s a little unreliable at the minute I’m sure you’ll sort it all out Iain :thumb:

[Iain]

Yes it got straightened, then the cracks were welded and smoothed off. Then the plates on all four edges and the circle in the middle at the back. Nice and strong again now.

It's alive once more! I've had my ECU for a week or so and today the custom loom came. He's made it all up to my length specifications to suit where I'm mounting it and done a really neat job of it.

DTA S40:

http://iainel.co.uk/images/forums/NovaWIP2b/471.JPG

Loom nicely heat shrinked, new plugs, waterproofing and labelled:

http://iainel.co.uk/images/forums/NovaWIP2b/472.JPG

First tme the car's seen some engine wiring in a while. Fitted a new Meyle crank sensor. Wiring for coilpack, water temp sensor, air temp, crank sensor, TPS.... Also wiring for injectors that I'm going to tuck out of the way for now.

http://iainel.co.uk/images/forums/NovaWIP2b/473.JPG

And it's running! She fired up first time. Tested a few featuers like coolant fan switch, rev limiter etc, but can't drive it yet as waiting on a custom Jenvey-style to R1 TPS adapter loom.

http://iainel.co.uk/images/forums/NovaWIP2b/474.JPG

Properly chuffed with it.

[Stuart]

Awesome

I trust you and House are dragging your crappy cars to the 35th Anniversary meet at Brunters on the 14th July? (and then to the VBOA show ;) )

[Benn]

Very nice. Its great having a new loom isnt it.
Did you have a map already put on the ecu then?

[Iain]

Awesome

I trust you and House are dragging your crappy cars to the 35th Anniversary meet at Brunters on the 14th July? (and then to the VBOA show ;) )

It has not been discussed. Not looked at any shows this year actually. I’ll get on and see what’s what.

[Iain]

Very nice. Its great having a new loom isnt it.
Did you have a map already put on the ecu then?

Yeah new loom is ace. Lovely and thin and flexible too. If anyone wants a loom making PM for the guys details he was very reasonably priced compared to some I’ve seen and open to customisation.

Ive put Houses map on for now. As it’s only running ignition at the moment I’ll probably get away with leaving it. Hopefully find some jenveys in the future then consider mapping it.

[Iain]

TPS adapter loom for R1 carbs has arrived. Set up the open/closed positions in he software and took it for a spin. I can confirm the car drives a million times better now. Really responsive in the low revs and doesn’t stop pulling.

[8valve-craig]

Placebo effect

[totalnova]

Placebo effect

lollollol

[Iain]

Croft yesterday. Not been before, but very interesting and technical circuit with lots to learn. Only really felt like I was getting most of a lap right towards the afternoon session.

Team Shonky attendees were Harvey in the Astra, House in the Nova and myself. Three started, and three finished with no breakages.

Pit garages were a little small but fitted three OK:

http://iainel.co.uk/images/forums/NovaWIP2b/475.JPG

Harvey's wife on the camera snapped some good shots:

http://iainel.co.uk/images/forums/NovaWIP2b/476.JPG

http://iainel.co.uk/images/forums/NovaWIP2b/477.JPG

http://iainel.co.uk/images/forums/NovaWIP2b/478.JPG

New ECU was faultless. EPAS stopped working momentarily and spat me off circuit but luckily no damage, so I'm going to look into a permanent resistor to solder in rather than the adjustment dial that I think is playing up.

[Iain]

Little video of me chasing the fast man


https://www.youtube.com/watch?v=sWnyWOxVn6Q&feature=youtu.be

[Iain]

Feedback I've received is I unsettle the car every single corner, even when trying to be smooth. I think this is down to my EPAS controller being too sensitive, all the time. To resolve this, I need to feed it a speed signal.

Harvey kindly made me a "wheel speed sensor starter kit", consisting of 15 pulse amp, sensor, wiring and bracket. The orange amp is part number 09185826 and is wired up as follows:
- 15 - ignition live
- 31 - ground
- IN1 - one of the ABS sensor wires
- IN2 - other ABS sensor wire
- OUT - 15 pulse speed signal to feed into EPAS

http://iainel.co.uk/images/forums/NovaWIP2b/479.JPG

This obviously requires an ABS ring on the CV, so I swapped out my non-ABS CV for one with a ring...

http://iainel.co.uk/images/forums/NovaWIP2b/480.JPG

... only to be told it's the wrong ring, having 40+ teeth rather than the required 29. So I relieved a spare CV of it's ABS ring and swapped it onto the newly fitted one:

http://iainel.co.uk/images/forums/NovaWIP2b/481.JPG

I then modified a sensor carrier to fit the Nova hub

http://iainel.co.uk/images/forums/NovaWIP2b/482.JPG

And got it so it fits in snug on the original backplate bolt hole. Because of how it's modified, it can't physically twist into the ABS ring and eat itself, which is great if it works loose.

http://iainel.co.uk/images/forums/NovaWIP2b/483.JPG

Factory fit!

http://iainel.co.uk/images/forums/NovaWIP2b/484.JPG

I'm still feeding a rev signal from the EPAS controller box so the steering works with the ignition on and engine not running, and it appears to work exactly as desired.

One week till I take the car to Rockingham to test it on corner one!

[House]

I wouldn't say you unsettle the car, in as much as you throw it in and hang on for dear life as the rear tyres scream for mercy.

This will help enormously!!

[8valve-craig]

One week till I take the car to Rockingham to test it on corner one!

Nice work Iain. Having been a passenger in your car i agree.

Also no braking for turn 1.

[Edd]

Why didn't you just fit a 15imp gearbox transducer instead of all that?

[total_vauxhall]

^^ thats what I used for boost by gear . But wont the abs set up show what each wheel is doing ? So I think the abs ring set up will be a far better set up in the long run

[C16xe]

How much was the coil bracket Iain? Really like this project mate keep the updates coming!:thumb:

[Iain]

The gearbox sender was my preferred approach however there doesn't appear to be a 15 pulse version that passes through the mechanical speedo drive. Correct me if I'm wrong?

My ABS sensor is actually only on one wheel, so no real benefit over the gearbox sensor.

Coil bracket was about £20 off eBay ages ago in preparation for finally going to coilpack, I think it's similar to SBD's old design. The alloy blank is a QED item.

[Edd]

SPI Nova's came with 15imp transducers on them AK are the identification letters on the transducer

I have one fitted with my EPAS

[Iain]

I have a Nova SPi AA one which is listed as 6 impulses.
AK is listed for digidash and 16 impulses so figured it would not have the mechanical speedo drive.

[House]

Iain stalking a TT at Rockingham from about 3.30 onwards

https://youtu.be/rnF6EaGwrNk

[Iain]

Booked on with TrackObsession at Rockingham 03/09/2018. We took the Novas, seemed to get a good reaction to how they performed.

Not much to report... Trashed some tyres, tested my EPAS speedo feed which worked flawlessly and achieved exactly what I wanted for the 120mph flat-out turn one.

Shame the circuit is closing end of 2018, the infield is great fun.

Benefit of the day... Free official photos!

http://iainel.co.uk/images/forums/NovaWIP2b/489.JPG

http://iainel.co.uk/images/forums/NovaWIP2b/490.JPG

http://iainel.co.uk/images/forums/NovaWIP2b/491.JPG

http://iainel.co.uk/images/forums/NovaWIP2b/492.JPG

http://iainel.co.uk/images/forums/NovaWIP2b/493.JPG

http://iainel.co.uk/images/forums/NovaWIP2b/494.JPG

http://iainel.co.uk/images/forums/NovaWIP2b/495.JPG

[Iain]

Cheeky bit of footage

https://youtu.be/3WLLe9AZ0ns

[House]

Decent day.

We were getting a lot of nova love!!!

[brucer]

Nice work, love watching your vids.

Ive fiited an abs sensor with the same relay to the rear of my nova, which is then wired into my ecu so i can my speed when it's spinning the wheels in the lower gears.

[Iain]

Good stuff, seems a good solution. Annoyingly there are ABS sensors in the Corsa B SRi disc rear hubs I am using, but some numpty (i.e. me) cut the wires off flush during installation.

[Iain]

So I re-adjusted my oil cooler to clear the radiator and my grille no longer fitted. Figured now is a good time to get a new grille on it. @total_vauxhall on here was kind enough to provide and gave a great tip to create an even quicker front end removal... M8 tap ran down the plastic pegs

http://iainel.co.uk/images/forums/NovaWIP2b/496.JPG

And it magically bolts to the bumper

http://iainel.co.uk/images/forums/NovaWIP2b/497.JPG

It's a bit floppy but it happily sits where it should without any additional fittings

http://iainel.co.uk/images/forums/NovaWIP2b/498.JPG

2k primed and painted it up in the garden

http://iainel.co.uk/images/forums/NovaWIP2b/499.JPG

Halfords finest mesh to provide the clearance required on the oil cooler
http://iainel.co.uk/images/forums/NovaWIP2b/500.JPG

Bish bash bosh all comes off in 10 seconds on four R-clips

http://iainel.co.uk/images/forums/NovaWIP2b/501.JPG

http://iainel.co.uk/images/forums/NovaWIP2b/502.JPG

[total_vauxhall]

:thumb:spot on job mate . Glad that little trick worked for ya

[scottmasterton]

Looks great :) going to do something similar this week

[House]

I don't like this

[Stuart]

totes stealing that

[Harvey]

Looks just like the Astra mk2 front bumper now with built-in grill, but as usual on a Nova it's a darn faff :( Good work sir.

[Iain]

So I've installed some Sabelt 6 point harnesses this weekend. However I've never liked the interference between the lap belt buckles and the seat holes, so I've moved all the mounting points backwards. Loads better.

Sills were the harder ones, I prepped some spreader plates and found a suitable size holesaw to allow me to sink the nuts into the sills flush. Crotch straps were a simple case of drilling and fitting spreader plates in the correct location.

http://iainel.co.uk/images/forums/NovaWIP2b/503.JPG

http://iainel.co.uk/images/forums/NovaWIP2b/504.JPG

http://iainel.co.uk/images/forums/NovaWIP2b/505.JPG

http://iainel.co.uk/images/forums/NovaWIP2b/506.JPG

http://iainel.co.uk/images/forums/NovaWIP2b/507.JPG

http://iainel.co.uk/images/forums/NovaWIP2b/508.JPG

Tunnel eye bolts were moved back a few inches too

http://iainel.co.uk/images/forums/NovaWIP2b/509.JPG

Can see the improved clearance of the adjusters here, perfec'

http://iainel.co.uk/images/forums/NovaWIP2b/510.JPG

[House]

Loads better than the old mounting points

[Harvey]

Get this diary updated you slacker as you have interesting stuff to add!!! If you don't all post a pic of my sexy vapour blasted high compression Omega pistons, you have been warned ;)

[Iain]

There are interesting updates. Coming soon.

[House]

There are interesting updates. Coming soon.

Are there???

[Iain]

Here's the start of the winter mods.... I have bought a donor car, you may recognise it.

http://iainel.co.uk/images/forums/NovaWIP2b/511.JPG

It came as a full working car, and unfortunately got butchered:

http://iainel.co.uk/images/forums/NovaWIP2b/512.JPG

So I'm having a tonne of parts off this to upgrade mine.... First off, the windows are pretty nice being Marguard coated and newer than mine, so in they go. Rears;

http://iainel.co.uk/images/forums/NovaWIP2b/513.JPG

http://iainel.co.uk/images/forums/NovaWIP2b/514.JPG

On to the fronts. I'm set with polycarbs now so instead of modding the seals I've removed the old window net brackets. They're not perfect but they're off:

http://iainel.co.uk/images/forums/NovaWIP2b/515.JPG

The clasp was also removed:

http://iainel.co.uk/images/forums/NovaWIP2b/516.JPG

Door stripped of all old parts, they're one piece so no separator etc required:

http://iainel.co.uk/images/forums/NovaWIP2b/517.JPG

Skin supports have to go to make room too:

http://iainel.co.uk/images/forums/NovaWIP2b/518.JPG

All in with new seals to suit the new one piece set up:

http://iainel.co.uk/images/forums/NovaWIP2b/519.JPG

[Iain]

Another cheeky one robbed from the red car, a Lifeline snap off splined boss.

http://iainel.co.uk/images/forums/NovaWIP2b/520.JPG

http://iainel.co.uk/images/forums/NovaWIP2b/521.JPG

Will update as I get round to the other bits, but the upgrades should make my car better all over. Some bits I don't need will be for sale.

[torquey]

Looking well. What you not using off the shell?

[Iain]

Main bits surplus are instruments, pedal box, fuel setup (alloy tank, pumps, swirl pot), Corsa 2.7 rack. Not a huge amount!

[House]

Poor old girl!!

[Iain]

Little dash display upgrade for the old girl. I'll keep it brief with photos, but it's a piece of bent ally screwed to the stalk mount on the column with the dash mounted on.

Finished item:

http://iainel.co.uk/images/forums/NovaWIP2b/522.JPG

Binnacle is blanked off with alloy wrapped in carbon vinyl, 14mm warning lights to keep it MOT legal and 4 buttons to control the dash.

http://iainel.co.uk/images/forums/NovaWIP2b/523.JPG

Warning lights in action:

http://iainel.co.uk/images/forums/NovaWIP2b/524.JPG

In order to protect the new pressure sensor I've got for it, it's remote mounted on a 0.5m braided hose, will be mounted on the bulkhead somewhere. I have fitted this to the current engine to make sure I have a reliable oil pressure gauge for when the new lump goes in:

http://iainel.co.uk/images/forums/NovaWIP2b/525.JPG

All working, temp sensors not connected up yet:

http://iainel.co.uk/images/forums/NovaWIP2b/526.JPG

Temp sensors and speedo mount will be done when the engine's out.

[House]

I have no words.

[8valve-craig]

If that dash could talk it would tell some stories !

[boffer8]

How did you do your wiring for the MOT dash lights?

[Iain]

How did you do your wiring for the MOT dash lights?It's all using the original wiring that went to the clocks. Just one wire to Led and the other to live or earth depending what it's for.

[Benn]

Liking the upgrades.

Very interesting about the dash lights. Somethings i've been thinking of.

[Iain]

Onto the exciting updates, leading to my first test drive in months today.


Gearbox, I'm now using a Quaife SCCR 4.2 with Quaife ATB diff. It came with the short option fifth gear, so I've swapped in the middle option.


Unexciting looking box:


http://iainel.co.uk/images/forums/NovaWIP2b/527.JPG


Removed fifth:


http://iainel.co.uk/images/forums/NovaWIP2b/528.JPG


Shiny new one:


http://iainel.co.uk/images/forums/NovaWIP2b/529.JPG


Onto the engine, I'm using the one from Houses red shell. Bottom end is 86.5mm with standard recently rebuilt crank/rods. However I wanted to use some bits off mine, namely the oil pump, pickup and cams. Both out for surgery:


http://iainel.co.uk/images/forums/NovaWIP2b/530.JPG


Now there was a slight issue, when the car came to me it was running on 3 cylinders. Turns out a snapped valve spring cap resulted it holding the valve open. Eek.


Head off for inspection:


http://iainel.co.uk/images/forums/NovaWIP2b/531.JPG


Intake ports look nice, think it's worked a little bit:


http://iainel.co.uk/images/forums/NovaWIP2b/532.JPG


New stem seals:


http://iainel.co.uk/images/forums/NovaWIP2b/533.JPG


And cleaned valves and seats:


http://iainel.co.uk/images/forums/NovaWIP2b/534.JPG


On and fitted with Kent AST1612 cams:


http://iainel.co.uk/images/forums/NovaWIP2b/535.JPG

[Iain]

Sump required fettling, my modified one bottom and new one on top received the same treatment:


http://iainel.co.uk/images/forums/NovaWIP2b/536.JPG


Also made a little speed sensor, trying to use the middle CV as a speed sensor:


http://iainel.co.uk/images/forums/NovaWIP2b/537.JPG


Finished and painted:


http://iainel.co.uk/images/forums/NovaWIP2b/538.JPG


Onto the fueling side of things... The carbs are gone. So I've fitted an in-tank Walbro 255 pump to go with my SPI tank, very neat solution:


http://iainel.co.uk/images/forums/NovaWIP2b/539.JPG


Finished pump:


http://iainel.co.uk/images/forums/NovaWIP2b/540.JPG


Fuel system is all AN fittings from the push-fit pump and fuel return on the tank side, with filter in the original location:


http://iainel.co.uk/images/forums/NovaWIP2b/541.JPG


And internal braided lines:


http://iainel.co.uk/images/forums/NovaWIP2b/544.JPG


http://iainel.co.uk/images/forums/NovaWIP2b/545.JPG

[Iain]

Onto the bay side of things, the horn got relocated behind the wing for more space:


http://iainel.co.uk/images/forums/NovaWIP2b/542.JPG


And the FPR and new Mocal catch tank mounted on the strut brace:


http://iainel.co.uk/images/forums/NovaWIP2b/543.JPG


Now onto some more juicy stuff robbed from Houses shell. Jenvey DTH throttle bodies with carbon trumpets:


http://iainel.co.uk/images/forums/NovaWIP2b/546.JPG


Bish bash bosh:


http://iainel.co.uk/images/forums/NovaWIP2b/547.JPG


Throttle cable sorted thanks to a handy kit from Venhill:


http://iainel.co.uk/images/forums/NovaWIP2b/548.JPG


And she runs:


http://iainel.co.uk/images/forums/NovaWIP2b/549.JPG


Finished engine bay, looking good:


http://iainel.co.uk/images/forums/NovaWIP2b/550.JPG


I'm also using the full Powerflow stainless sytem from Houses shell, although it's built for a mk1. Undecided whether I'm going to redo the tailpipe or not:


http://iainel.co.uk/images/forums/NovaWIP2b/551.JPG


First daylight in months and months:


http://iainel.co.uk/images/forums/NovaWIP2b/552.JPG

[scottmasterton]

Looking great! :d :thumb:

[House]

Poor old House you stole all his parts

[total_vauxhall]

Nice looking machine . Ps i think the tailpipe looks great as it is

[Benn]

Loving that! Tb's are a great add on.

[Iain]

Successful morning at AP Racing Engines, Jenveys are now all mapped up for the changes (trumpets, cams, etc).

Made just shy of 200 but still pulling hard at the rev limiter, which is set to a fairly conservative 7350rpm. Not bad for essentially a standard spec engine with some bolt ons.

http://iainel.co.uk/images/forums/NovaWIP2b/553.JPG

http://iainel.co.uk/images/forums/NovaWIP2b/554.JPG

[House]

Most impressive

[Iain]

Wired up some sequential shift lights. Love how it integrates into the dash settings. Also put in a momentary toggle to enable night mode.

https://youtu.be/N4HGsBtRIKI

[House]

Love this


Sent from my iPhone using Tapatalk

[Stuart]

Cheeky

[_Tomiboy]

Do you know the WHP?

[House]

Do you know the WHP?

When that engine made 197bhp at the fly it was 164 at the wheels

[Iain]

Shakedown at Blyton Park on 23rd June. Car performed very well, gearbox feels crisp and new engine pulls well.

http://iainel.co.uk/images/forums/Trackdays/20190623_Blyton/1.JPG

http://iainel.co.uk/images/forums/Trackdays/20190623_Blyton/2.JPG

http://iainel.co.uk/images/forums/Trackdays/20190623_Blyton/3.JPG

http://iainel.co.uk/images/forums/Trackdays/20190623_Blyton/4.JPG

http://iainel.co.uk/images/forums/Trackdays/20190623_Blyton/5.JPG

http://iainel.co.uk/images/forums/Trackdays/20190623_Blyton/6.JPG

http://iainel.co.uk/images/forums/Trackdays/20190623_Blyton/7.JPG

http://iainel.co.uk/images/forums/Trackdays/20190623_Blyton/8.JPG

http://iainel.co.uk/images/forums/Trackdays/20190623_Blyton/9.JPG

[House]

Tripod

[Harvey]

Have only the fiberglass bonnet and tailgate survived with the rest rusting away in true Team Shonky Vauxhall style? Lack of updates means you have lost your mojo much like myself :(

[Iain]

Few mods recently, I've upgraded my rear ARB from an Astra mk2 15mm to a Saab 93 uprated 22mm item. I intend on doing some back to back tests to see how it behaves.

http://iainel.co.uk/images/forums/NovaWIP2b/556.JPG

http://iainel.co.uk/images/forums/NovaWIP2b/557.JPG

Cadwell Park yesterday. Weather was atrocious, couldn't even see where you were going in the morning. Lots of red flags and nasty crashes.

Will upload a few official pics when they come through, but only snapped one to show how nice a mk2 front end looks:

http://iainel.co.uk/images/forums/NovaWIP2b/558.JPG

Bit of a lap video but pretty uneventful really:


https://www.youtube.com/watch?v=uu1VgIDFrpo&feature=youtu.be

[Iain]

Little upgrade to test out, Tranx 45/45 heavy preload plate diff to replace the ATB. It came out of Houses Quaife sequential when he upgraded to a Gripper, so I'll get it installed and see how I get on with it.


http://iainel.co.uk/images/forums/NovaWIP2b/559.JPG

[_Tomiboy]

I like my tranX plated. The car likes the full throttle turns, without that is understeering, but with is a little oversteering.

[Iain]

Official wet Cadwell 13/10/2019 snaps

http://iainel.co.uk/images/Trackdays/20191013Cadwell/I2.JPG

http://iainel.co.uk/images/Trackdays/20191013Cadwell/I3.JPG

http://iainel.co.uk/images/Trackdays/20191013Cadwell/I4.JPG

http://iainel.co.uk/images/Trackdays/20191013Cadwell/I5.JPG

http://iainel.co.uk/images/Trackdays/20191013Cadwell/I6.JPG

http://iainel.co.uk/images/Trackdays/20191013Cadwell/I7.JPG

http://iainel.co.uk/images/Trackdays/20191013Cadwell/I8.JPG

Wet tripod!?

http://iainel.co.uk/images/Trackdays/20191013Cadwell/I1.JPG

[JoeWak98]

Little upgrade to test out, Tranx 45/45 heavy preload plate diff to replace the ATB. It came out of Houses Quaife sequential when he upgraded to a Gripper, so I'll get it installed and see how I get on with it.


http://iainel.co.uk/images/forums/NovaWIP2b/559.JPG

Be interesting to see what it performs like with the 45 ramp angle on de- acceleration. I’ve always ran 45/90 on my tarmac rally car as I never wanted the diff to work on de acceleration/braking


Sent from my iPhone using Tapatalk

[boffer8]

Got a 45/60 in my hillclimb car and really like it compared to a 90, can really feel the diff fighting on decel, 45 will be interesting but the high preload should subdue it a little

[House]

Got a 45/60 in my hillclimb car and really like it compared to a 90, can really feel the diff fighting on decel, 45 will be interesting but the high preload should subdue it a little

I'm running 45/60 heavy pre load in mine and love it.

The 45/45 was a compromise for Iain as that was what I specified originally from Quaife, we'll see how he gets on with it

[Iain]

A few more mods before Snetterton.

This style coilpack bracket was nice, but made from stainless and far too brittle which led to it cracking:

http://iainel.co.uk/images/forums/NovaWIP2b/560.JPG

I've sourced an original C20XE coilpack bracket which mounds on 3 bolts on the head and is made from 5(ish)mm pressed metal. Just needs redrilling for the Ecotec coilpack:

http://iainel.co.uk/images/forums/NovaWIP2b/561.JPG

No water thermostat is fine in summer, but I saw temps in the 60s at Cadwell which will start adding more fuel. So I've fitted an 82C thermostat (LMF) and alloy radiator (TXAutosport).

http://iainel.co.uk/images/forums/NovaWIP2b/562.JPG

http://iainel.co.uk/images/forums/NovaWIP2b/563.JPG

Going to redesign the oil cooler top brackets too, I think.

http://iainel.co.uk/images/forums/NovaWIP2b/564.JPG

Diff was fitted a few days prior to Snet, new bearings, seals, swapped over crownwheel. Job is a pain upside down, should have taken the box out.

http://iainel.co.uk/images/forums/NovaWIP2b/565.JPG

[Iain]

Snetterton 01/11/2019

Wet day, couldn't really test the diff out was just holding on and battling no grip.

House brought his non-road-legal-wets which he hates for some reason, so we swapped some wheels and both ran Rainsports up front which worked pretty well for us.

Had a surprise visit from Rich off here just as the millionth red flag in the afternoon ended the day, so nice to meet you sir.

http://iainel.co.uk/images/forums/NovaWIP2b/566.JPG

http://iainel.co.uk/images/forums/NovaWIP2b/567.JPG

Couple of pro shots from the day:

http://iainel.co.uk/images/forums/NovaWIP2b/568.JPG

http://iainel.co.uk/images/forums/NovaWIP2b/569.JPG

[House]

Fuck, I look handsome from the back.....

What a post to be your 4000th!! Haha