Iain's 20XE Trackday Nova

[Iain]

Yes the diag up front will rest nicely on the front splash guard so that lends itself to tagging there too.
If the door bars were any higher then I'd look in to bends, but I think it'll be ok with just a straight bar - and agreed attach it to the exhaust tunnel.

Still not sure on the rear parts but might as well get enough CDS in case I choose to do it :d

[Adam]

Buy plenty off tubing so with what you have left you can give to me for me make a rear brace out of :p

[scott.parker]

Iain, you getting Wyatt to do this?

[burgo]

Aye, tag him into the tunnel in (almost) a V shape. Im sure Burgos is done like this to?

I got some pics from my 106 to illustrate if needed tho lolyush i have and hes already seen the pics and had a chat with me lol

[Iain]

Scott I'm doing the rollcage if that's what you're asking.

[scott.parker]

Scott I'm doing the rollcage if that's what you're asking.

lol no the paint job!

[Iain]

Oh, not sure yet, I'm still waiting on a couple of more local quotes as it'd be much easier for me to take it somewhere nearby. :)

[scott.parker]

Thats fair enough, just one thing i will say, the price quoted was at a slightly lesser rate as i said your a very good friend lol, also he would do a very good job, and i could go down and check up on it for you etc.

But if you get a better local quote even better for you as you say.

Scott

[Iain]

Cool, nice one.

[Iain]

Well I got the block back from being honed. Looks like there is a small gap missed where there's a slight lip on the bore, but I assume the rings will still bed in okay?

http://iainel.co.uk/images/forums/NovaWIP2/782.JPG

You can see what I mean here:

http://iainel.co.uk/images/forums/NovaWIP2/783.JPG

Also crank was reground -0.25mm on mains and big ends and polished up:

http://iainel.co.uk/images/forums/NovaWIP2/784.JPG

Replacement sump, already clean which is a bonus! Looks like it's been media blasted too?

http://iainel.co.uk/images/forums/NovaWIP2/785.JPG

Ruler test on the top checks out good so it's not warped either:

http://iainel.co.uk/images/forums/NovaWIP2/786.JPG

Now the parts are back I have ordered lots of OE (mainly Mahle) rings, bearings etc from Autovaux, which will hopefully arrive tomorrow.

[Connor]

Good progress :)

[draper]

be ready for an MOT soon then will it lionel ?

[Benn]

Get building dude.
Sumps deffo been blasted clean...

[Iain]

Draper, no.
Benn, not really sure about this hone job so not building it yet till I talk to someone who knows what they're doing.

[Iain]

Engine block is confirmed unusable, waiting to hear about about a usable std block, otherwise I'll be going for a rebore and larger (86.5mm) pistons.

Cyl head is coming on nicely, cleaned all the ports out and finishing lapping in the valves. Will get pics when it's built up!

Been tinkering with the rollcage triangulation tonight. Rigged up a DIY tube notcher using a 38mm holesaw:

http://iainel.co.uk/images/forums/NovaWIP2/787.JPG

Perfec':

http://iainel.co.uk/images/forums/NovaWIP2/788.JPG

Slots in here nicely with a bit of tweaking:

http://iainel.co.uk/images/forums/NovaWIP2/789.JPG

And a quick file and it sits nicely against the front leg:

http://iainel.co.uk/images/forums/NovaWIP2/790.JPG

For the diagonal I needed a notched section and a flat section:

http://iainel.co.uk/images/forums/NovaWIP2/791.JPG

Bish bosh bash, sits perfectly on the floor and leg:

http://iainel.co.uk/images/forums/NovaWIP2/792.JPG

Just need the top of the diag done now, which looks the hardest bit.

[draper]

good work !!!

[Adam]

Good work/skills, liking how well the new cage bits fit together!

Whats up with the block???

[Iain]

Lip on the cylinders is a bit bad, been told this can hit the upper piston ring and snap it so not going to risk it.

[Adam]

Where did you get the cage tubing from?

[Iain]

A mate got it for me from a kitcar place. It's 38mm CDS. Using roughly 2.2mm thick for the triangulation (same as a SD cage) but got some 2.6mm thick stuff I can use for between the B pillars.

[Adam]

Whats it costing you? Could do with some for a rear brace

[Iain]

Worked out about £10 a metre I think, but I bought over 10 metres. I may have a few lengths left over from this cage you could have off me. Get on Messenger to discuss :)

[scott.parker]

Looking good mate, keep on it, sorry to hear about the block though.

[Benn]

Awesome work on the cage, good way of doing the tubing ends.

[burgo]

nice one jeff :p

[The Simps]

Good work mate. Must of taken some time and patience with that pillar drill!

What was your technique for working out how to cut the notch?

[Iain]

You'd think that but it was surprisingly easy Mr Simp! I butted the tube up to the other one and drew a line at the angle the notch needed to be at and marked the top and bottom. Then just clamped it in the vice so the line of the angle was vertical under the drill, and put the holesaw through the 'top' mark. Finished it off and made small adjustments to the angle with a rounded file (the tube is surprisingly easy to work by hand) :)

[The Simps]

Excellent! Got my cage and tubing arriving shortly and got a fair bit of profiling to do! lol

[tom reid]

You need a rebore mate, no std blocks available, sorry.

[Prey]

Done well there mate!

[Iain]

Cheers Tom, think I'll go for those Autosprint flat-top pistons too then! Will give you a call/pop over next week :)

Well I blunted my holesaw so progress halted on the cage triangulation - and nowhere local sells a 38mm Bosch holesaw, grr!

So I did a mock engine fitting, and glad I did as it was an utter ballache. Block and box in, finally, after much agro:

http://iainel.co.uk/images/forums/NovaWIP2/793.JPG

You can see it's wonky already though...

http://iainel.co.uk/images/forums/NovaWIP2/794.JPG

Using the middle hole as it fits better this way:

http://iainel.co.uk/images/forums/NovaWIP2/795.JPG

Plenty of room gbox end:

http://iainel.co.uk/images/forums/NovaWIP2/796.JPG

Slightly slotted the rear mount to get it to fit:

http://iainel.co.uk/images/forums/NovaWIP2/797.JPG

Didn't realise the engine sat this high in the bay!

http://iainel.co.uk/images/forums/NovaWIP2/798.JPG

And as suspected, it's wonky as a wonky thing:

http://iainel.co.uk/images/forums/NovaWIP2/799.JPG

Which is going to cause bonnet clearance issues:

http://iainel.co.uk/images/forums/NovaWIP2/800.JPG

I tried dropping it down to the top hole:

http://iainel.co.uk/images/forums/NovaWIP2/801.JPG

Which seems to sit better (maybe a little wonky the other way now?):

http://iainel.co.uk/images/forums/NovaWIP2/802.JPG

But it just didn't go together very nicely, had to force the bracket for the block and it sat like this on the mount:

http://iainel.co.uk/images/forums/NovaWIP2/803.JPG

Because the solid mount's hole is kinda between the original 2 holes, I'm going to modify the bracket so it sits a bit lower:

http://iainel.co.uk/images/forums/NovaWIP2/804.JPG

Trial fit:

http://iainel.co.uk/images/forums/NovaWIP2/805.JPG

Hmm sitting a bit straighter now, but going to file the mount some more. I'll weld up the unused holes and make sure it's nice and strong when I'm happy with it:

http://iainel.co.uk/images/forums/NovaWIP2/806.JPG

[Adam]

Hmm, you are using different mounts than me, hence why mine sits level.
If i do a pic of mine from that angle in your last pic, the slam is level with the rocker gasket (as yours is on the gearbox end)

[Iain]

What the conversion brackets or the solid mounts themselves? Brackets were from Chris Astley and I think the mounts are TAS ones.

[Adam]

The solid mounts

[MK999]

What the conversion brackets or the solid mounts themselves? Brackets were from Chris Astley and I think the mounts are TAS ones.

Mounts look incredibly similar to my TAS ones.

[John]

I had the exact same problem with mine iain, I did the exact same thing as you, but still had to notch the bonnnet a little.

http://www.pngclub.com/forum/showthread.php?t=79715

[yayoboy]

i used the solid aluminium type from chris astley, and still had a problem getting everything to fit mate, try slackening them all off and go from there, helped me!

[Benn]

This is why i wouldn't touch solid mounts. Slotting mounting hole isnt good.

[Iain]

Cheers John, was browsing that thread earlier cos I remembered you had the same problem. I'll do as much adjustment as I can on the mount and space the mount down as a last resort.

Been the front mount won't remain slotted, I'll weld them up once I have the right position. Don't think the rear will be a problem either as it's tight against the front of the hole.

[Benn]

Still sh*te in my books. The fit should be way better. (not slating you there)

[Adam]

The fit is fine on mine apart from slotting the rear mount. Which isnt an issue at all

[scott.parker]

I sold that dam steel mount as it's just crap! i used the standard Vaux one on mine..

[MK999]

I sold that dam steel mount as it's just crap! i used the standard Vaux one on mine..

How/what standard vaux mount did you use on an XE? :confused:

[Mike]

I think Scott means the actual engine mount not the bracket.

EDIT: OR is that what you both mean, & im just confused as to mount or bracket lol lol

[MK999]

Ahhh the bouncy rubber *******, not too sure as I've been in his car and I loved the rattle from the competition mounts, so unless he had it fitted once and then sold it, I am also confused lol

edit for mike: I meant/thought he meant the bracket, as it's the only all steel bit and he said "steel mount" in his car there was a definite engine vibration going on from competition mounts at combe last year.

[scott.parker]

As in the standard cast mount for the engine to chassis, not the actual engine Mount, as i still have solid rubber ones.

[MK999]

As in the standard cast mount for the engine to chassis, not the actual engine Mount, as i still have solid rubber ones.

Engine to chassis goes through 2 parts, the bracket as mike is calling it (and makes much more sense and solves the whole confusion between the 2) and then the mount, i.e bouncy rubber GM thing, solid ally, TAS etc. I assume you mean the bracket (pressed btw, not cast :p), but then why do conversion mounts (brackets) exist if a standard gm one fits! :confused:

[scott.parker]

Dont know, as the standard fit better then them **** ones they sell.. lol

[The Simps]

Some people remove the pressed bit attached to the chassis leg, lower it and weld it back on.

[Iain]

I guess the benefit of using brackets rather than moving the part on the car is you can revert back to a trusty smallblock if you want to :)

Here's the drivers side mount after an evening's tinkering. I filed it upwards so the hole is just below the top hole, then welded a fat washer over it, and filled in the original hole at the back. Job's a goodun, and the engine sits almost perfectly level (if comparing bottom of rocker to the slam panel)

http://iainel.co.uk/images/forums/NovaWIP2/807.JPG

[chimp007_uk]

Thats "proper job" Ian... top work.

[Benn]

Your mount looks better now its welded up.

[burgo]

oooo liking that muchly :)

[Adam]

Good work on the mount Iain

[dj_wudgey]

some top class work gone in to this keep it up dude!!

[L14MNP]

Gonna be some motor mate. :)

[Iain]

Not that exciting but might as well keep the updates as I go along...

Drivers mount in place:

http://iainel.co.uk/images/forums/NovaWIP2/808.JPG

Welded a thick washer to the rear mount too:

http://iainel.co.uk/images/forums/NovaWIP2/809.JPG

And beefed up the strengthening:

http://iainel.co.uk/images/forums/NovaWIP2/810.JPG

Perfec':

http://iainel.co.uk/images/forums/NovaWIP2/811.JPG

This hows how level it now sits side to side:

http://iainel.co.uk/images/forums/NovaWIP2/812.JPG

[scott.parker]

Looks fine dude, it's only a track Nova! lol

[Paul]

I want solid mounts, but id have to weld the rear one in as mines ripped clean out of the floor :(

[Adam]

Lol /\

Good work Iain, sits bang on now!

[Connor]

Nice skills on the mount Iain

[Benn]

Mounts look mucho better.

[Damo]

Yea top work iain keep it up.

[SRimon]

Iain, I had to do this to one of my XE engine mounts, supposed to be made to sit level, mine was spaced in the end to make it sit right.

[The Simps]

Usual good attention to detail! What's next big job?

[brownbear]

Just read this from start to finish, Amazing work!

[Iain]

Cheers all. Started on the internal shifter so I can finish off the hole/welding on that, then the engine can come out and I can carry on with/finish off the rollcage.

[Iain]

Gear shifter is mostly sorted now! I think the engine can come out again now :)

Started out with a shifter with two kinks in the linkage end, so cut the bends out and welded it back straight:

http://iainel.co.uk/images/forums/NovaWIP2/813.JPG

Another issue I found was the end of the internal shifter was supposed to go inside the linkage (most other Vauxhalls seem to use this) so I tacked on the Nova end. Looks a bodge but this is just a mockup for now:

http://iainel.co.uk/images/forums/NovaWIP2/814.JPG

On to the car, I started drilling holes and found where I had welded over the hole I had left a gap between the 2 layers - pretty rubbish but this was the first bit of metalwork/welding I did on the project almost a year ago! Anyway I stood and looked at it, and thought it leant itself well to the nuts staying inside the car!

http://iainel.co.uk/images/forums/NovaWIP2/815.JPG

So welded those bad boys in:

http://iainel.co.uk/images/forums/NovaWIP2/816.JPG

Factory fit lol:

http://iainel.co.uk/images/forums/NovaWIP2/817.JPG

Shifter hole needed enlarging MORE - it's huge now!

http://iainel.co.uk/images/forums/NovaWIP2/818.JPG

But it's in and gets a couple of gears :):

http://iainel.co.uk/images/forums/NovaWIP2/819.JPG

Hooked up to my rosejointed linkage:

http://iainel.co.uk/images/forums/NovaWIP2/820.JPG

[Adam]

Look at you with your god damn captive nuts! lol

Looks well though, neat job.

That RJ linkage looks dirty though, sell it to me and make yourself a brand new one :)

[Iain]

Finished most of the 'mockup' now - seating position feels okay with the Corsa steering column and Cav shifter (which feels AWESOME with the rosejointed linkage):

http://iainel.co.uk/images/forums/NovaWIP2/821.JPG

Seat sits nice and low, which is good for a tall person!

http://iainel.co.uk/images/forums/NovaWIP2/822.JPG

Also trimmed my bonnet to clear the XE rocker cover, swiss cheese f/g bonnet lol

http://iainel.co.uk/images/forums/NovaWIP2/823.JPG

Engine can come out now and I can finish the rollcage off, at least I know it'll all bolt together easily now when it's painted :)

[Benn]

Good work.

Could you not have clinch/riv nutted the shirt box down?

[matt_vaughan]

Iain I've just read this thread all the way from start to finish, again, for what must be the 10th time

You keep inspiring me to work on mine again every time i read it :D

Awesome work man, nice to see someone doing a propper DIY job, and making a good job of it.

[Iain]

Benn yeah I could have used a rivetnut if I knew they existed!

Cheers Matt :) Wait till see you see it in person before saying I've made a good job though lol

[Iain]

We have passenger triangulation lol All notched just need to weld it up and start on the drivers:

http://iainel.co.uk/images/forums/NovaWIP2/824.JPG

http://iainel.co.uk/images/forums/NovaWIP2/825.JPG

http://iainel.co.uk/images/forums/NovaWIP2/826.JPG

Total weight of both bars = 2.85kg, not too bad!

[Benn]

Looking good dude.

[Adam]

Good work Lionel

[burgo]

love it long time

[scott.parker]

Stop ****ing around and get this thing back together! lol there wont be any track's left for you to run on by the time your finished! lol

Tops though dude..

[Iain]

Most of the triangulation is welded in now. Just the plating to do on the drivers side bulkhead left.

http://iainel.co.uk/images/forums/NovaWIP2/827.JPG

Stitched to the turret and side:

http://iainel.co.uk/images/forums/NovaWIP2/828.JPG

Bit of neat welding on the front leg:

http://iainel.co.uk/images/forums/NovaWIP2/829.JPG

Rest of the welding looks crap but oh well lol:

http://iainel.co.uk/images/forums/NovaWIP2/830.JPG

You can see where it's tacked to the front splash guard:

http://iainel.co.uk/images/forums/NovaWIP2/831.JPG

And an additional brace between the B pillars should help in the event of a side impact:

http://iainel.co.uk/images/forums/NovaWIP2/832.JPG

http://iainel.co.uk/images/forums/NovaWIP2/833.JPG

[NovaLad]

You're Sh1t!
Oj
Looking good Iain! <3

[Iain]

And since my block is getting rebored I've treated it to some Autosprint 'flat-top' 87mm pistons with larger valve cutouts should I ever want high lift cams:

http://iainel.co.uk/images/forums/NovaWIP2/834.JPG

http://iainel.co.uk/images/forums/NovaWIP2/835.JPG

http://iainel.co.uk/images/forums/NovaWIP2/836.JPG

[Benn]

Cage is looking awesome dude, not temped to plate from the tubing to the turret?

[Iain]

I'll tidy it up at the turret end yeah, thinking of an end plate and boxed to the turret. :)

[Benn]

Nice nice.

[Adam]

Awesome work.
http://iainel.co.uk/images/forums/NovaWIP2/829.JPG
That welding looks class!!!
Looks identical to the original cage welding.

[Angus Closier]

All looking good mate! love the cage-turret that looks good! was it too hard?

[Iain]

Nah not too hard really, just spent lots of time making sure the notched tubes sat together perfectly. Just got the strut brace and rear triangulation between B pillars and back arches to do now.

[Iain]

No more cage profiling left, winner! Rear additions are ready to be welded in:

http://iainel.co.uk/images/forums/NovaWIP2/837.JPG

http://iainel.co.uk/images/forums/NovaWIP2/838.JPG

Hopefully where I've chosen for the strut brace won't be in the way of any inlet/engine parts:

http://iainel.co.uk/images/forums/NovaWIP2/839.JPG

Will be welded on to be removable anyway with 4mm pressed steel saddle brackets:

http://iainel.co.uk/images/forums/NovaWIP2/840.JPG

[Paul]

Nice work simba

[Benn]

Awesome work, are you tagging the cage to the pillars too? I love the look of that.

[Iain]

It's welded to the shell on the A pillars, across the windscreen/roof strengthening, above each door and I think at the top of the B pillars. Just where the cage sits close to the car. Wasn't going to go for the gussets etc although I agree they look pretty mean!

[Adam]

Top work!!


That crossbar in the engine bay will get in the way of a set of throttle bodies ;)

[Benn]

Ah cool cool.

[Iain]

That crossbar in the engine bay will get in the way of a set of throttle bodies ;)
Yeah? They sit further back than the standard inlet/powercap? Guess I'll have to modify/replace it when I ditch the standard injection. :)

[Adam]

They sit up at an angle...

Looking at the pic im pretty sure the bodies would foul that bar.
You might get away with parrelel bodies fitted on a level inlet

[burgo]

this just keeps getting better

[Iain]

Rear cage finished now, just needs a lick with the grinder and painting matt black:

http://iainel.co.uk/images/forums/NovaWIP2/841.JPG

http://iainel.co.uk/images/forums/NovaWIP2/842.JPG

And here's the plan for tidying the front up, will add some strength to the turret also:

http://iainel.co.uk/images/forums/NovaWIP2/843.JPG

http://iainel.co.uk/images/forums/NovaWIP2/844.JPG

[draper]

good plans and work as usual mr L

[Benn]

Looks good, and just what i was talking about on the front turrets.

[burgo]

awwws i so proud :) looks really good buddy

[Prey]

when I ditch the standard injection. :)

COUGH

U wont

:roll:

[Connor]

Loving the cage,
Looks a very tidy job :d

[pastry]

Nice project!

[peester]

Top work!!


That crossbar in the engine bay will get in the way of a set of throttle bodies ;)

was gonna say ull need the soundtrack to go with the cage'd beasty looks

[Iain]

Finished boxing around the turrets, has neatened up the engine bay no end:

http://iainel.co.uk/images/forums/NovaWIP2/845.JPG

http://iainel.co.uk/images/forums/NovaWIP2/846.JPG

http://iainel.co.uk/images/forums/NovaWIP2/847.JPG

Quite proud how well some of the welding came out:

http://iainel.co.uk/images/forums/NovaWIP2/848.JPG

Strut brace saddle brackets welded to the horizontals:

http://iainel.co.uk/images/forums/NovaWIP2/849.JPG

http://iainel.co.uk/images/forums/NovaWIP2/850.JPG

Welded the other half to the strut brace and bolted it in, looks nice:

http://iainel.co.uk/images/forums/NovaWIP2/851.JPG

Just enough room to fit/remove it around the Corsa servo:

http://iainel.co.uk/images/forums/NovaWIP2/852.JPG

[Adam]

Can we get a resize? :p lol

From what i can see from the 10mp pics, welding looks fooking spot on!!!

[Iain]

I was so proud of the welding I had to upload 4000x4000 pics lol

Nah, uplaoded the biguns by mistake, fixed now.

[Adam]

I had to scroll across to see an inch of weld....... lol lol

Nah, does look awesome. Class weldage skills!!!!!!!

[Benn]

Turrets work is awesome, weld is fantastic too.

[Adam]

Soooo, are we going see this out this year or what???

[Iain]

Hopefully, I just want to repaint the underneath of the car cos I'm not happy with the Hammerite, then off for paint + get it built up.

[Benn]

Get on with it then!

[The Simps]

Great work on the turret boxing mate. Strut brace is a good idea. Gonna look great once all in paint.

[burgo]

i love you iain

[Iain]

Seam sealered the triangulation to make it watertight in the engine bay (and look a bit nicer!)

http://iainel.co.uk/images/forums/NovaWIP2/853.JPG

And plenty of matt black, the additions blend in to the rest quite nicely!

http://iainel.co.uk/images/forums/NovaWIP2/854.JPG

http://iainel.co.uk/images/forums/NovaWIP2/855.JPG

http://iainel.co.uk/images/forums/NovaWIP2/856.JPG

http://iainel.co.uk/images/forums/NovaWIP2/857.JPG

Finished cleaning my engine block and started painting it in Halfords High Temperature Engine Enamel. +100bhp red of course!

http://iainel.co.uk/images/forums/NovaWIP2/858.JPG

http://iainel.co.uk/images/forums/NovaWIP2/859.JPG

Bored and honed cylinders for the new pistons:

http://iainel.co.uk/images/forums/NovaWIP2/860.JPG

(Excess paint will be removed before assembly of course)

[General Baxter]

is all that cage really needed, ?

are you planning on running a season in the wrc?

[Iain]

Yes it is, I drive like an idiot.

[General Baxter]

Yes it is, I drive like an idiot.

so all this work, and your planning on crashing,

fair bob to you lol

[Adam]

Clean the paint off from where the stater motor bolts on too.

Good work though, cage looks fooking immense!!!!!
But youve sprayed all the cage up, surely its going have to go car colour?

[Iain]

Hoping it can be masked off to stay matt black when it's painted inside.

[scott.parker]

Fair play for bothering, but as Baxy said Is it really needed? i dont think you'll reap the benefits of them TBF and it's extra weight you dont need.. (just my thoughts on it) As for masking it up...jesus that's a mission lol

Keep on it, but hurry up, you'll want to sell by the time you have finished lol

Scott

[burgo]

why skimp on safety?? i know im gonna feel much happier thrashing my light blue one knowing its got an epic cage.

looking lush tho iain :D will have to buy decent masking paper so as to not pull the matt black off

[tom reid]

Keep up the good work Iaiiaan

[The Simps]

Lovin the cage - hardcore.

[Benn]

Cage looks great, sure it will work get on the track...

[Adam]

I actually cant believe Baxter of all people said "Is it worth it"
With some of the things youve done in the past!!! lol lol lol

If i had the skills i would definently do the same thing on my shell :)

As for the extra weight, just fit bodies or a boost!!! :cool:

[Connor]

Looking good Iain :cool:

[draper]

looking good as usual lionel

[General Baxter]

I actually cant believe Baxter of all people said "Is it worth it"
With some of the things youve done in the past!!! lol lol lol


sorry but i dont see the point, a 6 point is good enough, just what extra help are them bits going to the struts going to do, and the one across the floor between the B pillers

apart from making it that stiff its going to cock its leg up going around an island at 5mph ?

[draper]

sorry but i dont see the point, a 6 point is good enough, just what extra help are them bits going to the struts going to do, and the one across the floor between the B pillers

apart from making it that stiff its going to cock its leg up going around an island at 5mph ?

its going to help with the suspension turrets not moving/flexing meaning the suspension can do its job properly.

the one across the floor picks up the middle which will help stop the floor flexing

[General Baxter]

its going to help with the suspension turrets not moving/flexing meaning the suspension can do its job properly.

the one across the floor picks up the middle which will help stop the floor flexing

you need a little bit of flex lol

hes fitting a bloody xe not a million FTLB v20 lol

[djbrowney]

sorry but i dont see the point, a 6 point is good enough, just what extra help are them bits going to the struts going to do, and the one across the floor between the B pillers

apart from making it that stiff its going to cock its leg up going around an island at 5mph ?

cage looks awsome buddy, i have to say itsdefernatly time and money well fookin spent. notonly will you have half a chance if you (god for bid) ever bin it. i will also help with movement from the engine putting the shell under strain. let face it a nova was meant for a 1.6 100 bhp not what were doing to them :thumb:

[Iain]

Thanks all. Don't regret the extra weight, my additions are very worthwhile IMO! In fact proud of myself for stopping where I did without using up the remaining CDS in my garage lol

Whipped the pistons off the rods just now:

http://iainel.co.uk/images/forums/NovaWIP2/861.JPG

Shame the block was worn as the standard pistons are in very good condition. They're the early forged ones, dunno if they're worth anything?

http://iainel.co.uk/images/forums/NovaWIP2/862.JPG

New piston vs old:

http://iainel.co.uk/images/forums/NovaWIP2/863.JPG

Most notable difference is the shape of the skirt, anyone know the benefits of this?

http://iainel.co.uk/images/forums/NovaWIP2/864.JPG

Will I be ok pressing in the pin with a vice or is it a pro job?

[MK999]

The main benefits of running a very stiff shell are that any changes to the suspension you know for sure it's what you did that made it better/worse rather than making the shell flex slightly differently, so as mentioned it makes sure the suspension is doing it's job.

As for needing a little bit of flex, well, not really, it can make a badly setup car handle better, but F1 cars are that stiff that wheel centres remain within about 5mm of where they should sit at all times, that's 5mm of flex in the entire chassis corner to corner. It's all swings and roundabouts and "ideally... buts" though, end of the day if Iain wants to play about with it, fair play to him, I plan on doing the same to my shell just because it's something I'm interested in and seeing points of flex around the suspension will bug me.

[Adam]

Hmm, those pistons are going to up your compression.

[Paul]

Thats good for an NA Ad, you say it as though its a bad thing!

[Adam]

Thats good for an NA Ad, you say it as though its a bad thing!
Not on standard management it isnt ;)

[MK999]

Not on standard management it isnt ;)

Well there's an excuse to go standalone if ever there was one lol

[scott.parker]

Quick back track to the Cage, what i was getting at is, i think you need to through more money into the rest of the car and be a very very good driver to 100% notice the benefits of the triangulation, but i see the point in the brace between B pillars, i have thought, and might do that to mine yet.

Scott

[burgo]

sorry but i dont see the point, a 6 point is good enough, just what extra help are them bits going to the struts going to do, and the one across the floor between the B pillers

apart from making it that stiff its going to cock its leg up going around an island at 5mph ?

the brace between the B pillers is the most important bar imo. you'll do well to **** yourself up in a front or rear impact but if someone hits you in the side you are bye bye!!

[The Simps]

Whether the cage is overkill or not who cares. Do it right once I say. He may not be able to fully justify all elements of the cgae for what he has planned now but if the direction of the car changes he's one step ahead. Its like when people do a strip down build on the enginebay to get it all sprayed and do a little welding. IMO, whether you're fitting an XE/LET or not you might aswell fit the plating kit and sticth weld so that if you do go that route later your full bay respray isn't a waste of time!

[Prey]

Does look very impressive dude - good to see some progress!

[Adam]

apart from making it that stiff its going to cock its leg up going around an island at 5mph ?
Thats down to suspension travel/damper+spring length

[MK999]

Thats down to suspension travel/damper+spring length

and how stiff the chassis is to some extent, but ideally as you say it's decided purely by the suspension, that way you know whats doing what.

[trackdaynova]

sorry butbut nothing.

love all the people that have never even sat in a track car, telling you how good and bad its going to be, although, Iain - be careful on going around roundabouts at 5mph :confused: like WTF

He's building a car to be driven, probably/hopefully very driven hard, not to worry about how many wheels are on the black stuff, and cocking a leg.

Does make me smile though, so please do carry on.

Iain, you don't need me to tell you that you're doing a cracking job, its great reading how much you're learning, and how the car is progressing - well done :thumb:

[Iain]

lol Touch a nerve Olly? How you doing anyway? Thanks for the kind words :)

Just been in the garage and found something pictureworthy to do! The following shows the chamfered edge for ARP bolts which were done by Autosprint:

http://iainel.co.uk/images/forums/NovaWIP2/865.JPG

Cleaned all the rods up on a bench grinder with wire wheel and made sure all the ARPs fit the chamfer okay (only hand tight):

http://iainel.co.uk/images/forums/NovaWIP2/866.JPG

And the front of my engine, spent most of yesterday painting it lol:

http://iainel.co.uk/images/forums/NovaWIP2/867.JPG

[vaughanmc]

Very impressive cage mate! Will be an interesting car when it's done :)

[Adam]

So now get those 4 lumps of metal into the block.... :p ;)

I want to get on track with you before I-
A-Blow mine up
B-Stack it
C-Break it

lol

[Benn]

Re the cage, what about CP's? This cage is huge like yours and that's only a 1.6.. That's no different really to this...

[Count Vaux Alot]

Looks awesome I'm off to start from page one!

[twin40s]

Did you use a new corsa servo plate to weld in for your servo to mount if so were do you get that from?

[Iain]

The plate was taken from a Corsa B in the scrappy, it unbolts from the Corsa.

Well, I've decided I don't like the Hammerite under my car - it's just going to chip off, look rubbish and leave little protection in 6 months time.

So I've started stripping it down:

http://iainel.co.uk/images/forums/NovaWIP2/868.JPG

I'm using this stuff, POR15 from America, meant to be applied to bare metal and supposedly stops rusting very well on vehicle chassis':

http://iainel.co.uk/images/forums/NovaWIP2/869.JPG

I applied POR15 Marine Clean, then POR15 Metal Ready, rinsed off, let it dry and applied POR15 Rust Preventative paint:

http://iainel.co.uk/images/forums/NovaWIP2/870.JPG

Plan is to topcoat this with POR15's Whitecote - a similar product but white. :)

Also took another trip to Autosprint where he re-balanced my crank as it has been reground since last doing it. Also balanced my rods up for the new pistons:

http://iainel.co.uk/images/forums/NovaWIP2/871.JPG

You can see material taken off here. Some have lost their numbering I filed in, but I guess it won't matter too much since everything is brand new?

http://iainel.co.uk/images/forums/NovaWIP2/872.JPG

Crank is ready for bolting in now, so I've sorted out the endfloat centre main bearing. Both sides got materal removed with 240 grit...

http://iainel.co.uk/images/forums/NovaWIP2/873.JPG

...until I could fit a 0.1mm feeler blade in the gap. IIRC Haynes says 0.07 to 0.3mm gap so should be fine:

http://iainel.co.uk/images/forums/NovaWIP2/874.JPG

[Benn]

I really wouldn't have washed it. The POR15 looks good tho. Good work on the rods.. Get the engine built up.

[Iain]

Washed what?

[Benn]

Well you said rinsed.. I wouldn't have gone anything wet.

[Iain]

Was a bit weird wetting bare metal, but they recommend POR15 Marine Clean and POR15 Metal Ready which both require rinsing off with water. Blasted it with my compressor it and made sure it was dry before painting anyway.

[Connor]

It wasnt the washing that was the issue,
it was the very dark grey cloud approaching after the first coat :p
You get the second coat on Iain?

[Iain]

lol Yeah rain held off ok, got the second coat on once the first was tacky as per the instructions. Does look quite good black, but maybe just cos it's different to what I'm used to seeing, hmm.

[Adam]

Is this not finished yet???

[draper]

Is this not finished yet???

it was nearly ready for building back up


then he stripped it and started again lol

[Paul]

He is a long long man.

[scott.parker]

He is a long long man.

Too much info there Paul! lol

To be fair i dont blame him for stripping it and re doing it, if it was me and i thought it was not quite what i wanted i would do it too, best things come to thoughts who wait..





BUT fecking hurry up...lol

[Adam]

He is a long long man. Lmao
Looking at the time of your post Paul, been on the bulmers? lol

[Iain]

lol wtf

Armed with this:

http://iainel.co.uk/images/forums/NovaWIP2/875.JPG

I planned to get my bottom end ready to go together. Got two pistons together nicely:

http://iainel.co.uk/images/forums/NovaWIP2/876.JPG

With the assembly lube on the gudgeon pin:

http://iainel.co.uk/images/forums/NovaWIP2/877.JPG

New Mahle bearings:

http://iainel.co.uk/images/forums/NovaWIP2/878.JPG

Now I think there's a problem with two of the pistons... There's literally no interference fit with the gudgeon pin and the piston. It'll move about with my finger, even if I shake it!

http://iainel.co.uk/images/forums/NovaWIP2/879.JPG

http://iainel.co.uk/images/forums/NovaWIP2/880.JPG

....So will call the guy at Autosprint next week to see what's going on. The other two pistons don't move by hand, although you can twist them inside the piston if you insert reverse pliers in to the pin to grip it. Hmm.

Bottom end had its final clean out to remove rebore/honing debris, fitted up the bearings to this too (Mahle again), crank will be cleaned and fitted tomorrow. :)

http://iainel.co.uk/images/forums/NovaWIP2/881.JPG

[brucer]

thats strange, have you measured the gudgeon pins or the piston to see if there different than the others?

[Iain]

No, but I'll get a measuring caliper on it later, good thinking.

[Adam]

Are the pins new?

[Iain]

Of course.

[Adam]

May just have been sent two different sized pins then...

[Iain]

Measured up the pins and they're all bang on Haynes size given.

Stripped down the built pistons and tinkered with the gudgeon pins and realised... The others were probably only tighter because they were greased up. The two 'loose' ones were dry. A quick ring to the guy at Autosprint and Tom Reid off here and I was happy they would be fine. Built all four up again and they all feel the same:

http://iainel.co.uk/images/forums/NovaWIP2/882.JPG

Crank had a final clean, journals cleaned with brake cleaner and blown off with the air compressor:

http://iainel.co.uk/images/forums/NovaWIP2/883.JPG

And shells covered with plenty of assembly lube:

http://iainel.co.uk/images/forums/NovaWIP2/884.JPG

End oil seal got some grease as per Haynes instructions:

http://iainel.co.uk/images/forums/NovaWIP2/885.JPG

It's bolted in hand-tight at the moment, fancy a new torque wrench to make sure it's all correct.

Haynes piston ring gap is 0.3mm, so I put the ring in the top of the cylinder:

http://iainel.co.uk/images/forums/NovaWIP2/886.JPG

And pushed it down with a piston:

http://iainel.co.uk/images/forums/NovaWIP2/887.JPG

And the 0.3mm feeler blade fits in perfectly, winner:

http://iainel.co.uk/images/forums/NovaWIP2/888.JPG

Although not sure why it says 1.00 on the ring itself?

http://iainel.co.uk/images/forums/NovaWIP2/889.JPG

Can't find any info on which ring goes where in Haynes too. I have eight 2.00mm rings but four have a slight corner missing from the underside outer edge - is this the top or the bottom?

[auzzy-b]

Good stuff! very interesting reading up on engine rebuilds in detail!:thumb:

[Adam]

Good stuff. This is a "PROPER" wip thread

[Benn]

Very good work dude. Proper impressed.

[Rich]

should be labled 1, 2 and 3 in the packet, and the rings say top on them

[Iain]

There were no labels, just all wrapped up together. I have

- Four 2mm rings with 'TOP 1.00' written on them (what does 1.00 refer to?)
- Four 2mm rings with 'TOP 1.00' written on them, and the bottom outside edge has a step on (what does 1.00 refer to?)
- Four oil scrapers (how do I gap these to the bore? They are coiled tighter than the bore's diameter)
- Eight thin oil scraper rings (do I gap these to Haynes specification?)

[scott.parker]

Top work mate, your getting very technical, fair play to you..

Scott

[Damo]

There were no labels, just all wrapped up together. I have

- Four 2mm rings with 'TOP 1.00' written on them (what does 1.00 refer to?)
- Four 2mm rings with 'TOP 1.00' written on them, and the bottom outside edge has a step on (what does 1.00 refer to?)
- Four oil scrapers (how do I gap these to the bore? They are coiled tighter than the bore's diameter)
- Eight thin oil scraper rings (do I gap these to Haynes specification?)

Right mate the four rings with the cut out on the bottom edge go at the top of the piston with the cut out to the top thats just incase the bore has a little lip so it dosent break the ring.

The other four 2mm rigs go underneath

And the oil scrapers go underneath those and as far as i know mate you dont have to gap them you just put them on the piston but seen as you have 3 separate rings for the scraper put the gaps at different places on all 3 dont know why though its just what my local engineering shop told me.

Hope this helps if you can make sense of it all.

Good luck.

Damo.

[MK999]

If you put the gap in the rings at different points around the bore it limits the amount of blow by that just shoots straight through the gap in the ring, it has to go round the bore twice before it gets out if you put the gaps on opposite sides

[Iain]

Cheers for the info, yeah I knew about the ring gaps in different positions, think it mentions something in Haynes.

The 2mm ring with the step says 'TOP' on the side opposite the step though?! So I can't have the step facing upwards and 'TOP' on top too.

[burgo]

Measured up the pins and they're all bang on Haynes size given.

Stripped down the built pistons and tinkered with the gudgeon pins and realised... The others were probably only tighter because they were greased up. The two 'loose' ones were dry. A quick ring to the guy at Autosprint and Tom Reid off here and I was happy they would be fine. Built all four up again and they all feel the same:?

Told you so, shoulda listened to uncle burgo :p

[Iain]

Got myself some Halfords Professional torque wrenches today (good price with trade discount!) and torqued up my main bearings. On to the end one I used this sealant:

http://iainel.co.uk/images/forums/NovaWIP2/890.JPG

Part number for those interested (assuming you want to trust I'm using the right product!):

http://iainel.co.uk/images/forums/NovaWIP2/891.JPG

Haynes was very vague on this, and a quick search revealed nothing. So I've applied sealant along the groove, and on the inside edge like this:

http://iainel.co.uk/images/forums/NovaWIP2/892.JPG

Bolted in and smoothed the remaining sealer like so:

http://iainel.co.uk/images/forums/NovaWIP2/893.JPG

Be OK in the block won't it?

http://iainel.co.uk/images/forums/NovaWIP2/894.JPG

Started fitting the rings to my pistons. For those interested, they go as follows:

- Top ring has a silver edge and is the one WITHOUT the step (not as Damen said above). 'TOP' is on top.
- Middle ring has a black edge and is the one WITH the step. 'TOP' is on top.
- Oil scraper etc on bottom, don't think it matters which way up this lot goes?!

Planning on having my ring gaps as follows (if I've interpreted Haynes correctly):

- Top ring, gap at top (if looking from exhaust side)
- Second (middle) ring, gap on bottom (if looking from exhaust side)
- Oil scraper, gap at top. Two rings next to oil scraper approx 3cm away from oil scraper gap (each 3cm away in opposite directions, so 6cm away from eachother).

http://iainel.co.uk/images/forums/NovaWIP2/895.JPG

[burgo]

i would be tempted to clean all the sealant off of the inside of the block. if it comes off and clogs your pick-up pipe all you hard work will be for nothing

[Benn]

Good engine work dude.

[Connor]

Getting there Iain

[Count Vaux Alot]

i would be tempted to clean all the sealant off of the inside of the block. if it comes off and clogs your pick-up pipe all you hard work will be for nothing

Good work mate, i second burgo's comment though.

[Iain]

Thanks for the advice, sealer now removed from inside the crankcase.

First piston offered up to the bore:

http://iainel.co.uk/images/forums/NovaWIP2/896.JPG

On with the ring compressor that's been sitting boxed in my toolbox for months:

http://iainel.co.uk/images/forums/NovaWIP2/897.JPG

And all in, winner:

http://iainel.co.uk/images/forums/NovaWIP2/898.JPG

Got the ARPs to fit tomorrow as it's just in on std bolts at the mo, then on to the cyl head to build up again.

[Adam]

Good work son!!!!

[Damo]

Sorry for the incorrect info iain normally the top ring has a groove in it facing upwards incase the bore has a lip at thetop so the ring wont break if it comes into contact with it:tard: .

Glad you got it sorted though mate.

Damo.

[Connor]

Weheey looking good iain

[Benn]

Pistons around the right way yeah?

[Iain]

Yep, arrow on the piston pointing towards the cams, lugs on the conrods pointing towards the flywheel. :)

[Iain]

Trying to stop dirt entering my block so fitted these. Fitted the gasket on the breather but does the sensor have anything?!

http://iainel.co.uk/images/forums/NovaWIP2/899.JPG

Temporarily fitted the waterpump and oil pump:

http://iainel.co.uk/images/forums/NovaWIP2/900.JPG

Slight modification so it clears the early belt cover nicely (you can see on the lug at the top) - also where the hell does the tab on the waterpump go? Can't find anything about it in Haynes!

http://iainel.co.uk/images/forums/NovaWIP2/901.JPG

Bottom end seals - anyone any ideas?

http://iainel.co.uk/images/forums/NovaWIP2/902.JPG

[chrisnovaturbo]

i would say the top left is the crank shaft to oil pump seal all the rest im not sure

[chrisnovaturbo]

oh yeah the engines looking smart mate

[Iain]

Cheers. Yeah I guessed the oil pump seal one, and I imagine the black rubber is for the oil pickup pipe. Dunno about the rest tho!

[Rich]

Left looks like the crank sensor seal?

Next in sump plug seal.

Put the cambelt back plate on before waterpump, theres a notch in it that the waterpump lines up with. Looks about right where it is now

[Iain]

Crank sensor is the one I've fitted on the front of the block?

[Iain]

Put the cambelt back plate on before waterpump, theres a notch in it that the waterpump lines up with. Looks about right where it is now
Pretty sure the belt cover goes on after the pump as it hides one of the bolt heads. Also there's no marks on it to show where the pump sits. It's an early XE backplate if that makes a difference.

Edit: This looks like a rundown of all bottom end gasket items:
1 x Sump Plug Washer (Bottom, second from left)
1 x Oil Pressure Relief Valve Washer (Bottom, right)
1 x Oil Pump Gasket
1 x Oil Pick Up Pipe o-ring (Bottom, second from right?)
1 x Crank Sensor o-ring (Bottom, left?)
1 x Crankshaft Oil Seal - Oil Pump End
1 x Crankshaft Oil Seal - Flywheel End
1 x Water Pump o-ring
1 x Dipstick Gasket
2 x Cork Sump Gaskets

[Iain]

One clean oil pump housing (thanks to Tom who I bought it off tbh, did a very nice job of cleaning it for me!):

http://iainel.co.uk/images/forums/NovaWIP2/903.JPG

Good condition gears:

http://iainel.co.uk/images/forums/NovaWIP2/904.JPG

Removed the relief valve from my old pump:

http://iainel.co.uk/images/forums/NovaWIP2/905.JPG

But it doesn't look in that good condition, some scratches on the outside - usable?

http://iainel.co.uk/images/forums/NovaWIP2/906.JPG

[Adam]

The crank sensor has a rubber o-ring on it

Edit-Ignore that, you already know

Engines looking fooking awesome btw!

[djbrowney]

by a nylon relife valve from sbd i know there a lot of money but worth every penny imo, just wrapp your engine in cling film that what i do, then just un wrap it next time you do something lol

[djbrowney]

looks good btw lol

[Iain]

I'm using bubble wrap atm, keeping the dust out but not as annoying to unwrap as clingfilm every day lol

[Benn]

I'd very lightly sand then polish the relife valve, i did it on one of mine and it stopped it sticking.

[tom reid]

What Benn said ^

[Adam]

Dont bother with this SBD nylon crap either.

[Iain]

According to Haynes this is the outer gear marking to show which way round it goes:

http://iainel.co.uk/images/forums/NovaWIP2/907.JPG

And according to many resources I've read packing the oil pump with Vaseline helps it prime quicker on first startup. So I have:

http://iainel.co.uk/images/forums/NovaWIP2/908.JPG

Sanded and polished relief valve looks perfect now:

http://iainel.co.uk/images/forums/NovaWIP2/909.JPG

Oil pump seal greased as per Haynes instructions:

http://iainel.co.uk/images/forums/NovaWIP2/910.JPG

Started bolting it on and realised I won't be able to! The later pumps obviously use allen headed bolts, d'oh!

http://iainel.co.uk/images/forums/NovaWIP2/911.JPG

So that's me stumped on the bottom end. Time to do some work on the head.

Fancied doing the 'porous mod' with a hollow tube - just in case the head is suffering from the fault since I don't know the history. Bought B&Q 8mm aluminium alloy tube, and sanded it back on a bench drill till it was a better fit. Approx 7.5-7.8mm I think:

http://iainel.co.uk/images/forums/NovaWIP2/912.JPG

Positioned in (followed by Loctite 638 then tapped in to place):

http://iainel.co.uk/images/forums/NovaWIP2/913.JPG

Mmm I've done a damned good job of cleaning it if I may say so myself!:

http://iainel.co.uk/images/forums/NovaWIP2/914.JPG

First valve seat in:

http://iainel.co.uk/images/forums/NovaWIP2/915.JPG

And valve stem seal fitted using a 12mm deep socket:

http://iainel.co.uk/images/forums/NovaWIP2/916.JPG

[burgo]

vasaline FTW :d

[Adam]

Good stuff Iain.
That vaseline looks a neat job, have you used it before?

[Iain]

Oh Adam behave, you know I have.

[Adam]

Oh you big tease, youre making me blush

[Iain]

Not touched the Nova in about a week (which is a long time for me so far).

Been trying to get quotes for local shot blasting to strip the underside of the car back to bare metal. I don't have the patience for it with a grinder tbh (and I hate making that much noise).

Following on from a thread where I was pondering what headgasket I'll need, I realised I should try and work out my compression ratio. So I've bought a piece of polycarbonate and a burette in an attempt to do this myself.

Plug and valves fitted with a bit of grease to seal them, polycarb on with more sealing grease:

http://iainel.co.uk/images/forums/NovaWIP2/917.JPG

And a 50ml burette to measure how much fluid goes in:

http://iainel.co.uk/images/forums/NovaWIP2/918.JPG

Looks good in the pics but I used brake cleaner and it leaked through the valve. lol Any ideas for sealing them better? Or will I need to fit the springs and collets...

[dj_wudgey]

engine looks top notch mate!! good work!

[Connor]

Top work yet again Iain
Let us know how much they charge to blast the underneath
will be interested to know

[Benn]

Stop funking about with the blasting. Get the grinder out and you'll have it done in a day.

[Count Vaux Alot]

If its underseal on there blasting wont shift it anyway - its grinder and a wire knot unfortunately

[burgo]

ive always found ive had to refit the valve springs to hold the valves closed tight enough

[Iain]

Count, it's a mixture of: etch primer, normal primer, canned stonechip, seam sealer and Hammerite. Already gone over the underneath removing the rubbery underseal which is why I CBA doing it all again.

Think I'll have to end up doing that Mr Burgo

[Benn]

Stop stalling and get cracking.

[Iain]

Measurement with the above burette was 41.7ml in the head chamber. I have then used this calculator http://www.csgnetwork.com/compcalc.html with the following figures (assumed 1.3mm multilayer headgasket as I know their compressed thickness):

Measurements: MM
Bore size: 87
Piston stroke: 86
Head gasket bore: 88
Compressed gasket thickness: 1.3
Combustion chamber: 41.7cc
Piston dome volume: -1cc (for the valve cut-outs)
Piston deck clearance: -0.4mm (as it sticks out the block approx 0.4mm)

which gives a CR of 11.6:1, so I may use a 1.9mm Cometic headgasket to bring that down to 10.8:1 (standard is 10.5:1) as I'm using standard injection etc.

Today's progress:

Clean valve and a bunch of spring platforms and collets:

http://iainel.co.uk/images/forums/NovaWIP2/919.JPG

Brand new GM valve springs, you can see how much the old one has squished compared to the new:

http://iainel.co.uk/images/forums/NovaWIP2/920.JPG

In they go:

http://iainel.co.uk/images/forums/NovaWIP2/921.JPG

Wahey!

http://iainel.co.uk/images/forums/NovaWIP2/922.JPG

Today's de-progress

Went to bolt up my oil pickup pipe and found one of the bolt threads on the oil pump was stripped :mad: Going to clean up a spare I've got to see how good condition it's in:

http://iainel.co.uk/images/forums/NovaWIP2/923.JPG

[Benn]

Good work, i'm gonna have to do this to mine soon, hate the thought of it.

Shame about the pump.

[brucer]

tidy work on figuring out the compression ratio, must have been tedious work.

[Iain]

Finally sorted my front arches, both back to bare metal (or as near as I could be bothered!)

http://iainel.co.uk/images/forums/NovaWIP2/924.JPG

And painted in POR15:

http://iainel.co.uk/images/forums/NovaWIP2/925.JPG

http://iainel.co.uk/images/forums/NovaWIP2/926.JPG

Rear arches will get the same treatment, and I think I'll just chip off the Hammerite on the underside as it's only the top layer (unlike the arches). Think I'll try using my compressor to spray some UPOL Gravitex all over (thick and rubbery stuff that dries properly unlike underseal?)

http://martinbrownpaints.net/images/product_grav.jpg

[Benn]

Yeah it dries hard, but i've found always cracks after time. (its what the bodyshop use after doing mot welding)

[Iain]

Got a new front seal for my new pump housing. It's a bit thinner than the standard one so sits a bit in, but shouldn't be an issue?

http://iainel.co.uk/images/forums/NovaWIP2/927.JPG

Bolted on with new allen headed bolts:

http://iainel.co.uk/images/forums/NovaWIP2/928.JPG

Am I right in thinking the bottom pulley bolts tight to the thrust washer that sits inside the seal? Surely this will put a lot of pressure on the inner oil pump gear?

http://iainel.co.uk/images/forums/NovaWIP2/929.JPG

[Iain]

Thought I'd mention a problem I've encountered. There's no info on this forum about it but there is some people on MIGweb who discuss it.

The thrust washer/ring/spacer that sits inside the oil pump and behind the bottom pulley can wear a groove in from where the oil seal lip sits, like so:

http://iainel.co.uk/images/forums/NovaWIP2/930.JPG

This means it may not seal right. Some suggestions on MIG are reverse it so the groove sits inside, but since this one is a little corroded I'm not sure it'll seal 100%. Hoping to find somewhere that'll sell one cheaper than Vauxhall's £40 :roll:

[peester]

cripes those arches look smooooth as.

[Iain]

Rear arches are now equally smooth, ordered some 3M stonechip so there'll be more pics when I put that on.

My Cometic gasket turned up so looking to get the head on and engine finished.

In preparation for this I wanted to check my head bolts have plenty of room for tightening down.

First off I measured the amount of bolt protruding when it has bottomed out in the block:

http://iainel.co.uk/images/forums/NovaWIP2/931.JPG

Then summed the gasket thickness (1.5mm), the depth of the head, and the thickness of a bolt washer:

Head:

http://iainel.co.uk/images/forums/NovaWIP2/932.JPG

Washer:

http://iainel.co.uk/images/forums/NovaWIP2/933.JPG

This sums to 84.7mm which means I've got about 5mm of thread left in the block. This should be fine as I measured the length of a new and old bolt and they only stretch about 0.2-0.3mm, does this sound about right?

http://iainel.co.uk/images/forums/NovaWIP2/934.JPG

[Paul]

Uprised your not putting it on studs & nuts to be honest Iain.

[Iain]

What's the benefits? Re-usable?

[Prey]

Think you need to come clean/paint and measure stuff up on mine - i can never be bothered lol

[Paul]

What's the benefits? Re-usable?

Yeh and you can torque them down better as they dont feel as though theyre going to snap.

[The Simps]

Good progress with this mate.

With regards to the underseal, if you mix in a little old engine oil it makes the mixture tacky and it stays tacky. Not great to work round and it will get dirt cling to it but it won't crack and you won't get water bubbles under the surface. My old man swears by it, that and covering brake pipes with grease.

[Iain]

Hmm not sure about that, I really want to avoid tacky underseal for the reason that it's annoying to work near! Plan is to apply some 3M stonechip with a brush to get a textured effect, and I've ordered some Glacier White 2pack to brush/roller over it. :)

[Iain]

Got the bottom sprocket on and torqued to 250Nm, only managed to angle tighten it another 20 degrees and not the 40 like Haynes says but Jesus is it tight! also got the oil pickup bolted on with 8v sump gasket.

http://iainel.co.uk/images/forums/NovaWIP2/935.JPG

Ooooh look how clean that sump is, think it's been blasted cos it's quite rough:

http://iainel.co.uk/images/forums/NovaWIP2/936.JPG

Bolted on with some new M6x20 bolts:

http://iainel.co.uk/images/forums/NovaWIP2/937.JPG

Think one of the oil pump sump holes was threaded (don't think I did it?!), but not to worry as I can put a nut on the other side :)

http://iainel.co.uk/images/forums/NovaWIP2/938.JPG

On with my Cometic gasket. Quite a tight fit around the dowels but it fitted quite well otherwise:

http://iainel.co.uk/images/forums/NovaWIP2/939.JPG

As per Cometic instructions, make sure the rivets are not on the block face:

http://iainel.co.uk/images/forums/NovaWIP2/940.JPG

Head on and tightened finger tight for now:

http://iainel.co.uk/images/forums/NovaWIP2/941.JPG

http://iainel.co.uk/images/forums/NovaWIP2/942.JPG

Rocker on to keep the dirt out (dunno what colour to paint this...)

http://iainel.co.uk/images/forums/NovaWIP2/943.JPG

And a bit of mincing from the other night, my new storage for all my new nuts and bolts (each tray is a different size and length!)

http://iainel.co.uk/images/forums/NovaWIP2/944.JPG

[Connor]

Glacier White rocker ;)
oh and it's good to see you look after your nuts

[AlexW]

Funny, the trays all look the same size :p

Good work though, You just need a decent car to fit it to now.

[Iain]

Dunno about glacier white, was thinking more red, dunno if it'll be too much though. You're welcome to come round and touch my nuts Connor. Very funny AW lol

[Benn]

White same as the car, awesome work dude! Engine looks great.

[scott.parker]

Looking good dude! i say either White with red plug cover (OEM look) or Red with dark grey/white plug cover..

Fancy rebuilding mine for me lol

[Adam]

Engine looks awesomely clean Iain, good stuff!

[Iain]

Inspired by Prey's WIP I had a go at fitting my Citroen ZX single wiper motor also. Got it on with 2 bolts so far, currently pondering a way of securing the third without having a bolt through the scuttle vents:

http://iainel.co.uk/images/forums/NovaWIP2/945.JPG

Welded a nut on the underside of the scuttle to secure the passenger side bolt:

http://iainel.co.uk/images/forums/NovaWIP2/946.JPG

Painted my rocker and plug cover (can see my belt cover in the background also). Looks okay in the pics but a lot of dust and runs so it'll get flatted back and resprayed:

http://iainel.co.uk/images/forums/NovaWIP2/947.JPG

http://iainel.co.uk/images/forums/NovaWIP2/948.JPG

Dug my cams out:

http://iainel.co.uk/images/forums/NovaWIP2/949.JPG

But some damage on the inlet cam means I probably won't be using one of them. It's scuffed quite deep where the oil seal sits so I'll probably source a new cam, if anyone knows of one for sale:

http://iainel.co.uk/images/forums/NovaWIP2/950.JPG

[vaughanmc]

You going to be polishing up the 'Vauxhall...etc' on the plug cover ?

[Iain]

How is it done? Block and fine sanding paper to get it back to bare metal?

[vaughanmc]

I think so mate then you could re-lacquer it or keep it polished and waxed to protect it

That's the way I'd do it - They look bland when it's all one colour and you can't see the writing

[Iain]

Will leave it for now - I have another plug cover where the original powdercoating hasn't flaked so I can always use that if it looks too bland.

[nova ian]

Looking good Iain, I like the nut welded on the underside of the scuttle, nicely done :d

As for securing the other end I opted for a colour coded motorsport fastener lol

http://img.photobucket.com/albums/v314/cruisindude/nova/IMG_0408.jpg

Couple of q's for you mate... 1. Could you get the part number off the breather hose that goes from dipstick to rocker cover if you get chance, as now mines on and all the slam etc on I can't see it without taking it off!

and B. Where did you get your CDS for the cage from? Might also want to borrow a door bar of yours to test fit and copy off as I never got door bars with my cage :(

[Iain]

Motorsport fastener lol I'll go out and see if that'll work now. Get the feeling it'll need to be a set distance from the slam with a bolt.

I'll see if I can find the hose in my bag of XE crap, I have a Roose silicone one to go on so don't know if I've got it.

CDS was got through a mate who got it from a kitcar place. I remember seeing some motorsport/rally place near Clifton somewhere but it was about £18 a metre.

You sure can borrow a doorbar, pop over and take them away with you if you want :)

[nova ian]

Thanks Iain

Yea I Emailed Roose about the hose and it was £24 delivered, was just going to see what the price of a new GM one was in comparison, but I think the roose one will be stronger so prob the best bet.

Motorsport place near Clifton?? where!?!?

[Iain]

Oh my bad it's 'North Clifton' in Newark-Upon-Trent. lol £18 a metre is a bit steep though.
http://www.prepfab.co.uk/