Iain's 20XE Trackday Nova

[Iain]

Decided yesterday that I was going to take my Nova off the road again and do some bits to it that I regret not doing when I first built it (See my original WIP (http://www.pngclub.com/forum/showthread.php?t=70561)). :) The major aim is to get a good layer of paint, tidy up the underneath and maybe a bit more power?!

Been stripping some of the front end down today.

Bagan with it looking like a normal car

http://iainel.co.uk/images/forums/NovaWIP2/001.JPG

http://iainel.co.uk/images/forums/NovaWIP2/002.JPG

First off, strip the front suspension off and drain the oil

http://iainel.co.uk/images/forums/NovaWIP2/003.JPG

http://iainel.co.uk/images/forums/NovaWIP2/004.JPG

All off (new driveshafts have only covered a few miles since fitting lol)

http://iainel.co.uk/images/forums/NovaWIP2/005.JPG

Stripped engine bay back and drained fluids, hopefully borrow an engine crane to remove it at some point

http://iainel.co.uk/images/forums/NovaWIP2/006.JPG

http://iainel.co.uk/images/forums/NovaWIP2/007.JPG

http://iainel.co.uk/images/forums/NovaWIP2/008.JPG

And in typical WIP fashion, the engine bay good and bad bits

http://iainel.co.uk/images/forums/NovaWIP2/009.JPG

http://iainel.co.uk/images/forums/NovaWIP2/010.JPG

http://iainel.co.uk/images/forums/NovaWIP2/011.JPG

[Iain]

http://iainel.co.uk/images/forums/NovaWIP2/012.JPG

http://iainel.co.uk/images/forums/NovaWIP2/013.JPG

http://iainel.co.uk/images/forums/NovaWIP2/014.JPG

That's it so far :)

[Dar]

Did you get your horn from the General Lee? (http://mosh.nokia.com/content/48CAAF2AB2733533E040050A44307E0C)

[Iain]

lol They're not musical ones.

[Sloth]

looking good matey, whats the plans for powaaaaahh then?

[Jay]

Sell me the engine.. :)

[Adam]

So whats the plan Iain? Mini rebuild??? Respray?


Whens the xe going in? :p

[General Baxter]

Whens the xe going in? :p

he said power not weight lol

[Adam]

Power increase outweighs the extra 20kilo........

[CoolTiger]

i got dixe horns :D nout wrong with them lol,

looking good :) will it be at pv

[vaughanmc]

i got dixe horns :D nout wrong with them lol

I have an air-horn setup as well with like 2 trumpets

There absolutely awsome lol

[John]

Nice work iain, always really liked your car. As others have said, what's the plans engine wise?

[burgo]

if you need a hand gayer then give us a shout

[brainsnova]

train horn FTW.

[Iain]

lol Glad to see my horn is liked. Yeah just a mini rebuild, bit of nice paint, and treat the underside properly since it made it through winter.

Hopefully be done for PV yeah.

Cheers Burgo. :)

Dunno about engine yet TBH, might just tweak the 1600 a bit, maybe aftermarket management?

[Adam]

I'll lend a hand too if im not busy with work and shizzle!!!!

Txt me.

[Emmy]

Nice cant beat a white Nova :thumb:

[Sloth]

iain, you need boost dude....

[matt_vaughan]

az it got boost yer.......

[Iain]

Stripped a little more off tonight after work

http://iainel.co.uk/images/forums/NovaWIP2/016.JPG

http://iainel.co.uk/images/forums/NovaWIP2/019.JPG

http://iainel.co.uk/images/forums/NovaWIP2/017.JPG

http://iainel.co.uk/images/forums/NovaWIP2/018.JPG

Shot myself in the foot though as I can't remove my dash due to the front cage section lol Might be able to lift it out if I remove the windscreen, need to get a car cover so I can do that.

[Mike]

Cracking on aint you chap!! Your car reminds me of mine now circa 2006 pre reshell, nothing but an empty white shell lol lol

[Adam]

That exhaust system has rusted quickly!!!

Theres a few white empty shells on here atm lol lol

[Iain]

Luckily I didn't put much back on last time so there's hardly anything to remove lol

Yeah, it's rusted mainly along where it faces the floor. Will give it a blast of high temp paint.

[Mike]

That exhaust system has rusted quickly!!!

Theres a few white empty shells on here atm lol lol

Everyone an there dog has a Glacier white non sunroof shell dont they lol

[Benn]

Good work, yet you can get a light switch out... hahahaha

[Iain]

Made the most of the nice weather this afternoon and whipped the little 1600 out.

Picked up an engine crane and engine stand from my mate:

http://iainel.co.uk/images/forums/NovaWIP2/020.JPG

Bonnet and wings off for easier access:

http://iainel.co.uk/images/forums/NovaWIP2/021.JPG

Engine crane supports engine while I undo the mounts:

http://iainel.co.uk/images/forums/NovaWIP2/022.JPG

And engine sitting on a tyre and two skateboards:

http://iainel.co.uk/images/forums/NovaWIP2/023.JPG

Car up in the air:

http://iainel.co.uk/images/forums/NovaWIP2/024.JPG

And it's out:

http://iainel.co.uk/images/forums/NovaWIP2/025.JPG

Box and clutch off:

http://iainel.co.uk/images/forums/NovaWIP2/026.JPG

http://iainel.co.uk/images/forums/NovaWIP2/027.JPG

I'm no clutch expert but this isn't good?

http://iainel.co.uk/images/forums/NovaWIP2/028.JPG

And empty bay, can't rip wiring out until I've removed the dash:

http://iainel.co.uk/images/forums/NovaWIP2/029.JPG

Gotta put the engine on its stand tomorrow, and will probably remove the rear beam and fuel tank. :)

[Adam]

Nice work Iain.

Clutch is ****ed

[tom reid]

You welding up the engine bay?

[Benn]

lol you have a hoist and use it to lift the car? lol crazy.

Good work tho, that clutch has got years left it in...

[Iain]

I find lifting the car over the engine is loads easier than squeezing the engine out the top.

Tom yeah I was thinking of doing some of the seams, got myself a Clarke MIG so if I get good enough with some practice I'll give it a go.

Today's progress...

Got engine on its new stand, never used one before but it's really cool the access it gives you.

http://iainel.co.uk/images/forums/NovaWIP2/030.JPG

http://iainel.co.uk/images/forums/NovaWIP2/031.JPG

Drained fuel tank using the pump:

http://iainel.co.uk/images/forums/NovaWIP2/032.JPG

And removed. Bit scabby under there (found no major nasty bits so far though) but it'll all get treated:

http://iainel.co.uk/images/forums/NovaWIP2/033.JPG

Pic of today's removals:

http://iainel.co.uk/images/forums/NovaWIP2/034.JPG

[John]

Lol, good old skateboards still being used for engine removal lol.

[Iain]

lol Had to find them and dig them out from when I first fitted the engine

[tom reid]

You haven't found any holes yet?, your'e not hitting the usual area's hard enoughlol

[Adam]

Whens the XE going in?

[burgo]

mmmm a blank canvas.....lovely

[Benn]

Squezzing? hahaha

So what are you refitting then? Keeping the 1.6?

[Leeboo]

Good progress there mate, I remember seeing your Nova in a rolling road feature in Total Vauxhall.

I say maybe a bit of headwork and a cam in the 1600 :cool:

[Paul]

Whens the XE going in?

As above, nice work IAN, look like a really nice clean shell actually, got some tasteful mods already done to it, a nice engine would be my next step (no offence btw :thumb: )

[Adam]

Iain's engine is impressive for what it is.
Kept with my 1600 16v no probs at all!!!

(his is fully stripped though :p )

[Iain]

Out come the weight advantage excuses lol Just because you couldn't get away from 96bhp of pure grunt.

Think I'm gonna keep the 1.6 for the time being yeah, might try my first engine rebuild on it. If I manage to strengthen the bay it'll be good for whatever in the future though.


You haven't found any holes yet?, your'e not hitting the usual area's hard enoughlol
I think we got most of the usual spots first time round. :cool:

Been trying to remove the brake lines tonight, all came off fairly easily except one front flexi that's being a bugger.

[AlexW]

C/X16XE :cool:

[Iain]

Finally got my brake lines off, although broke one trying to undo the flexi. Might as well replace them anyway.

http://iainel.co.uk/images/forums/NovaWIP2/035.JPG

Bay's looking emptier now, still need a car cover to remove the windscreen to get the rest of the loom out though

http://iainel.co.uk/images/forums/NovaWIP2/036.JPG

[draper]

nice bag ;)

[Benn]

What are the plans for the bay?

[Iain]

Leave the bag out of this Draper lol

Bay is hopefully going to be stitch welded and sprayed up nice again. All the rust will be treated.

Finally got the screen out today, was dead easy. This allowed me to get the dash out through the gap and remove all the wiring.

Started by peeling back all the rubber on the inside:

http://iainel.co.uk/images/forums/NovaWIP2/037.JPG

And it popped straight out:

http://iainel.co.uk/images/forums/NovaWIP2/038.JPG

http://iainel.co.uk/images/forums/NovaWIP2/039.JPG

http://iainel.co.uk/images/forums/NovaWIP2/040.JPG

Which allowed me to remove this:

http://iainel.co.uk/images/forums/NovaWIP2/041.JPG

http://iainel.co.uk/images/forums/NovaWIP2/042.JPG

Dunno if I'll put a dash back in, looks cool without.

Got myself a cover too to keep the rain out while there's no windows in:

http://iainel.co.uk/images/forums/NovaWIP2/043.JPG

[Ernie]

Everyone an there dog has a Glacier white non sunroof shell dont they lol

I dont know what you meen lol.
http://img.photobucket.com/albums/v617/chunny01/JDL%20Project/jdlnova076.jpg
http://img.photobucket.com/albums/v617/chunny01/JDL%20Project/jdlnova004.jpg
Nice build mate keep it up.
:thumb:

[Benn]

You know you can remove the dash with the screen in yeah?

[Iain]

Not without bending it in half and ruining it. The front cage legs have it wedged in place.

[Benn]

Ah ok, didnt think the cage would be jamming it in.

[Adam]

Good work iain

[Cle]

http://iainel.co.uk/images/forums/NovaWIP2/039.JPG

Halfords axle stands FTW lol i got them too :)

[Iain]

Yeah they're not bad for a few quid.

Today's progress, its pretty much a bare shell now.

Used a battery to activate the electric windows to get the windows out:

http://iainel.co.uk/images/forums/NovaWIP2/044.JPG

Out:

http://iainel.co.uk/images/forums/NovaWIP2/045.JPG

http://iainel.co.uk/images/forums/NovaWIP2/046.JPG

Pedals etc out:

http://iainel.co.uk/images/forums/NovaWIP2/047.JPG

The mess of a loom, going to replace it and start fresh with the wiring:

http://iainel.co.uk/images/forums/NovaWIP2/048.JPG

Trial fitted my new wings, good fit:

http://iainel.co.uk/images/forums/NovaWIP2/049.JPG

Decided to attack the nasty bits with a screwdriver, and found a hole behind the passenger turret:

http://iainel.co.uk/images/forums/NovaWIP2/050.JPG

http://iainel.co.uk/images/forums/NovaWIP2/051.JPG

http://iainel.co.uk/images/forums/NovaWIP2/052.JPG

[scott.parker]

Fook me didnt see this coming!

So you planning to re-build in places and respray the shell in-out?

Scott

[draper]

im now in the white nova gang lol

can i have my wings back please

[tom reid]

Thought I recognised those wings, take them off Iain, theyr'e jinxed, lol

[Iain]

lol Jinxed, when I write it off you're to blame Draper!

Yeah Scott I'll fix up the dodgy areas and hopefully get a good layer of paint all over, and paint up the underneath white too. Gonna need two rear arches this time too I think. :(

[scott.parker]

Really? they looked ok in the pics? you could just patch them up good (lol if patching up can be counted as good?)

[Iain]

They were patched up when I first put it on the road, we welded in an extra lip and fillered it to shape. For some reason the rust is coming back through again so it's time to do it properly.

[draper]

how bad is your drivers wing buddy ?

[Iain]

Will PM you Draper.

[Matt]

Some good swift work there. Bay will look a thousand times better painted and tidied up.

:thumb:

[Adam]

They were patched up when I first put it on the road, we welded in an extra lip and fillered it to shape. For some reason the rust is coming back through again so it's time to do it properly.
When the arches are rusty there is no way of stopping it :)
As the rust is coming through from the inner arch panel, so no matter what you do to the outer arch/lip, it'll just come through from the inside again...

The only fix is new panels.

[Ste L]

nice work Iain, wish i had this motivation lol

[Iain]

Got a bit more done on the interior today.

I tried spot weld drill bits and had no success with them so went for the grinder approach.

Back end up to get my rear suspension out of the way:

http://iainel.co.uk/images/forums/NovaWIP2/053.JPG

Chopped off the bracket:

http://iainel.co.uk/images/forums/NovaWIP2/054.JPG

And grinded the remains down over the spot welds:

http://iainel.co.uk/images/forums/NovaWIP2/055.JPG

All gone:

http://iainel.co.uk/images/forums/NovaWIP2/056.JPG

Mutilated the rear seat brackets for easier access:

http://iainel.co.uk/images/forums/NovaWIP2/057.JPG

All seat brackets gone:

http://iainel.co.uk/images/forums/NovaWIP2/058.JPG

Looks much nicer:

http://iainel.co.uk/images/forums/NovaWIP2/059.JPG

The remains:

http://iainel.co.uk/images/forums/NovaWIP2/060.JPG

Now for this to go to make way for an internal shifter:

http://iainel.co.uk/images/forums/NovaWIP2/061.JPG

Going:

http://iainel.co.uk/images/forums/NovaWIP2/062.JPG

Gone:

http://iainel.co.uk/images/forums/NovaWIP2/063.JPG

[Sloth]

woo another s/b track slut! i cant wait! im toying with the internal shifter btw...

[Adam]

Looking good iain.

SO, whats the plans? Respray???? Engine??? :p

[peester]

christ, more hardcore for 09..
nowt wrong with 1.6 8v, ad..

[Iain]

SO, whats the plans? Respray???? Engine??? :p

Yes to both :plol

Yeah should be a bit better for this year when it's done :cool:

[Dar]

Another perfectly good nova being hacked to bits by a nutter with an angle grinder! Poor car. Fair play though Lionel, looks like your cracking on with it :thumb:

Not bad for a geek.

[Benn]

Why have you cut the bit of dub skin out of the tunnel?

[Iain]

Thanks Dar lol
Benn, what do you mean dub skin? I removed the metal in the front to make way for an internal shifter to try and get a better gearchange feel.

[AlexW]

And to get rid of the rattle you said about Ages ago?

Looking good, what engine is going back in? Please say youve seeen the smallblock 16v light?

[Iain]

Yeah that annoying rattle through the stick will hopefully disappear! I'm keeping the 1.6 8v, end of :Dlol

[AlexW]

Ah you homo. But at least il have similar power ;)

[Benn]

Thats what i ment.

[Iain]

Stopped raining long enough for me to sort out the internal shifter hole. I hope it's in the right place :roll:lol

Following Dars guide and the competition build manual I drew up a very scientific diagram to take out with me:

http://iainel.co.uk/images/forums/NovaWIP2/064.JPG

Marked up:

http://iainel.co.uk/images/forums/NovaWIP2/065.JPG

Cut:

http://iainel.co.uk/images/forums/NovaWIP2/066.JPG

http://iainel.co.uk/images/forums/NovaWIP2/067.JPG

Started smoothing off the rear seat brackets to make it look a bit nicer:

http://iainel.co.uk/images/forums/NovaWIP2/068.JPG

[Adam]

Neat work.
What did you cut the shifter hole with??? Hole saw and then grinder?

EDIT-I see a jigsaw lol

[Iain]

Holesaw (in the second pic) and jigsaw.

[Leeboo]

Looks like hes drilled a hole at either end and cut out the middle bit with grinder!

neat work mate.

[Mike]

Looking good Lionel, same appraoch as mine, fcuking off all the useless shiz. Will defiently have a nosey round this when I next see it.

[burgo]

looking good sexy

[Jay]

Looking good mate, Daily progress is always a good sign

[dj_wudgey]

looks good matey good to see we have another slag being built!!

[Paul]

nice work Ian. Looks all good.

[draper]

crack on mincer lol

[scott.parker]

Good lad, job well done! same as mine lol

[Iain]

Been practicing my welding this morning, and got confident enough to weld up my new wings (I know it's just tacking but...)

Cleaned up with a plate behind:

http://iainel.co.uk/images/forums/NovaWIP2/069.JPG

Welded:

http://iainel.co.uk/images/forums/NovaWIP2/070.JPG

Cleaned up the back and put some rust treatment on:

http://iainel.co.uk/images/forums/NovaWIP2/071.JPG

Same with passenger wing:

http://iainel.co.uk/images/forums/NovaWIP2/072.JPG

Dodgy photo, but I filled in the sideskirt holes with weld. Also filled 3-4 holes along the lip (mudflaps I assume):

http://iainel.co.uk/images/forums/NovaWIP2/073.JPG

Ghetto lip rolling:

http://iainel.co.uk/images/forums/NovaWIP2/074.JPG

One done, just needs some sanding:

http://iainel.co.uk/images/forums/NovaWIP2/075.JPG

[Adam]

Good stuff Iain :)

[Iain]

Wings almost complete

http://iainel.co.uk/images/forums/NovaWIP2/076.JPG

And picked up an internal shifter

http://iainel.co.uk/images/forums/NovaWIP2/077.JPG

[Adam]

Good stuff, got to wait till the engine/box is back in before you can cut/weld the shifter??

[Sloth]

oooh nice mince iain, weldin looks spot on!

[Iain]

Good stuff, got to wait till the engine/box is back in before you can cut/weld the shifter??

Yeah think so. Still worried the hole won't be in the right place/big enough when I come to fit it though :tard:

[Adam]

Just take a grinder to the hole!!

[Benn]

Nice work dude, you only wanna spot plates on for hole plating anyway.

[scott.parker]

Should be fine, ill get you pic of mine tomo for you mate.

Scott

[scott.parker]

Right after you said about the internal selector i went to look at mine and get you a pic (Dar did do mine too)

Well i got some pics, but also decided to cut more out of it, as i had noticed before when trying to get into reverse gear it would not be easy, and the leaver would pop back off the rev/lip thing etc.

So here's a pic or two for you.

Before i cut and butchered it lol

4th gear position

http://img6.imageshack.us/img6/2136/dscf0255small4th.jpg

Close up

http://img6.imageshack.us/img6/9656/dscf0258small4th.jpg

Reverse position

http://img6.imageshack.us/img6/2464/dscf0256smallrev.jpg

Close up

http://img6.imageshack.us/img6/3236/dscf0257smallreverse.jpg

So, i noticed it was hitting, and rubbing on the cut out, I'm not saying Dar got it in the wrong place, as I'm sure he didn't, but car engine mounts, hight, positions might make this vary, so there is not perfect right or wrong..

So i got some snips out, cut a bit out (till it got to double skin) and bent it slightly with mold grips, I'll be covering it over with some rubber or something, so it don't need to be pretty.

http://img6.imageshack.us/img6/9574/dscf0254small.jpg

That's made it fit loads better now, oh also mesured up and this what i think is about right to cut out to.


Measuring from the weld/ bulk join back it's 20mm to first pen mark, then from the same bulk join the bottom mark is 140mm

Hope this helps?

Scott
http://img6.imageshack.us/img6/5281/dscf0262small.jpg

[Iain]

Nice one for the pics Scott. Yeah it's hit and miss whether it'll be fine then! Oh well we'll find out eventually.

[scott.parker]

Nice one for the pics Scott. Yeah it's hit and miss whether it'll be fine then! Oh well we'll find out eventually.

Think if you follow the guide line Ive set out it should be OK, so cut 20mm from the bulk seam, then your bottom cut should be 140mm from that same bulk seam.

Scott

[Iain]

The guide says 70/80mm from the seam!?

[scott.parker]

Well on mine you can clearly see it's not that dude! lol

[Iain]

Still not got the welding skillz to fix the rot so been tinkering with my tailgate. Figured as it'll be getting painted I'd get rid of the unused holes instead of just using grommets.

How it started

http://iainel.co.uk/images/forums/NovaWIP2/078.JPG

Plate lined up

http://iainel.co.uk/images/forums/NovaWIP2/079.JPG

Welded

http://iainel.co.uk/images/forums/NovaWIP2/080.JPG

Washer hole was annoying due to box section, so had to carefully plate a piece of metal in with the magnet

http://iainel.co.uk/images/forums/NovaWIP2/081.JPG

In

http://iainel.co.uk/images/forums/NovaWIP2/082.JPG

Both welds ground down ready for filling

http://iainel.co.uk/images/forums/NovaWIP2/083.JPG

http://iainel.co.uk/images/forums/NovaWIP2/084.JPG

http://iainel.co.uk/images/forums/NovaWIP2/085.JPG

And left it mid-filler, just needs a bit of finishing

[Adam]

Good stuff. I see you took my magnet advice :p

[Iain]

Small bit of progress but the weather is ruining my Easter weekend plans.

Plated the shifter hole and stitch welded the bracing on the floor. Still not sure if I'm going to remove the original seat brackets and go for rails instead.

http://iainel.co.uk/images/forums/NovaWIP2/086.JPG

Cleaned up all the seams around the engine bay, plated most of the rust and started a bit of stitch welding.

http://iainel.co.uk/images/forums/NovaWIP2/087.JPG

http://iainel.co.uk/images/forums/NovaWIP2/088.JPG

Stitched around the turrets.

http://iainel.co.uk/images/forums/NovaWIP2/089.JPG

Still got to do the bulkhead, under the front arches and around the back.

[Iain]

Figured while it's raining I'll get my doors off and work on those in the garage.

Proper tool makes life easier:

http://iainel.co.uk/images/forums/NovaWIP2/090.JPG

http://iainel.co.uk/images/forums/NovaWIP2/091.JPG

Bare shell apart from rear axle now!

http://iainel.co.uk/images/forums/NovaWIP2/092.JPG

[tom reid]

Keep at the welding, looks good so far, what size wire are you using?

[Iain]

I think it's 0.6mm.

[Adam]

Nice work Iain.
Does that door removal tool work well??

[Iain]

Yeah it's great IMO, had both doors off in minutes. Do it with the wing off and door closed and it just lifts off, one person job.

[Iain]

Rain stopped so managed to get the bulkhead area stitched. Welding started good but went downhill around the lower arm mounts, I assume because the metal is crappy and rusted.

http://www.iainel.co.uk/images/forums/NovaWIP2/093.JPG

http://www.iainel.co.uk/images/forums/NovaWIP2/094.JPG

http://www.iainel.co.uk/images/forums/NovaWIP2/095.JPG

Ran out of welding wire after that, should I go with 0.8mm or stick with 0.6mm?

[Adam]

0.6 tends to be better for proper thin sheet metal.
Most people use 0.8. Obviously you'll need 0.8 tips too.

Welding looks good, getting some nice burns on the inside of the panels??

[Iain]

Yep.

http://iainel.co.uk/images/forums/NovaWIP2/096.JPG

[Jay]

Nice progress Iain. I need to learn to weld.

[novait]

nice work iain.. keep it up..

[Adam]

:cool:

[chrisnovaturbo]

if you have just started welding it looks good. as long as you melt the to metals together it will be strong.:thumb:

[Iain]

Yeah very new to welding, finished my first ever bottle of gas that came with the welder earlier lol

[Ste L]

Yep.

http://iainel.co.uk/images/forums/NovaWIP2/096.JPG



YEAH BABY, Penitration :cool:




nice work Iain, coming on well

[tom reid]

I'd stay with the 0.6mm wire, 0.8 is too much for most of the light stuff your'e doing.
Ste L, you want penetrating?

[AlexW]

OHHHH no... Reid and his... yes :D

Looking good as i said on MSN Iain :D

[tom reid]

OHHHH no... Reid and his... yes :D

Looking good as i said on MSN Iain :D

You getting jealous darlin??

[Iain]

Will get another reel of 0.6mm wire and crack on with it then, thanks for the reply.

[burgo]

looking great iain

[Iain]

Finished stitch welding the passenger side inner arch today

http://iainel.co.uk/images/forums/NovaWIP2/097.JPG

Also used a flapwheel on all my engine bay welds to flatten them off so you can't see them through the new seam sealer

http://iainel.co.uk/images/forums/NovaWIP2/098.JPG

Next up, drivers side wheel arch then underneath and the back end!

[draper]

good work iain, be done for next year at this rate

[burgo]

im jealous :(

[Benn]

Good work dude.

[scott.parker]

good work iain, be done for next year at this rate

Fook off rate he's going he'll be at the national day in this! lol

Good work dude, oh did you ever extend the shifter cut out toward the bulk?

Scott

[Iain]

lol National Day, no chance. Thanks for all the comments.

I did extend the hole actually after your suggestions, see the top of page 12 with the bulkhead penetration photo, you can see it in that pic.

[scott.parker]

Cool thought so that's why i asked ;)

[Iain]

Spent yesterday and today afternoon doing a bit more on this. Welding ability has come on quite a bit which is good so went over some old welds and neatened them up a bit.

Better pic of the repair I did on the pass. side bay seam. Was a bit grotty and although previously repaired was a bit bent out of shape and thin in places. So I plated the whole lot up, will tidy it up with a bit of filler and sealer.

http://iainel.co.uk/images/forums/NovaWIP2/099.JPG

Found more rust here, so cut it out so I could treat inside the box section and plated it up.

http://iainel.co.uk/images/forums/NovaWIP2/100.JPG

http://iainel.co.uk/images/forums/NovaWIP2/101.JPG

And stitch welded the drivers arch. Have I missed anywhere?

http://iainel.co.uk/images/forums/NovaWIP2/102.JPG

http://iainel.co.uk/images/forums/NovaWIP2/103.JPG

Manky bit of crossmember plated.

http://iainel.co.uk/images/forums/NovaWIP2/104.JPG

Behind pass. turret plated, welded the metal underneath to this plate to make a complete repair. (I know it looks crap but it's hard to get a nice angle and steady hand here! lol)

http://iainel.co.uk/images/forums/NovaWIP2/105.JPG

Thought strengthening the engine mount brackets would be a good idea (!?!?) so stitched around them.

http://iainel.co.uk/images/forums/NovaWIP2/106.JPG

http://iainel.co.uk/images/forums/NovaWIP2/107.JPG

Then discovered my slam panel was fairly manky at both ends. Contemplated a new one but I'd still need to repair the drivers side hole in the inner wing so might just plate them up.

http://iainel.co.uk/images/forums/NovaWIP2/108.JPG

http://iainel.co.uk/images/forums/NovaWIP2/109.JPG

[Iain]

Finished the front end stitch welding today by doing the front chassis legs. Just the rear to do now!

http://iainel.co.uk/images/forums/NovaWIP2/110.JPG

My car support

http://iainel.co.uk/images/forums/NovaWIP2/111.JPG

Ready

http://iainel.co.uk/images/forums/NovaWIP2/112.JPG

Going

http://iainel.co.uk/images/forums/NovaWIP2/113.JPG

Up

http://iainel.co.uk/images/forums/NovaWIP2/114.JPG

http://iainel.co.uk/images/forums/NovaWIP2/115.JPG

Stitch welded chassis legs

http://iainel.co.uk/images/forums/NovaWIP2/116.JPG

http://iainel.co.uk/images/forums/NovaWIP2/117.JPG

Bit of rust to tackle but not found anything too bad yet.

http://iainel.co.uk/images/forums/NovaWIP2/118.JPG

Penetration

http://iainel.co.uk/images/forums/NovaWIP2/119.JPG

[tom reid]

Good work mate, your welding skills have really come on.Now, try welding upside down, lol

[Iain]

I've tried the odd bit and it's horrendous, which is why I opted for the car-on-its-side approach! lol

[7ova]

nice welding mate
keep up the good work

[Adam]

Welding looks top notch now, impressive!!!

[burgo]

looking good babes

[scott.parker]

Looks really good Iain, good welds too.

Have you checked round the spring seats? It's always quite bad there mate, but if your running coilovers next don't worry too much.

Scott

[Iain]

Looks really good Ian, good welds too.

Iain :p

Not looked at the back end yet TBH. Now the front's all welded up I'll focus on the rear, but I don't remember the spring seats looking too bad.

[scott.parker]

Alright it's not my fault your olds spelled it wrong! lol

[Iain]

Managed half of the rear end yesterday - middle floor join, drivers chassis leg and passenger arch. Will need to tip the car over on its other side for the rest.

What I started with:

http://iainel.co.uk/images/forums/NovaWIP2/120.JPG

This cleaned up very well after seeing pics of how some rot here!

http://iainel.co.uk/images/forums/NovaWIP2/121.JPG

http://iainel.co.uk/images/forums/NovaWIP2/122.JPG

Stitched:

http://iainel.co.uk/images/forums/NovaWIP2/123.JPG

http://iainel.co.uk/images/forums/NovaWIP2/124.JPG

Rear arch cleaned up around the seams and stitched (found it quite difficult to do the main splash guard seam due to metal thickness!?):

http://iainel.co.uk/images/forums/NovaWIP2/125.JPG

http://iainel.co.uk/images/forums/NovaWIP2/126.JPG

Today's penetrative actions lol

http://iainel.co.uk/images/forums/NovaWIP2/127.JPG

Half way there now:

http://iainel.co.uk/images/forums/NovaWIP2/128.JPG

Also welded up the gearshifter plate from underneath and filled in the existing bolt holes. Also removed the threaded bits for the exhaust heatshields and ground flat the rear seat bolt brackets for a few grams saving:

http://iainel.co.uk/images/forums/NovaWIP2/129.JPG

http://iainel.co.uk/images/forums/NovaWIP2/130.JPG

[Benn]

Good work, Aw says your gay.

[Iain]

Err thanks lol

[vaughanmc]

Nice work Iain, are you doing underneath body colour or just black!

Should be a nice example once its done fella! :thumb:

[Iain]

Going to be white underneath and in the arches, still working out what to use for that though!

[vaughanmc]

I'd remove all loose underseal thats already on there then give it nice thick even coats of Stonechip then fire over it with some white Hammerite...

[scott.parker]

Looks really good dude, that seam across the rear floor area is a bitch, they split open (as it is in before weld pic) and then rot between, mine had slightly, but i cured it.


Going to be white underneath and in the arches, still working out what to use for that though!

I'm sure you can buy White underseal, so you could strip it all, then paint in a primer/base coat, then use white underseal! :thumb:

keep up the good work mate.

Scott

[Adam]

Nice work.

[tom reid]

Iain, ideally you'd etch prime all the bare meat bits before painting.

[Benn]

I'm sure you can buy White underseal, so you could strip it all, then paint in a primer/base coat, then use white underseal! :thumb:


Be not point in painting it then... Just put the white under seal stright on.

[Iain]

Bit more work done today

Rolled it over the other way

http://iainel.co.uk/images/forums/NovaWIP2/131.JPG

Drivers rear arch done

http://iainel.co.uk/images/forums/NovaWIP2/132.JPG

Although how do I clean this area up for welding?! I can't get my grinder in there.

http://iainel.co.uk/images/forums/NovaWIP2/133.JPG

Few holes found in the rear panel so I cut it all out and welded in new metal (maybe overkill but I was having fun welding lol)

http://iainel.co.uk/images/forums/NovaWIP2/134.JPG

http://iainel.co.uk/images/forums/NovaWIP2/135.JPG

http://iainel.co.uk/images/forums/NovaWIP2/136.JPG

Extra strengthening around the harness eyebolt mounts

http://iainel.co.uk/images/forums/NovaWIP2/137.JPG

http://iainel.co.uk/images/forums/NovaWIP2/138.JPG

Welded these holes up in the front arches

http://iainel.co.uk/images/forums/NovaWIP2/139.JPG

http://iainel.co.uk/images/forums/NovaWIP2/140.JPG

Lots of penetration. I know it's a good sign but it's made the floor all bumpy feeling so I'll probs have to flick over it with the flapwheel to prep for paint?!

http://iainel.co.uk/images/forums/NovaWIP2/141.JPG

Think that's pretty much the underside done now

[Plug]

get on matey good progress there :thumb:

[Rickyb]

what a sweet project im well jelous.
rick

[scott.parker]

Good work dude! almost done ready for paint!

[Iain]

It still needs new rear quarters, one of the arch lips fell off on me earlier lol

[kevster]

nice work dude

[burgo]

looking wicked buddy

[peester]

yeah ide flap wheel the floor dude.

£££'s worth of work done

[Iain]

Unwrapped the car again yesterday

http://iainel.co.uk/images/forums/NovaWIP2/142.JPG

Flapwheeled the floors flat and cleaned some seams out for more stitch welding inside

http://iainel.co.uk/images/forums/NovaWIP2/143.JPG

http://iainel.co.uk/images/forums/NovaWIP2/144.JPG

http://iainel.co.uk/images/forums/NovaWIP2/145.JPG

And chopped out pass. side seat rails ready for rails for new seats. Couldn't be bothered with trying to remove all traces of them after seeing how others have struggled. They're made from quite thick metal!

http://iainel.co.uk/images/forums/NovaWIP2/146.JPG

http://iainel.co.uk/images/forums/NovaWIP2/147.JPG

http://iainel.co.uk/images/forums/NovaWIP2/148.JPG

Planning on staggered rails from box section like so

http://iainel.co.uk/images/forums/NovaWIP2/149.JPG

[Graeme]

Should hopefully now be nice and strong, good progress

[Jay]

Gettin the Iain, thats next on my list is to do the underneath of mine :)

[Iain]

Stitch welded the insides today. Not sure if some of it was necessary but it won't hurt!

http://iainel.co.uk/images/forums/NovaWIP2/150.JPG

http://iainel.co.uk/images/forums/NovaWIP2/151.JPG

http://iainel.co.uk/images/forums/NovaWIP2/152.JPG

Smoothed the beesting aerial hole off, should never have fitted one!

http://iainel.co.uk/images/forums/NovaWIP2/153.JPG

Only issue left now is my slam panel. Cut out all the rusted metal and left with quite big holes. Mostly covered up by the wing so I'll probably plate them seeing as a replacement panel won't fix it all.

http://iainel.co.uk/images/forums/NovaWIP2/154.JPG

[Benn]

So is that every seam stiched up?

[Iain]

Yeah, can't think of/find any more seams to do.

[Adam]

Think of all the weight of that extra weldage.....

[draper]

good work iain

[Iain]

The weight will be worth it when it beats you around track Adam :eek:

[burgo]

fapping awesome. proper shell prepage

[Iain]

Finally got that pesky slam panel patched up.

Plate made

http://iainel.co.uk/images/forums/NovaWIP2/155.JPG

Welded

http://iainel.co.uk/images/forums/NovaWIP2/156.JPG

Other side the same

http://iainel.co.uk/images/forums/NovaWIP2/157.JPG

http://iainel.co.uk/images/forums/NovaWIP2/158.JPG

Found it difficult to do without blowing lots of holes but got there in the end.

Currently looking at metal box section to sort my seat rails out. Needs to be about 3mm thick?

[Adam]

The weight will be worth it when it beats you around track Adam :eek:
We'll see ;)

[Benn]

Nice, i'll teach you to cut metal nicely one day too...

[Iain]

lol Thanks Sir Benn, I look forward to your lesson.

[Spudly]

Looks like a lot of graft going into this lemon will be good to see her back looking like a car again at some point:thumb:

[Benn]

lol, its most a time saving thing, the neater you can cut it, the neater everything else becomes.

[nova ian]

Currently looking at metal box section to sort my seat rails out. Needs to be about 3mm thick?

Iain, get some 1 inch by 1 inch box secion. Thats what I used, went to a steel place and asked a bloke in the yard if they had any and got a length for free :thumb:

PM'd you

[Iain]

Thanks for the info Ian. Something like this is what I need I guess? Click here (http://cgi.ebay.co.uk/Mild-steel-box-section-25mm-x-25mm-x-3mm-x-2-5-mtr_W0QQitemZ380126440887QQcmdZViewItemQQptZUK_BOI _Metalworking_Milling_Welding_Metalworking_Supplie s_ET?hash=item58814d2db7&_trksid=p3286.c0.m14&_trkparms=72%3A1683|66%3A2|65%3A12|39%3A1|240%3A13 18|301%3A1|293%3A1|294%3A50)

[draper]

Looks like a lot of graft going into this lemon will be good to see her back looking like a car again at some point:thumb:

completed by PV2013 if he pulls his finger out

[skidmarkz]

cool build, just reminded me just how much welding i have left to do underneath my car, i was happy lol...

Keep going mate looks cool :)

[Jonezy]

Alright mate, I used 3x2 box section for the seat rails on my rally car

[Iain]

My new seats arrived during the week :cool: Will be attempting to fit them this weekend.

http://iainel.co.uk/images/forums/NovaWIP2/159.JPG

[Adam]

Im not jealous

[Benn]

Not a fan of ears, but they do look cool as.

[Jay]

Cnut! Another member with the Revo's! How much you pay £344 each?

[Iain]

About that yeah

[trackdaynova]

You won't regret the purchase of those seats Iain... well cool :D

[burgo]

you cock!!! i funking love them seats :( so jealous

[Iain]

You won't regret the purchase of those seats Iain... well cool :D

Already do lol The XL version is gonna be a TIGHT fit to mount!!!

http://iainel.co.uk/images/forums/NovaWIP2/160.JPG

Passenger one where I want it is going to sit right over the seatbelt mount:

http://iainel.co.uk/images/forums/NovaWIP2/161.JPG

Not much room to bring it towards the middle:

http://iainel.co.uk/images/forums/NovaWIP2/162.JPG

How the drivers needs to be, the cross bracing gets in the way:

http://iainel.co.uk/images/forums/NovaWIP2/163.JPG

So I can either mount the passenger seat the same as the drivers seat, or attempt to bring it in towards the exhaust tunnel and poke the harness through a small gap.

Drivers will need the bracing cutting out and it should squeeze in, I hope.

[trackdaynova]

How come you went with XL? Any particular reason?

[Iain]

Went to Demon Tweeks and sat in all the seats, the one they had on display was the XL size and it was really comfy and supportive without being too tight. The standard size Revenge was wayyy too tight for me so figured XL is best.

It's gonna be a tight fit in the car :(

[trackdaynova]

Suprised at that, only because I sat in a XL, and it felt a bit sloppy jo, and too much movement, having sat in a standard width, i fit alot better in that one!

That said, maybe I have a slimbum lol

[draper]

you have a welder and a grinder, anything fits ;)


what you doing with the old seats ?

[Iain]

Yeah it's a weird one Olly, I look skinny but must have wide hips as I couldn't even fit them in to some of the seats. lol

Angle grinder you say? Chopped out all metal that was remotely in the way lol Can be tidied up later

http://iainel.co.uk/images/forums/NovaWIP2/164.JPG

http://iainel.co.uk/images/forums/NovaWIP2/165.JPG

I think the issue I'm having is worsened by the sidemounts - they easily add an inch width per side. Think I'm going to ditch them and get some flat ones, which would give me this kind of width:

http://iainel.co.uk/images/forums/NovaWIP2/166.JPG

And this kind of room:

http://iainel.co.uk/images/forums/NovaWIP2/167.JPG

http://iainel.co.uk/images/forums/NovaWIP2/168.JPG

Old seats, dunno, for sale probs when I finally have some that fit to my car lol

[trackdaynova]

What are / were your old seats?

Good hacking action bud, I'd remove the complete 'brace' that goes across the floor tho, whilst you're at it, at least then you have a flat surface to work on, maybe?

[Iain]

Corbeau Forza, base mounted on proper tailored Nova subframes - ahhh the joys of something that bolts straight in with no fuss.

Yeah I might chop the brace out, annoyingly I've stitch welded the bugger in so won't be trying to drill out the spot welds :cry:

I reckon something like this would solve my problems:
http://www.demon-tweeks.co.uk/resources/images/zoom/omp_HC_730_E_08.jpg
http://www.demon-tweeks.co.uk/products/ProductDetail.asp?cls=MSPORT&pcode=OMPHC/730EBLK

[AlexW]

Looking good gayboy, Give me price on old seats :p

One thing tho, clean the metal when you weld it, much better welds then.

[Iain]

I use a grinder with wire wheel attachment before welding. The latest pics look like I haven't cleaned it up because I was using some 'weld through zinc primer' or something like that.

[Iain]

After this mornings disaster with the seats, I cracked on with other stuff. I accidentally made an alternator cutout so I guess I'll have to fit a 20XE, oh well.

Marked out:

http://iainel.co.uk/images/forums/NovaWIP2/169.JPG

Cut out:

http://iainel.co.uk/images/forums/NovaWIP2/170.JPG

Shamelessly copied Count Vaux Alot: (http://www.pngclub.com/forum/showpost.php?p=1084665&postcount=211)

http://iainel.co.uk/images/forums/NovaWIP2/171.JPG

http://iainel.co.uk/images/forums/NovaWIP2/172.JPG

http://iainel.co.uk/images/forums/NovaWIP2/173.JPG

And welded up my rear seatbelt holes for a smoother look:

http://iainel.co.uk/images/forums/NovaWIP2/174.JPG

[Jay]

Nice!

[Benn]

Good work dude!

[draper]

i still reckon my baby will out do your gay big block+

[Adam]

I accidentally made an alternator cutout so I guess I'll have to fit a 20XE, oh well.

FPMSL, best quote ever!!! lol lol lol
Good lad!!!

Draper, ive driven both, big xe's destroy baby xe's ;) :p lol

[Iain]

I must work really slow, as I've only managed to get my splash guards sorted today.

Fruity template made:

http://iainel.co.uk/images/forums/NovaWIP2/175.JPG

On to old bonnet:

http://iainel.co.uk/images/forums/NovaWIP2/176.JPG

Cut out:

http://iainel.co.uk/images/forums/NovaWIP2/177.JPG

Stubby splash guard cleaned to bare metal:

http://iainel.co.uk/images/forums/NovaWIP2/178.JPG

Tacking on with new wing in place to get a good fit:

http://iainel.co.uk/images/forums/NovaWIP2/179.JPG

Crap welding, couldn't get a good flow, but it's on and not moving:

http://iainel.co.uk/images/forums/NovaWIP2/180.JPG

Stitched on at back:

http://iainel.co.uk/images/forums/NovaWIP2/181.JPG

Finished articles:

http://iainel.co.uk/images/forums/NovaWIP2/182.JPG

http://iainel.co.uk/images/forums/NovaWIP2/183.JPG

Also cleaned up drivers side arch. Given them both lots of rust killer and will etch prime them later:

http://iainel.co.uk/images/forums/NovaWIP2/184.JPG

[Adam]

Got a xe yet????

[Iain]

I'll have yours when you wrap it around a tree :plol

[Adam]

Oh thanks :roll: :roll: :roll:

[Iain]

Don't worry I'll wrap mine around a tree too; I'm getting used to 1.1 Fiesta power.

[Adam]

lmao, wait till you floor a xe then......
compared to a 1.1 fiesta... hmmm lol

[Iain]

Front arches came up well. No doubt the rust will come back through again a month after I've had it on the road.

http://iainel.co.uk/images/forums/NovaWIP2/185.JPG

http://iainel.co.uk/images/forums/NovaWIP2/186.JPG

http://iainel.co.uk/images/forums/NovaWIP2/187.JPG

http://iainel.co.uk/images/forums/NovaWIP2/188.JPG

http://iainel.co.uk/images/forums/NovaWIP2/189.JPG

[scott.parker]

Getting there mate!

Looks like it should be a nice car wen finished.

Scott

[Jay]

Coming along well

[Iain]

Rang Beevers auto panels in the week to order my rear quarters. Made it quite clear I was going to pick them up to avoid damage (as recommended by Paul off here), thought that was that and then they arrived in the post :roll:

http://iainel.co.uk/images/forums/NovaWIP2/190.JPG

One is good:

http://iainel.co.uk/images/forums/NovaWIP2/191.JPG

The other is damaged:

http://iainel.co.uk/images/forums/NovaWIP2/192.JPG

So will be ringing them on Monday and asking for a replacement... Collected, if they know what that means. :roll:

[Mike]

Looking good cheif, TBH i reckon that dint in the arch would ping out tho?

[Iain]

I can push it out slightly but it doesn't take its original shape. The lip is bent out of shape too and there's an "outy" dent on the square arch bit which I can imagine being a pain to get looking nice.

Don't see the point in spending £70 odd to mess about with dents.

[Mike]

Don't see the point in spending £70 odd to mess about with dents.

Thats true yea, TBH you might be better of returning in person & collecting a new one whilst your there?

[Iain]

That's the plan, the same plan I had all along (minus returning dented ones)! lol

[Mike]

That's the plan, the same plan I had all along (minus returning dented ones)! lol

Sorted then, give them a slap whilst you there too :D

[Adam]

Could you not just go up there and buy two "over the counter" ?

[Iain]

They have to order it in for the next day, which is why I ordered/paid for them on the phone.

[Benn]

Awesome work on the splash guard!
Get a good sealer and then paint them body colour and the under side should stay good.

Quarters good good, well bar the 2dents.

[Iain]

Nice chap on the phone at Beevers today, he's going to order me in a new drivers quarter and I'll go up and replace it :thumb:

Thanks Benn, going white underneath/arches is why I went for fabricated splash guards as my current plastic ones (Corsa B IIRC) are black.

[Iain]

Drilled out all visible spot welds this afternoon, just got to work out where the inner tub meets the arch - if anybody has any info please share.

http://iainel.co.uk/images/forums/NovaWIP2/193.JPG

Looks a bit of a mess but should straighten out ok:

http://iainel.co.uk/images/forums/NovaWIP2/194.JPG

http://iainel.co.uk/images/forums/NovaWIP2/195.JPG

http://iainel.co.uk/images/forums/NovaWIP2/196.JPG

Also for fitting on the B & C pillars and sill, should I overlap the new panel over the current bit or should I cut it so they sit flush together?

[Benn]

They meet on the lip. Thats why grinder them breaks the seal and they rust worse.

If you can get a *cant remember name* tool it makes a lip on the edge of the pannel, so you over lap them but they sit in the lip so they still lay flat.

[Iain]

They meet on the lip. Thats why grinder them breaks the seal and they rust worse.

That'll be fun, drilling out spot welds from a rusted, filled and rolled arch! :(

[scott.parker]

Don't bother then, just cut it off and then create another lip with some more steel to over lap the two?

[burgo]

They meet on the lip. Thats why grinder them breaks the seal and they rust worse.

If you can get a *cant remember name* tool it makes a lip on the edge of the pannel, so you over lap them but they sit in the lip so they still lay flat.

that'll be a joggler

[Spudly]

Good work lemon youre a very brave lad doing it all yourself keep it up:thumb:

[Iain]

Thanks all, I'm having at least an attempt at everything so we'll see what it turns out like lol

Today's carnage/weight saving:

http://iainel.co.uk/images/forums/NovaWIP2/197.JPG

Cross brace removed to make way for seat rails:

http://iainel.co.uk/images/forums/NovaWIP2/198.JPG

Got to grips with spot weld drilling now:

http://iainel.co.uk/images/forums/NovaWIP2/199.JPG

Well, almost. These ones are so thick they're a real pain to get off without damaging the wafer thin floor!

http://iainel.co.uk/images/forums/NovaWIP2/200.JPG

Fixing my mess:

http://iainel.co.uk/images/forums/NovaWIP2/201.JPG

http://iainel.co.uk/images/forums/NovaWIP2/202.JPG

Rust treated (as it had all rusted where it meets the floor!) and etch primered:

http://iainel.co.uk/images/forums/NovaWIP2/203.JPG

[Iain]

Bit of filler on the exhaust tunnel where the grinder touched the floor:

http://iainel.co.uk/images/forums/NovaWIP2/204.JPG

Rear seat brackets smoothed (again, welding the rear chassis legs cracked most of it off lol):

http://iainel.co.uk/images/forums/NovaWIP2/205.JPG

Smoothed rear seatbelt holes is hopefully a unique touch:

http://iainel.co.uk/images/forums/NovaWIP2/206.JPG

Started smoothing the slam panel where I welded in new plates. It won't look factory (they have a little drainage hole under where the wing meets it) but it'll look neat:

http://iainel.co.uk/images/forums/NovaWIP2/207.JPG

http://iainel.co.uk/images/forums/NovaWIP2/208.JPG

Aerial fully smoothed off and finished:

http://iainel.co.uk/images/forums/NovaWIP2/209.JPG

Dent in the door fixed, needs a bit more work in the middle but almost sorted:

http://iainel.co.uk/images/forums/NovaWIP2/210.JPG

[burgo]

i love you iain

[scott.parker]

What about the car you gay? lol

Getting there mate, starting to shape up.

[AlexW]

You spend so much time making it lighter and then put filler into it.

Just kidding dude, Looks good. Hurry up and get it finished.

Love you gayboy.

[Iain]

I'm trying to use a minimal amount of filler to get it looking good. :)

Off with the old rear quarter today.

Cut along the B and C pillars, but lower than the repair panel so I've got some scope or trimming it perfectly:

http://iainel.co.uk/images/forums/NovaWIP2/211.JPG

Lopped it in half to get most of the panel off:

http://iainel.co.uk/images/forums/NovaWIP2/212.JPG

Gone:

http://iainel.co.uk/images/forums/NovaWIP2/213.JPG

Managed to save this on the car, so can retain the door nut thing:

http://iainel.co.uk/images/forums/NovaWIP2/214.JPG

Cut all around the lip as it was rusty and manky:

http://iainel.co.uk/images/forums/NovaWIP2/215.JPG

More spot welds:

http://iainel.co.uk/images/forums/NovaWIP2/216.JPG

Almost...

http://iainel.co.uk/images/forums/NovaWIP2/217.JPG

Off:

http://iainel.co.uk/images/forums/NovaWIP2/218.JPG

More spot welds along here to remove the lower section:

http://iainel.co.uk/images/forums/NovaWIP2/219.JPG

[Iain]

Trial fit of the new quarter, seems a good fit!

http://iainel.co.uk/images/forums/NovaWIP2/220.JPG

http://iainel.co.uk/images/forums/NovaWIP2/221.JPG

http://iainel.co.uk/images/forums/NovaWIP2/222.JPG

Naked car!

http://iainel.co.uk/images/forums/NovaWIP2/223.JPG

Worst of the rot:

http://iainel.co.uk/images/forums/NovaWIP2/224.JPG

So cut it out and plated it up:

http://iainel.co.uk/images/forums/NovaWIP2/225.JPG

http://iainel.co.uk/images/forums/NovaWIP2/226.JPG

http://iainel.co.uk/images/forums/NovaWIP2/227.JPG

http://iainel.co.uk/images/forums/NovaWIP2/228.JPG

[Iain]

Also realised while hacking out my brackets I would need something here for the seat rail. Here's where the handbrake sits (granted after quite a few clicks) which would hit the rail:

http://iainel.co.uk/images/forums/NovaWIP2/229.JPG

Mocked something up:

http://iainel.co.uk/images/forums/NovaWIP2/230.JPG

And welded on. Left the back open as otherwise things would fall in and be a pain to get out. Also welded a strip to the floor first to spread the load.

http://iainel.co.uk/images/forums/NovaWIP2/231.JPG

[Iain]

Currently waiting on a pair of seat subframes to arrive from Magnum Motorsport. Hopefully be the same as this one I've borrowed off Tom Reid:

http://iainel.co.uk/images/forums/NovaWIP2/232.JPG

These give more room for harnesses and slight adjustments in the seat position. Would like quite the seat rails in before the rear quarters are done as the quarters tend to collect dust and rubbish inside them.

All that's left is seat rails, fit rear quarter, remove and fit drivers quarter, then strip the underneath off and stonechip + paint!

[scott.parker]

Good progress mate!

Like them seat rails, might look into some...

[Benn]

Dude! Funk.

Good woork tho.

[peester]

christ! :-o

be at billing??

top work mate

[novaload1992]

:thumb:

[tom reid]

I'm impressed mate.

[Adam]

Awesome work Iain, takes some b***ocks to go cutting big panels off your car.

[Iain]

Doubt it'll be at any shows this year! Thanks all, it's not that bad when you get stuck in to it.

[scott.parker]

Dude bit off topic, but what head light bulbs was it you had in the nova?

Scott

[Iain]

Very off topic lol I had Osram Silverstar (http://www.picbits.co.uk/catalog/product_info.php/cPath/22_40_45/products_id/99) bulbs.

[scott.parker]

Cheers dude, just remember them being very good bulbs etc.

[silvertornado_sr]

some very good work i see there iain :) when get my nova running will nip over and have a look at some of the work :)

[Iain]

Some progress on the seat brackets.

3mm Spreader plates, roughly 70mm x 70mm:

http://iainel.co.uk/images/forums/NovaWIP2/233.JPG

Which will sit roughly like this:

http://iainel.co.uk/images/forums/NovaWIP2/234.JPG

http://iainel.co.uk/images/forums/NovaWIP2/235.JPG

Aiming to have the passenger seat around here:

http://iainel.co.uk/images/forums/NovaWIP2/236.JPG

http://iainel.co.uk/images/forums/NovaWIP2/237.JPG

Some room to get to the harness mounting eyebolt now:

http://iainel.co.uk/images/forums/NovaWIP2/238.JPG

Seat rails will be made from 25mm x 25mm x 3mm box section (my pole only just fits in my garage, har har):

http://iainel.co.uk/images/forums/NovaWIP2/239.JPG

Cut to roughly the right size:

http://iainel.co.uk/images/forums/NovaWIP2/240.JPG

[Iain]

"All this looks very heavy!" I hear you cry.

All 8 spreader plates weigh roughly 1kg:

http://iainel.co.uk/images/forums/NovaWIP2/241.JPG

And 2 seat rails weigh roughly 2kg:

http://iainel.co.uk/images/forums/NovaWIP2/242.JPG

http://iainel.co.uk/images/forums/NovaWIP2/243.JPG

So each seat rail setup will weigh approx 2.5kg. Each seat weighs approx 6.6kg. This is a combined weight of 9.1kg per side - a saving of nearly 6kg per seat over the original setup.

[burgo]

good lad for weighing it all

[peester]

the seat is awesome.. proper suggestive

[Adam]

Nice one, so your old buckets/frames were around 15kg each???