985cc Turbocharged Nova Sprint Car

[Jonlem]

Sent you a email Colin.

[Benn]

Wow am loving the brake set up. Discs look huge.

[_Jake]

New brakes look very nice :) colin how do you get away with running rear coilovers but not having turrets? as i know you not allowed to remove metal in such areas

[novarally]

New brakes look very nice :) colin how do you get away with running rear coilovers but not having turrets? as i know you not allowed to remove metal in such areas


They're just small coilovers, so no metal needs to be removed. 1.9" ID springs, rather than the normal 2.25".

[novarally]

In an effort to fund my engine rebuild (just got the first part of the bill!), I need to sell a lot of stuff.

There's a batch of bits on EBAY now, search for HILLCLIMBESCORT as my User Name to find them.

Items include;

ISR 4-pot calipers
ISR floating discs and alloy bells
STACK dash display system
STACK 52mm boost pressure, fuel pressure and wide-band lambda gauges
Carbon fibre dashboard
and lots more stuff to follow soon..........

[Benn]

That lot is gonna go thru the roof^ Looking at the way it it wants me to bid...lol

[novarally]

It needs to go through a very high roof to cover the costs of this engine rebuild.

My 2012 crash is proving to be an extremely expensive mistake!

[Benn]

Funny, crashes at full speed arnt normally cheap....



And put it this way, the bit i thought i'd try a price on wanted more than 65 pounds....

[novarally]

Not a huge amount to report on, but I have just got the front disc bells, the rear hubs and the steering rack mounts back from the anodisers.

I had a slight re-think, and I'm now going to use the smaller diameter brakes and the 4-pot calipers, rather than the big 280mm discs and 6-pots.

The freshly coloured bells are now re-attached to the brake rotors, and look quite nice;

http://i285.photobucket.com/albums/ll66/hillclimbescort/006_zps9aec2cc8.jpg (http://s285.photobucket.com/user/hillclimbescort/media/006_zps9aec2cc8.jpg.html)

http://i285.photobucket.com/albums/ll66/hillclimbescort/007_zps6c6fface.jpg (http://s285.photobucket.com/user/hillclimbescort/media/007_zps6c6fface.jpg.html)

My latest plan is to utilise mountain bike brakes on the rear end. I will get some stainless steel brake discs laser cut to suit, and use these Hope Mono calipers.

http://i285.photobucket.com/albums/ll66/hillclimbescort/008_zpse961abf8.jpg (http://s285.photobucket.com/user/hillclimbescort/media/008_zpse961abf8.jpg.html)

I reckon if I use a big master cylinder, plus a pressure limiting valve, the back brakes will be doing so little work that they shouldn't overheat and self-destruct.

That's the theory anyway. The back brakes have to be functional if a scrutineer wanted to check, so as long as it can stop a back wheel turning when the car's jacked up, that's good enough.

[Benn]

Will the hope ones have enough power? I know they lock a bike wheel up but a car one is a lot heaver.

[novarally]

Will the hope ones have enough power? I know they lock a bike wheel up but a car one is a lot heaver.

Not sure on that, I will do some testing before anything gets fabricated.

[Benn]

Cant you get tiny single pot ones? From motobikes? Sure i've seent them, They are about 3inch long with a 1long piston. Ment to be mega light..

[novarally]

Cant you get tiny single pot ones? From motobikes? Sure i've seent them, They are about 3inch long with a 1long piston. Ment to be mega light..


That is my other option if the MTB option fails. Something like this;

http://www.bikehps.com/acatalog/info-ISR2MON.html

Those are £150 each though, they're very trick, and certainly lightweight at 150g. Just not as light or as cheap as a Hope caliper.

[_Jake]

I would want atleast mono 6ti' calipers!!

[Benn]

That is my other option if the MTB option fails. Something like this;

http://www.bikehps.com/acatalog/info-ISR2MON.html

Those are £150 each though, they're very trick, and certainly lightweight at 150g. Just not as light or as cheap as a Hope caliper.

Yeah what i thought of. Tiny and light but work really well. But yeah the price can be a killer.

[Connor]

I would want atleast mono 6ti' calipers!!
What he said^^^

Or look up hope moto calipers, they have plenty of braking force, even on my mates bike who is 26+ stone lol

[Connor]

STACK dash display system
Carbon fibre dashboard

Did these sell colin?

[novarally]

Did these sell colin?

Yes, both those sold now.

[Connor]

Yes, both those sold now.
Ahh ok no worries :)

[novarally]

Some of you may have seen my post in the 'Wanted' section.

My engine builder has finally come back to me with some figures for the rebuild of my 1000cc turbo engine (the one that's always been in the car). It's due to be rebuilt with steel rods, forged pistons, new valves and springs, custom camshaft etc.

The total bill (with Arrows rods) is going to be about £5,500. It's not unreasonable given the parts and labour involved.

But I have to accept that I simply haven't got access to that sort of money right now. So the 1000cc rebuild is on the back-burner for a while (very much still my plan to do it though).

The rest of the car is 80% ready to race again, so I am thinking of installing a different (cheaper) engine just so I can get out and have a bit of fun with the car.

Just got to find a suitable engine (or donor car) now - XE, LET, smallblock, 8v, 16v, hopefully something suitable will turn up.

The garage floor has now been laid, so once that's completely dried out, at last I have somewhere to work on the car.

[rallypvc]

How much you looking to spend on a full car Colin either ex let or whatever? As I often come across them as I spend hours searching the net but don't have the money to buy them myself lol but I'm sure your budget is better than mine

[novarally]

How much you looking to spend on a full car Colin either ex let or whatever? As I often come across them as I spend hours searching the net but don't have the money to buy them myself lol but I'm sure your budget is better than mine

Don't assume that!

If anything I'd prefer to buy a full car, so I know I have everything to get it going, and also I can recoup some money on selling off the rest of the thing in pieces.

But if I was just to buy a complete, ready to install engine, I could probably stretch to £1000, possibly a touch more. And I could part-exchange Nova parts into the deal if that was appropriate.

So I haven't got a lot to cash to work with.

[rallypvc]

Don't know if you'd be interested but there's a corsa c z20leh on Ebay cheap at the mo think it's up to £1750

[novarally]

At last, the Nova has a new home.

This was the garage as at 18th December;
http://i285.photobucket.com/albums/ll66/hillclimbescort/004_zps6b4658ba.jpg (http://s285.photobucket.com/user/hillclimbescort/media/004_zps6b4658ba.jpg.html)

http://i285.photobucket.com/albums/ll66/hillclimbescort/003_zpsd8783dcf.jpg (http://s285.photobucket.com/user/hillclimbescort/media/003_zpsd8783dcf.jpg.html)

And then on the 19th December;
http://i285.photobucket.com/albums/ll66/hillclimbescort/005_zps0d641014.jpg (http://s285.photobucket.com/user/hillclimbescort/media/005_zps0d641014.jpg.html)

http://i285.photobucket.com/albums/ll66/hillclimbescort/007_zps71ffed88.jpg (http://s285.photobucket.com/user/hillclimbescort/media/007_zps71ffed88.jpg.html)

And then this morning it was time to move the Nova in from its resting place on the patio;

http://i285.photobucket.com/albums/ll66/hillclimbescort/009_zps6f3b2a80.jpg (http://s285.photobucket.com/user/hillclimbescort/media/009_zps6f3b2a80.jpg.html)

http://i285.photobucket.com/albums/ll66/hillclimbescort/010_zpsda1a43f4.jpg (http://s285.photobucket.com/user/hillclimbescort/media/010_zpsda1a43f4.jpg.html)

http://i285.photobucket.com/albums/ll66/hillclimbescort/014_zps8891dacc.jpg (http://s285.photobucket.com/user/hillclimbescort/media/014_zps8891dacc.jpg.html)

[novarally]

The 'new' garage, looking rather busy already, and it's only had a floor for a week or so;

http://i285.photobucket.com/albums/ll66/hillclimbescort/015_zpse23c69fc.jpg (http://s285.photobucket.com/user/hillclimbescort/media/015_zpse23c69fc.jpg.html)

http://i285.photobucket.com/albums/ll66/hillclimbescort/018_zps255e36a8.jpg (http://s285.photobucket.com/user/hillclimbescort/media/018_zps255e36a8.jpg.html)

http://i285.photobucket.com/albums/ll66/hillclimbescort/019_zps5bf3dec7.jpg (http://s285.photobucket.com/user/hillclimbescort/media/019_zps5bf3dec7.jpg.html)

I need more space, already;

http://i285.photobucket.com/albums/ll66/hillclimbescort/020_zps127a1bc3.jpg (http://s285.photobucket.com/user/hillclimbescort/media/020_zps127a1bc3.jpg.html)

[BRoadGhost]

Look at that sexy 4th engine mount.

Y U NO PAINT FLOOR?

[novarally]

Y U NO PAINT FLOOR?

I have 2-pack epoxy paint waiting to go on, but the weather isn't suitable for that to dry. A job for the Summer.

[jonn]

nice work cant wait to see more progress, what shafts are you running for the wide arch setup?

[thedjse]

Awesome work pal garage floor looks good

[novarally]

nice work cant wait to see more progress, what shafts are you running for the wide arch setup?

Standard smallblock driveshafts, it's only the wheels which are wider.

[jonn]

a ok, what offset and width are they wheels?

[novarally]

a ok, what offset and width are they wheels?

The fronts are 7.5" wide, but I've never measured the offset, there are 3 sets of wheels for the car which were all custom made to suit.

[jonn]

ok thanks

[Benn]

Garage looks great, wish i had that space.

[novarally]

I've just picked up a Corsa bias pedal box from Jezz (Toymex), which will hopefully solve my issues with lack of legroom caused by the original floor mounted pedal box I had.

Further details to follow, and additional thanks to Simon (STT) who has sent me loads of details regarding modifications to the Corsa B pedal box which can be used in place of the Nova one.


If this set-up sorts things out, all I then have to do is adapt the clutch pedal to actuate a hydraulic master cylinder (as I'm on a hydraulic clutch system).

[novarally]

My garage is looking full. I sold a lot, then filled it up with more stuff...........note the Alfa 33 race car I have recently acquired;

http://i285.photobucket.com/albums/ll66/hillclimbescort/021_zps991d32f9.jpg (http://s285.photobucket.com/user/hillclimbescort/media/021_zps991d32f9.jpg.html)

http://i285.photobucket.com/albums/ll66/hillclimbescort/002_zps70f5632f.jpg (http://s285.photobucket.com/user/hillclimbescort/media/002_zps70f5632f.jpg.html)

http://i285.photobucket.com/albums/ll66/hillclimbescort/004_zps2f572822.jpg (http://s285.photobucket.com/user/hillclimbescort/media/004_zps2f572822.jpg.html)

I've also bought a 1400 Tigra, as I am going to fit my Nova with a smallblock XE engine, fitted with Jenvey throttle bodies and an MBE ECU/loom. As there's currently no way I can afford to get my 1.0 turbo engine rebuilt, the 1400cc 16v engine is the cheapest way to get my car back out racing (now over 18 months since it last raced).

http://i285.photobucket.com/albums/ll66/hillclimbescort/018_zps87944665.jpg (http://s285.photobucket.com/user/hillclimbescort/media/018_zps87944665.jpg.html)

http://i285.photobucket.com/albums/ll66/hillclimbescort/019_zpsdd69a39a.jpg (http://s285.photobucket.com/user/hillclimbescort/media/019_zpsdd69a39a.jpg.html)

http://i285.photobucket.com/albums/ll66/hillclimbescort/020_zps47167fca.jpg (http://s285.photobucket.com/user/hillclimbescort/media/020_zps47167fca.jpg.html)

Throttle body kit waiting;

http://i285.photobucket.com/albums/ll66/hillclimbescort/001_zpsd1d57590.jpg (http://s285.photobucket.com/user/hillclimbescort/media/001_zpsd1d57590.jpg.html)

[Benn]

Good plan buying the tigra.

[novarally]

Good plan buying the tigra.

Even more so as it was only £130 for the whole car!

I've got another Tigra 1600cc as my daily driver now, they are just so cheap it makes sense.

[burgo]

I so want the alfa. One of my biggest regrets getting rid of my 33 especially as it was a green cloverleaf

[novarally]

The mock-up engine was removed yesterday;

http://i285.photobucket.com/albums/ll66/hillclimbescort/001_zpsa5f94f0d.jpg (http://s285.photobucket.com/user/hillclimbescort/media/001_zpsa5f94f0d.jpg.html)

http://i285.photobucket.com/albums/ll66/hillclimbescort/002_zpsa7353732.jpg (http://s285.photobucket.com/user/hillclimbescort/media/002_zpsa7353732.jpg.html)

And the smallblock XE engine I'm going to use will soon be ready to go in;

http://i285.photobucket.com/albums/ll66/hillclimbescort/003_zps9e0f9f47.jpg (http://s285.photobucket.com/user/hillclimbescort/media/003_zps9e0f9f47.jpg.html)

http://i285.photobucket.com/albums/ll66/hillclimbescort/004_zpsbd144ecf.jpg (http://s285.photobucket.com/user/hillclimbescort/media/004_zpsbd144ecf.jpg.html)

I'm going to paint the engine bay today so it's grey again.

[novarally]

Got a bit more done this weekend.

Spaceframe re-painted;

http://i285.photobucket.com/albums/ll66/hillclimbescort/001_zps98d7a288.jpg (http://s285.photobucket.com/user/hillclimbescort/media/001_zps98d7a288.jpg.html)

Started work on fitting the new front brakes, requiring new caliper mounting brackets. I've got one side finished now, and just need to make a mirror image for the other side. I've done them in steel for the moment, but once they've been tested and proved I will get the brackets re-made in alloy;

http://i285.photobucket.com/albums/ll66/hillclimbescort/002_zpsf5feaa46.jpg (http://s285.photobucket.com/user/hillclimbescort/media/002_zpsf5feaa46.jpg.html)

http://i285.photobucket.com/albums/ll66/hillclimbescort/028_zps6510881d.jpg (http://s285.photobucket.com/user/hillclimbescort/media/028_zps6510881d.jpg.html)

http://i285.photobucket.com/albums/ll66/hillclimbescort/029_zps51b12988.jpg (http://s285.photobucket.com/user/hillclimbescort/media/029_zps51b12988.jpg.html)

And after lots of thought, and buying several different pedal boxes, I've decided to use a (Classic) Mini pedal box. I've started the fabrication and it looks like it should work pretty well. The Mini pedal box is nice and lightweight, and has a hydraulic clutch pedal as standard. The master cylinders are going to sit in the battery tray area, it's going to be tight for clearance against the bulkhead panel by the look of things;

http://i285.photobucket.com/albums/ll66/hillclimbescort/003_zpsad350e01.jpg (http://s285.photobucket.com/user/hillclimbescort/media/003_zpsad350e01.jpg.html)

http://i285.photobucket.com/albums/ll66/hillclimbescort/004_zps8b578913.jpg (http://s285.photobucket.com/user/hillclimbescort/media/004_zps8b578913.jpg.html)

http://i285.photobucket.com/albums/ll66/hillclimbescort/008_zpsdd10d9d5.jpg (http://s285.photobucket.com/user/hillclimbescort/media/008_zpsdd10d9d5.jpg.html)

http://i285.photobucket.com/albums/ll66/hillclimbescort/005_zps4ff59d31.jpg (http://s285.photobucket.com/user/hillclimbescort/media/005_zps4ff59d31.jpg.html)

http://i285.photobucket.com/albums/ll66/hillclimbescort/006_zps1ca65351.jpg (http://s285.photobucket.com/user/hillclimbescort/media/006_zps1ca65351.jpg.html)

http://i285.photobucket.com/albums/ll66/hillclimbescort/007_zpsee28c473.jpg (http://s285.photobucket.com/user/hillclimbescort/media/007_zpsee28c473.jpg.html)

[Novaload_Nick]

Good work, must be a first for the mini pedal box too? Start a trend? Lol

[BRoadGhost]

I used an escort pedal box; more metal to it though & extra weight over what you have there.

BTW Colin do you have a nova steering coupling lying around?

[_Jake]

why the change from floor mounted?

[novarally]

why the change from floor mounted?

It didn't give me enough legroom, I found the driving position very uncomfortable as the pedal box was too close.

I'm not allowed to modify the bulkhead to move it further away, so hopefully this will be the solution.

[_Jake]

It didn't give me enough legroom, I found the driving position very uncomfortable as the pedal box was too close.

I'm not allowed to modify the bulkhead to move it further away, so hopefully this will be the solution.

having the same dilemma myself, although i want to have a floor mounted one if possible!

[novarally]

having the same dilemma myself, although i want to have a floor mounted one if possible!

Assuming you can't move the seat any further back, then you have 2 solutions as far as I can see;

1. Cut out and box the bulkhead to accommodate the master cylinders (see the Project thread that 8valve-Craig has done for his Nova to see this). I'm not allowed to cut the bulkhead in this fashion under the Regulations I race to.

2. Use a floor-mounted pedal box which reverse-mounts the master cylinders (i.e. they sit in front of the pedals). The problem I see with this is that you need a false floorpan to cover the cylinders, and obviously your feet are then raised up. Can't say I've ever seen one of these pedal boxes in a Nova, but I would be interested to have a try in one.

[_Jake]

Assuming you can't move the seat any further back, then you have 2 solutions as far as I can see;

1. Cut out and box the bulkhead to accommodate the master cylinders (see the Project thread that 8valve-Craig has done for his Nova to see this). I'm not allowed to cut the bulkhead in this fashion under the Regulations I race to.

2. Use a floor-mounted pedal box which reverse-mounts the master cylinders (i.e. they sit in front of the pedals). The problem I see with this is that you need a false floorpan to cover the cylinders, and obviously your feet are then raised up. Can't say I've ever seen one of these pedal boxes in a Nova, but I would be interested to have a try in one.

i'll be making whatever i eventually decide to use, seriously swaying towards number 2 seeing as im 6ft2 and all my height is in my legs!

[C612DNM]

I use an OBP floor mounted box in my Belmont V8 Thundersaloon. That has reverse mounted master cylinders, and requires a false floor. Took a bit of getting used to as my feet are something like 4-5" higher than they were with the old Gp.4 Escort pedal box that I used to use.

Being a Thundersaloon and built for two/multi-driver races, the seat is on runners, and I have to run it almost right back. That also meant running a longer/extended steering column, and all the issues that go with that. I still have lots more to sort in that area - going to fabricate a new column at some point to replace the "spear" (as on series organiser calls it) that I currently have.

I can certainly recommend the OBP pedal boxes. Very good - beware of fakes/imitations though -it seems that there are cheap (and poor) Chinese copies appearing in the market.

They do a wide range of bulkhead mount ones too.

[_Jake]

I use an OBP floor mounted box in my Belmont V8 Thundersaloon. That has reverse mounted master cylinders, and requires a false floor. Took a bit of getting used to as my feet are something like 4-5" higher than they were with the old Gp.4 Escort pedal box that I used to use.

Being a Thundersaloon and built for two/multi-driver races, the seat is on runners, and I have to run it almost right back. That also meant running a longer/extended steering column, and all the issues that go with that. I still have lots more to sort in that area - going to fabricate a new column at some point to replace the "spear" (as on series organiser calls it) that I currently have.

I can certainly recommend the OBP pedal boxes. Very good - beware of fakes/imitations though -it seems that there are cheap (and poor) Chinese copies appearing in the market.

They do a wide range of bulkhead mount ones too.
Could you or someone be kind enough to post some pics of the escort ones? i have one here im going to offer up tomorrow but im interested to see as to how other people have done it

[C612DNM]

Here's a link to eBay.... looky and see...

http://www.ebay.co.uk/itm/Escort-Mk2-Brake-Balance-Bar-Bias-Pedal-Box-Cable-Clutch-with-New-Pressed-Pedals-/230859697441

Mine had hydraulic clutch too, but on a Nova/Corsa you'll be wanting the cable variety I'll guess....

[C612DNM]

Having just re-read your post Jake, I don't have any pics of it in situ. It's a case of offering it up to where you want it, then bolting it in position. To get the best position it's a two-man-job and if you can, do it with the dash out so you can see what you're doing.

[_Jake]

Having just re-read your post Jake, I don't have any pics of it in situ. It's a case of offering it up to where you want it, then bolting it in position. To get the best position it's a two-man-job and if you can, do it with the dash out so you can see what you're doing.

Hmm interesting, thankyou! car wont be running a dash and has a hydraulic clutch so neither of that is a problem :)

[jimbob-mcgrew]

http://i285.photobucket.com/albums/ll66/hillclimbescort/004_zpsbd144ecf.jpg (http://s285.photobucket.com/user/hillclimbescort/media/004_zpsbd144ecf.jpg.html)


^ can you remember what sized belt you used for the alternator mate ?

[maddogdaz666]

I used a Mk4 Astra 1.4 16v belt I think, as they're electric PAS. So no pump.

[novarally]

Still working on the brake system, took a couple of photos of the proposed pedal box (Mini) actually fitted in a Mini - the hillclimb car of a friend;

http://i285.photobucket.com/albums/ll66/hillclimbescort/006_zps2f85b971.jpg (http://s285.photobucket.com/user/hillclimbescort/media/006_zps2f85b971.jpg.html)

http://i285.photobucket.com/albums/ll66/hillclimbescort/007_zps000fa8d9.jpg (http://s285.photobucket.com/user/hillclimbescort/media/007_zps000fa8d9.jpg.html)

I'm not 100% convinced as to whether this is the answer, and I've recently spotted this rather impressive looking newly released pedal box, which is designed to suit sloping floorplans, and may gain me the extra legroom I need;

http://i285.photobucket.com/albums/ll66/hillclimbescort/523235178983_zps1fe32ac6.png (http://s285.photobucket.com/user/hillclimbescort/media/523235178983_zps1fe32ac6.png.html)

I'll do some measuring today.

Meanwhile after a huge amount of Google-time, I found some rear brake discs which should be perfect, and at 300g each, lighter, and better looking too;

http://i285.photobucket.com/albums/ll66/hillclimbescort/001_zps918a6189.jpg (http://s285.photobucket.com/user/hillclimbescort/media/001_zps918a6189.jpg.html)

http://i285.photobucket.com/albums/ll66/hillclimbescort/003_zpsef79cabf.jpg (http://s285.photobucket.com/user/hillclimbescort/media/003_zpsef79cabf.jpg.html)

http://i285.photobucket.com/albums/ll66/hillclimbescort/002_zpscb418df8.jpg (http://s285.photobucket.com/user/hillclimbescort/media/002_zpscb418df8.jpg.html)

http://i285.photobucket.com/albums/ll66/hillclimbescort/005_zps72657316.jpg (http://s285.photobucket.com/user/hillclimbescort/media/005_zps72657316.jpg.html)

http://i285.photobucket.com/albums/ll66/hillclimbescort/004_zpsf6c7ebff.jpg (http://s285.photobucket.com/user/hillclimbescort/media/004_zpsf6c7ebff.jpg.html)

I shall be ordering the new rear calipers from the USA today, they're not available on the shelf in the UK;

http://i285.photobucket.com/albums/ll66/hillclimbescort/Billet_Go-Kart-lg_zpsc90c7aaf.jpg (http://s285.photobucket.com/user/hillclimbescort/media/Billet_Go-Kart-lg_zpsc90c7aaf.jpg.html)

[thedjse]

Really nice brake set up matey

Be interesting to see what your thoughts are on the power output on the x14

[Benn]

Those hubs are beautiful. Bike caliper?

[novarally]

Those hubs are beautiful. Bike caliper?

The hubs are KAD (Kent Auto Developments) for a Mini. I modified the stub axle to allow them to fit, and it means I have 101.6mm PCD on the back. One day I have a plan to modify the front hubs so I can have the same PCD all round to make life easier.

The calipers are sold mostly for Karting, but they also use them on Junior Dragsters apparently.

[Benn]

Ah, so you'd have to run two different wheels then, that would be a pita. And Karting calipers... Very cool, i guess they'll give just enough effort.

[8valve-craig]

Do you intend to be out at Gurston this year Colin? Its a much shorter drive for you now!

Would be great to see it in action again.

[novarally]

Do you intend to be out at Gurston this year Colin? Its a much shorter drive for you now!

Would be great to see it in action again.

It's certainly my plan to be racing later this season, but it all depends on whether I can find enough time to get it all back together again.

I have all the major parts which are needed now, but it's time which is in short supply with it being crazy busy at work, and in my spare time trying to renovate my house as well.

[novarally]

OK, decision made, and yet another pedal box is on the way to me;

http://sewardraceparts.co.uk/shop/article_5/Superlight-pedal-assembly-SPA-102.html?sessid=cPR2efHCIuYQCU67fzCMm5fnzXeWRoFo11 gNaoLMH7UF5IGJHrSqWxWwn3J0Jsmb&shop_param=cid%3D2%26aid%3D5%26

This can be mounted on the sloped bit of floorpan behind the standard Nova pedal box, and should give me a much more comfortable driving position.

I've mocked it up in the car with a cardboard version of the pedal box, and this time I am confident. Famous last words.

What's more it will save me a fair bit of weight compared to the previous set-up.

Can't wait until it arrives now, and will have to sell off various things to cover the cost!

[toymex]

I like the pedal box Colin

[novarally]

I like the pedal box Colin

Hi Jez.

It's nice isn't it?

I've spoken at length with the man who designed and produced it, he really knows his subject, so I'm sure it's going to be good. It seems like amazing value for money when compared to the equivalent offering from AP Racing/Tilton etc.

Photos to follow when it arrives, naturally.

[_Jake]

colin how tall are you? still ****ing about with the pedal box in mine and id love to know how you get on. cut a hole in the floor 8valve craig style and made a floor mounted box to find it still didnt give enough room, to say i was pissed off was an understatement! hate patching up holes that i made myself. bulkheak mounted is looking like the way its going for me..

[Southie]

Colin have you thought about hanging floor pedals instead?
This is on a BMW, think they used akit iirc:
http://i345.photobucket.com/albums/p379/SOUTHIE01/8C7CC6E1-75EC-4BA1-89C1-468D53564B53_1.jpg (http://s345.photobucket.com/user/SOUTHIE01/media/8C7CC6E1-75EC-4BA1-89C1-468D53564B53_1.jpg.html)

[novarally]

colin how tall are you? still ****ing about with the pedal box in mine and id love to know how you get on. cut a hole in the floor 8valve craig style and made a floor mounted box to find it still didnt give enough room, to say i was pissed off was an understatement! hate patching up holes that i made myself. bulkheak mounted is looking like the way its going for me..

5' 10", so not tall. But I can't get my seat any further back due to the design of the rollcage.

[toymex]

Hi Jez.

It's nice isn't it?

I've spoken at length with the man who designed and produced it, he really knows his subject, so I'm sure it's going to be good. It seems like amazing value for money when compared to the equivalent offering from AP Racing/Tilton etc.

Photos to follow when it arrives, naturally.
I might have to have a winter upgrade funds permitting

[novarally]

The new pedal box has arrived.

It's in kit form, so off to bolt it together now and then test-fit. More to follow.....

[novarally]

A few photos from yesterday, it fits a treat, and the driving position is so much better now. Obviously just trialling it at the moment.

It's a very comprehensive kit, even includes spanners and allen keys;

http://i285.photobucket.com/albums/ll66/hillclimbescort/005_zps2ccb9542.jpg (http://s285.photobucket.com/user/hillclimbescort/media/005_zps2ccb9542.jpg.html)

http://i285.photobucket.com/albums/ll66/hillclimbescort/006_zps63fe3454.jpg (http://s285.photobucket.com/user/hillclimbescort/media/006_zps63fe3454.jpg.html)

http://i285.photobucket.com/albums/ll66/hillclimbescort/008_zps393962a7.jpg (http://s285.photobucket.com/user/hillclimbescort/media/008_zps393962a7.jpg.html)

The floorpan of my Nova, showing the plate where the old floor mounted pedal box was located (this plate will get removed soon);

http://i285.photobucket.com/albums/ll66/hillclimbescort/003_zps844d0af2.jpg (http://s285.photobucket.com/user/hillclimbescort/media/003_zps844d0af2.jpg.html)

New pedal box loosely in place (without mounting brackets at this stage);

http://i285.photobucket.com/albums/ll66/hillclimbescort/002_zpsbadfe837.jpg (http://s285.photobucket.com/user/hillclimbescort/media/002_zpsbadfe837.jpg.html)

http://i285.photobucket.com/albums/ll66/hillclimbescort/001_zpsd99917f1.jpg (http://s285.photobucket.com/user/hillclimbescort/media/001_zpsd99917f1.jpg.html)

Very lightweight as well, it's going to save me over 2kg compared to the old pedal box;

http://i285.photobucket.com/albums/ll66/hillclimbescort/012_zps0e75e1c1.jpg (http://s285.photobucket.com/user/hillclimbescort/media/012_zps0e75e1c1.jpg.html)

[bazzap8389]

Damn that's nice

[Connor]

Awesome bit of kit that :thumb:

[Prey]

faaancy, just had a catch up on this thread, good stuff!

[novarally]

Been building up the pedal box today, lots of messing about as the pushrods on my master cylinders were too short for my new pedal box.

Fortunately I had a selection of F1 alloy/titanium master cylinders in a drawer, so they have donated their titanium pushrods to the cause.

Now I have to cut the pushrods down to size, mustn't get that wrong!

http://i285.photobucket.com/albums/ll66/hillclimbescort/056_zpsddb554c5.jpg (http://s285.photobucket.com/user/hillclimbescort/media/056_zpsddb554c5.jpg.html)

http://i285.photobucket.com/albums/ll66/hillclimbescort/055_zps3a4dc32f.jpg (http://s285.photobucket.com/user/hillclimbescort/media/055_zps3a4dc32f.jpg.html)

[novarally]

The new pedal box is now ready to install, and I have some remote reservoirs for it to be mounted in the battery tray area;

http://i285.photobucket.com/albums/ll66/hillclimbescort/005_zps1082a8f4.jpg (http://s285.photobucket.com/user/hillclimbescort/media/005_zps1082a8f4.jpg.html)

http://i285.photobucket.com/albums/ll66/hillclimbescort/006_zpsece9e3e1.jpg (http://s285.photobucket.com/user/hillclimbescort/media/006_zpsece9e3e1.jpg.html)

http://i285.photobucket.com/albums/ll66/hillclimbescort/001_zpsf6bff72a.jpg (http://s285.photobucket.com/user/hillclimbescort/media/001_zpsf6bff72a.jpg.html)

Just got the hoses to make up to feed the master cylinders now.

And a rather nice 99p purchase from EBAY to round up;

http://i285.photobucket.com/albums/ll66/hillclimbescort/004_zps0de6e594.jpg (http://s285.photobucket.com/user/hillclimbescort/media/004_zps0de6e594.jpg.html)

[8valve-craig]

Some nice parts. I found that my push rods werent long enough either, but instead of replacing them cut them down a little, then used a threaded steel sleeve and some 5/16 treaded bar to lengthen them. Hopefully will work fine with a bit of locktite.

[Benn]

That petal box is lovely. Can see what you've bought that one.

[Mike]

Tidy pedal box that.

Braille also make carbon bodied super duper light weight batteries Colin ;)

[novarally]

Braille also make carbon bodied super duper light weight batteries Colin ;)

Indeed they do, I really want one, but can't afford it.

[novarally]

Don't seem to have had much time to do anything to the car, but I did get a couple of hours in yesterday.

Scuttle area prepared for the new fluid reservoirs;

http://i285.photobucket.com/albums/ll66/hillclimbescort/001_zps5118e057.jpg (http://s285.photobucket.com/user/hillclimbescort/media/001_zps5118e057.jpg.html)

http://i285.photobucket.com/albums/ll66/hillclimbescort/002_zps9d299f36.jpg (http://s285.photobucket.com/user/hillclimbescort/media/002_zps9d299f36.jpg.html)

http://i285.photobucket.com/albums/ll66/hillclimbescort/004_zps0c6a6d8a.jpg (http://s285.photobucket.com/user/hillclimbescort/media/004_zps0c6a6d8a.jpg.html)

And some work on prepping the floorpan, where I removed the mounting plate from the old pedal box;

http://i285.photobucket.com/albums/ll66/hillclimbescort/003_zps6729a27b.jpg (http://s285.photobucket.com/user/hillclimbescort/media/003_zps6729a27b.jpg.html)

And just to make me feel like some progress, I placed the engine into the bay;

http://i285.photobucket.com/albums/ll66/hillclimbescort/005_zps29fcda3c.jpg (http://s285.photobucket.com/user/hillclimbescort/media/005_zps29fcda3c.jpg.html)

Can't fit it yet as I am waiting for my gearbox to come back after a check over, which has now been delayed because my LSD is knackered, and I need to buy a new one. An expense I really could have done without after the costs of my accident.

I picked up an interesting engine for spares today - more details and photos to follow tomorrow.............

[toymex]

As we discussed Colin ,I bet the slipper was the cause of your mishap,how are you going to fix the reservoir ,I might have to get one of them as my girling ones leak every time the car is used in anger,if you ever come across a hewland box please bear me in mind

[Novasport]

Pics and details of interesting engine...

[novarally]

As we discussed Colin ,I bet the slipper was the cause of your mishap,how are you going to fix the reservoir ,I might have to get one of them as my girling ones leak every time the car is used in anger,if you ever come across a hewland box please bear me in mind

I'm going to silicone round the bottom of the reservoir to make it a 'fireproof' seal, and then it's just the little carbon fibre right-angled bracket which picks up onto the old battery mounting stud (see photo). I think that will be adequate, as the pipes to the master cylinders also retain it.

You thinking of going sequential then? Or do you want a dog 'box from a Vectra Challenge car?

[novarally]

Pics and details of interesting engine...

Haven't done any photos yet, but it's a 1600cc 8v engine with dry sump system, uprated cam, fancy engine mount, different crank pulley. It's come out of a single seater.

[Andy]

Haven't done any photos yet, but it's a 1600cc 8v engine with dry sump system, uprated cam, fancy engine mount, different crank pulley. It's come out of a single seater.
hmmmm,interesting indeed!

[toymex]

I'm going to silicone round the bottom of the reservoir to make it a 'fireproof' seal, and then it's just the little carbon fibre right-angled bracket which picks up onto the old battery mounting stud (see photo). I think that will be adequate, as the pipes to the master cylinders also retain it.

You thinking of going sequential then? Or do you want a dog 'box from a Vectra Challenge car?
I would love a sequential ,but that puts me up a class so it's the dog box that I am after ,although I might start saving for a sequential ,there doesn't seem too many options though I was thinking Sadev as I have heard good things about them

[novarally]

I would love a sequential ,but that puts me up a class so it's the dog box that I am after ,although I might start saving for a sequential ,there doesn't seem too many options though I was thinking Sadev as I have heard good things about them

You probably know that Ben (Boffer8) has a Sadev for his Nova, so he'll be the man to speak to. They're going to be the most readily available option, and the bellhousing to suit is 'off the shelf'. Depends whether you think you'll still be competitive in a higher Class I guess.

The Hewland dog 'boxes are hard to find, and I'd want to check what spares back-up is like these days.

[novarally]

As we discussed Colin ,I bet the slipper was the cause of your mishap,how are you going to fix the reservoir ,I might have to get one of them as my girling ones leak every time the car is used in anger,if you ever come across a hewland box please bear me in mind

Jezz.

My gearbox guy doesn't think the LSD was the cause of the accident, but I remain unconvinced. Naturally I want something to blame apart from driver error!

The ramp and some of the plates have picked up due to wear from a driveshaft, he's a gearbox specialist and says he has never seen one go like this before, and doesn't know why.

[dgbnova#1]

Haven't done any photos yet, but it's a 1600cc 8v engine with dry sump system, uprated cam, fancy engine mount, different crank pulley. It's come out of a single seater.
Watched this on eBay extenders on the pully to clear the mount looks like a crazy mount on the cambelt end
was it worth the money i passed on it tbh but was interested in the setup though

[novarally]

Watched this on eBay extenders on the pully to clear the mount looks like a crazy mount on the cambelt end
was it worth the money i passed on it tbh but was interested in the setup though

For £200 I thought it was a good buy. The dry sump pan and oil pumphave got be worth that.

[dgbnova#1]

Yes I thought that just wondered if there was anything nicer inside the motor seems a lot of work for it to be standard motor ?

[novarally]

Yes I thought that just wondered if there was anything nicer inside the motor seems a lot of work for it to be standard motor ?


I've not delved inside it yet. I suspect the cam might be uprated, but I would expect everything else is standard. It will have been used in a one-chassis/one-make single seater race series I guess, where the rules were strict, but dry-sumping was essential for cornering speeds and ground clearance.

[novarally]

Here's a few photos of the engine in question, it's not been used in a fair while by the look of it;

http://i285.photobucket.com/albums/ll66/hillclimbescort/002_zps09131b4b.jpg (http://s285.photobucket.com/user/hillclimbescort/media/002_zps09131b4b.jpg.html)

http://i285.photobucket.com/albums/ll66/hillclimbescort/007_zps37f92ab3.jpg (http://s285.photobucket.com/user/hillclimbescort/media/007_zps37f92ab3.jpg.html)

http://i285.photobucket.com/albums/ll66/hillclimbescort/008_zpsae4fb908.jpg (http://s285.photobucket.com/user/hillclimbescort/media/008_zpsae4fb908.jpg.html)

http://i285.photobucket.com/albums/ll66/hillclimbescort/005_zpsed3a9f80.jpg (http://s285.photobucket.com/user/hillclimbescort/media/005_zpsed3a9f80.jpg.html)

http://i285.photobucket.com/albums/ll66/hillclimbescort/003_zpsaae2ff78.jpg (http://s285.photobucket.com/user/hillclimbescort/media/003_zpsaae2ff78.jpg.html)

http://i285.photobucket.com/albums/ll66/hillclimbescort/004_zps33c66ec4.jpg (http://s285.photobucket.com/user/hillclimbescort/media/004_zps33c66ec4.jpg.html)

http://i285.photobucket.com/albums/ll66/hillclimbescort/006_zps1db09700.jpg (http://s285.photobucket.com/user/hillclimbescort/media/006_zps1db09700.jpg.html)

[mowgli]

formula vauxhall junior??

re the sequential thing... it wouldn't be massively difficult to make a seq. shifter box.

[C612DNM]

Yes, that's a FVJ engine. Bog standard Nova GSI engine with a dry sump kit fitted, and as you say Colin, worth it for the dry sump kit alone. I use one of the timing toothed wheels on my GSI engine.

They were all built by Scholar engines, who should still have spares on the shelf.

[scott.parker]

I saw this on ebay also, did find it very interesting, forgot to watch it though, but 200 quid aint bad at all..

[lee303]

i had a FVJ engine in my GTE a good while back, they are as said stock but blueprinted, later ones also had an enem cam iirc, great engine, interesting sump setup too as you say, single stage pump?

[novarally]

i had a FVJ engine in my GTE a good while back, they are as said stock but blueprinted, later ones also had an enem cam iirc, great engine, interesting sump setup too as you say, single stage pump?

Thanks for the info Lee, useful stuff.

I now have to hold my hands up and say I know almost nothing about dry sump systems. I have no idea if it's a single stage pump, idiots guide required please.....

[Southie]

Some info here Colin:
http://www.drysump.com/drysump.htm

[fearless]

re the sequential thing... it wouldn't be massively difficult to make a seq. shifter box.


Something similar to this ;)

http://billfalconer.webs.com/sequentialgearshifter.htm

[novarally]

Something similar to this ;)

http://billfalconer.webs.com/sequentialgearshifter.htm

Thanks for that link - this is a new one to me, it looks like quite a piece of engineering.

Do you know of anyone who's using one?

[burgo]

The mind boggles at the engineering in that little box

[scott.parker]

The mind boggles at the engineering in that little box

So im right in thinking that the black box has some mechanical workings inside to change gears on a standard gearbox by you simply pushing forward for up gears, and pulling back for down gears?
Humm, interesting, so does it replace the bolt on sector box on top of the gearbox then? lol im baffled by it.

[novarally]

So im right in thinking that the black box has some mechanical workings inside to change gears on a standard gearbox by you simply pushing forward for up gears, and pulling back for down gears?
Humm, interesting, so does it replace the bolt on sector box on top of the gearbox then? lol im baffled by it.

Yes, that's exactly how it works. It sounds like the turret on top of the 'box has to be modified as well. I'm wanting to see one installed in a car and hear from someone who's driven with it.

Typically I've got a section of rollcage running exactly where the gear-rod would want to go through the bulkhead.

[dgbnova#1]

The guy selling must have or know someone running one ?

it looks like it bolts on top of the selector unit so don't see what needs modding tbh just adjustment

[fearless]

The only other info I have on it is this link to YouTube

https://www.youtube.com/watch?v=9E5Gv9FLBRY

[dgbnova#1]

Does that mean it's always in looking at that video?

[novarally]

The only other info I have on it is this link to YouTube

https://www.youtube.com/watch?v=9E5Gv9FLBRY

Excellent, thanks. It looks to work very effectively.

Apart from the cost, and the fact I have a rollcage in the way, the only drawback I foresee is the lack of a gear indicator.

Having run a sequential 'box in my Escort Cosworth, it is absolutely vital to have a visible indicator to show what gear you're in.

[stt]

You can get some simple gear indicators from motorbike shops, they self calibrate from revs and speed input

[stt]

http://www.demon-tweeks.co.uk/Product.do?method=view&n=2138&p=45896&c=215&utm_source=Google&utm_medium=Base&utm_campaign=Gifts&gclid=CIXCu8LZ6r0CFWzHtAodlTsAbA

[novarally]

You can get some simple gear indicators from motorbike shops, they self calibrate from revs and speed input

Good point, I should have remembered those, I had one on my R6 about 15 years ago!

[novarally]

I had a very interesting and long chat with Bill Falconer today regarding the sequential gear lever kit he's developed (see link above to his website).

It now comes with a gear display panel, and I must say it sounds really promising. All I need now is to find the money to buy it.......

[toymex]

I had a very interesting and long chat with Bill Falconer today regarding the sequential gear lever kit he's developed (see link above to his website).

It now comes with a gear display panel, and I must say it sounds really promising. All I need now is to find the money to buy it.......
Does it have to be a dog box Colin

[novarally]

Does it have to be a dog box Colin

Hi Jezz.

It will work fine on the synchro 'box, it's just the flat-shift bit which only works with the dog set-up. And obviously you still need to use the clutch with the synchro 'box (unless you want regular rebuilds!).

Could you get away with a sequential gearshifter in your Class, if the actual gearbox is still a conventional 'H' pattern internally?

[toymex]

No I am not allowed to use it without going up a class ,I think for me I would be better served saving for a proper sequential ,shame I can't use it though

[novarally]

No I am not allowed to use it without going up a class ,I think for me I would be better served saving for a proper sequential ,shame I can't use it though

It seems good value at £1200, there's clearly been a lot of thought and engineering that's gone into the design.

As always it's a question of prioritising spending, and at the moment I have a knackered LSD to be replaced, which is more important than a different way of shifting gears.

Small upside today though as I managed to get my 2 damaged split rim wheels repaired for £40 cash. I thought they might end up needing new inner and outer sections, but they did a great job repairing them.

[novarally]

Had a whole day on the car today, so a reasonable amount of progress has been made.

Temporarily fitted the new (carbon fibre!) oil breather tank;
http://i285.photobucket.com/albums/ll66/hillclimbescort/059_zps5202f077.jpg (http://s285.photobucket.com/user/hillclimbescort/media/059_zps5202f077.jpg.html)

Still messing about with the installation of the new pedal box;
http://i285.photobucket.com/albums/ll66/hillclimbescort/064_zps9882c861.jpg (http://s285.photobucket.com/user/hillclimbescort/media/064_zps9882c861.jpg.html)

http://i285.photobucket.com/albums/ll66/hillclimbescort/063_zps07328b2a.jpg (http://s285.photobucket.com/user/hillclimbescort/media/063_zps07328b2a.jpg.html)

I bought this really nice carbon fibre foot tray/clutch footrest in the hope that it would work, but there's no way it will go in there, which is a huge shame;
http://i285.photobucket.com/albums/ll66/hillclimbescort/024_zps76642d5e.jpg (http://s285.photobucket.com/user/hillclimbescort/media/024_zps76642d5e.jpg.html)

Steering rack now fully installed;
http://i285.photobucket.com/albums/ll66/hillclimbescort/060_zpsfb76631a.jpg (http://s285.photobucket.com/user/hillclimbescort/media/060_zpsfb76631a.jpg.html)

And starting to make a new switch holder/fuse box;
http://i285.photobucket.com/albums/ll66/hillclimbescort/062_zpsb1ac551a.jpg (http://s285.photobucket.com/user/hillclimbescort/media/062_zpsb1ac551a.jpg.html)

http://i285.photobucket.com/albums/ll66/hillclimbescort/061_zps8f5ea36b.jpg (http://s285.photobucket.com/user/hillclimbescort/media/061_zps8f5ea36b.jpg.html)

[novarally]

But most of the day has been spent on putting the engine in. It's not got the correct gearbox on there at the moment, but it's at least in the bay, and allowing me to trial fit the Jenvey's etc;

http://i285.photobucket.com/albums/ll66/hillclimbescort/081_zpse8ab4141.jpg (http://s285.photobucket.com/user/hillclimbescort/media/081_zpse8ab4141.jpg.html)

http://i285.photobucket.com/albums/ll66/hillclimbescort/078_zps338ff34e.jpg (http://s285.photobucket.com/user/hillclimbescort/media/078_zps338ff34e.jpg.html)

http://i285.photobucket.com/albums/ll66/hillclimbescort/082_zpsd440663a.jpg (http://s285.photobucket.com/user/hillclimbescort/media/082_zpsd440663a.jpg.html)

http://i285.photobucket.com/albums/ll66/hillclimbescort/076_zps00be6674.jpg (http://s285.photobucket.com/user/hillclimbescort/media/076_zps00be6674.jpg.html)

Not a lot of clearance round the alternator, but this will be solved when I fit the small, lightweight one I have;

http://i285.photobucket.com/albums/ll66/hillclimbescort/079_zps81b763cf.jpg (http://s285.photobucket.com/user/hillclimbescort/media/079_zps81b763cf.jpg.html)

http://i285.photobucket.com/albums/ll66/hillclimbescort/080_zpsfef6c3ae.jpg (http://s285.photobucket.com/user/hillclimbescort/media/080_zpsfef6c3ae.jpg.html)

And the Throttle Bodies, at last.........I was really worried that the roll cage cross brace in the engine bay was going to be a major problem, but luckily I've got away with it;
http://i285.photobucket.com/albums/ll66/hillclimbescort/083_zpse6de46b9.jpg (http://s285.photobucket.com/user/hillclimbescort/media/083_zpse6de46b9.jpg.html)

http://i285.photobucket.com/albums/ll66/hillclimbescort/086_zps29bd3004.jpg (http://s285.photobucket.com/user/hillclimbescort/media/086_zps29bd3004.jpg.html)

http://i285.photobucket.com/albums/ll66/hillclimbescort/084_zps2f350f98.jpg (http://s285.photobucket.com/user/hillclimbescort/media/084_zps2f350f98.jpg.html)

The bulkhead needs a little bit of a 'tweak' to allow the air filter and trumpets to sit correctly. This exercise has at least confirmed that I need to use the foam air filter. I had been hoping to use this carbon fibre airbox I had, but there's certainly no room for that...........;
http://i285.photobucket.com/albums/ll66/hillclimbescort/087_zps26c3086b.jpg (http://s285.photobucket.com/user/hillclimbescort/media/087_zps26c3086b.jpg.html)

[boffer8]

Looks very nice Colin, where did the carbon foot tray come from? Also how much does the catch tank weigh?

[Benn]

Looking good on fitment.

[novarally]

Looks very nice Colin, where did the carbon foot tray come from? Also how much does the catch tank weigh?

The carbon footrest was from Poland, company called Carbontek. It's lovely quality, it would be OK with bulkhead mounted pedals, but there's just not enough width in a Nova shell with a floor mounted pedal box and a clutch footrest.

I'll have to weigh the catch tank again, I did do it ages ago but I can't recall what it was now. It's very light indeed for a 1 litre tank.

[novarally]

Also how much does the catch tank weigh?

Ben - the catch tank is 250g. I had to remove it anyway as the wing won't fit on with it in that location! Time to rethink the positioning.

I've done a few more bits today, fitting the wiring harness for the MBE ECU and Jenvey's;

http://i285.photobucket.com/albums/ll66/hillclimbescort/001_zps25b186bd.jpg (http://s285.photobucket.com/user/hillclimbescort/media/001_zps25b186bd.jpg.html)

http://i285.photobucket.com/albums/ll66/hillclimbescort/002_zps7b7bf020.jpg (http://s285.photobucket.com/user/hillclimbescort/media/002_zps7b7bf020.jpg.html)

http://i285.photobucket.com/albums/ll66/hillclimbescort/008_zpsab3d3e67.jpg (http://s285.photobucket.com/user/hillclimbescort/media/008_zpsab3d3e67.jpg.html)

http://i285.photobucket.com/albums/ll66/hillclimbescort/009_zps393448f4.jpg (http://s285.photobucket.com/user/hillclimbescort/media/009_zps393448f4.jpg.html)

Trial fitting the new radiator, which ideally I want to install in a slanted position;

http://i285.photobucket.com/albums/ll66/hillclimbescort/004_zpsa85a1161.jpg (http://s285.photobucket.com/user/hillclimbescort/media/004_zpsa85a1161.jpg.html)

http://i285.photobucket.com/albums/ll66/hillclimbescort/003_zpscb9bab57.jpg (http://s285.photobucket.com/user/hillclimbescort/media/003_zpscb9bab57.jpg.html)

I found that the throttle body kit I bought secondhand is missing a few bits - Air Temperature Sensor, Throttle Position Sensor and the 4 x rubber 'O' rings for the throttle bodies to inlet manifold seal. Anyone know the best place to get these (apart from Jenvey)?

This is the throttle linkage which came with the kit - I have no idea how it's supposed to fit! It's not obvious what it's mean to bolt to. Any suggestions/photos of linkage installation on smallblock XE motors would be welcome please;

http://i285.photobucket.com/albums/ll66/hillclimbescort/005_zps32216a3f.jpg (http://s285.photobucket.com/user/hillclimbescort/media/005_zps32216a3f.jpg.html)

I also made up a new carbon fibre tube windscreen brace (for the polycarbonate windscreen), which saves 100g over the aluminium bar;

http://i285.photobucket.com/albums/ll66/hillclimbescort/007_zps14761a28.jpg (http://s285.photobucket.com/user/hillclimbescort/media/007_zps14761a28.jpg.html)

[BRoadGhost]

The front end on this is brilliant

[novarally]

Only had a couple of hours to spare this weekend, so only a little update.

Carbon fibre binnacle being modified to fit and accept my STACK dash display;

http://i285.photobucket.com/albums/ll66/hillclimbescort/003_zpsee3c1024.jpg (http://s285.photobucket.com/user/hillclimbescort/media/003_zpsee3c1024.jpg.html)

http://i285.photobucket.com/albums/ll66/hillclimbescort/004_zps0f3602e3.jpg (http://s285.photobucket.com/user/hillclimbescort/media/004_zps0f3602e3.jpg.html)

http://i285.photobucket.com/albums/ll66/hillclimbescort/008_zpscd5676b2.jpg (http://s285.photobucket.com/user/hillclimbescort/media/008_zpscd5676b2.jpg.html)

And the STACK dash sensors now fitted, apart from the oil temperature sensor which I need to find a home for;

http://i285.photobucket.com/albums/ll66/hillclimbescort/009_zps6e19b7f6.jpg (http://s285.photobucket.com/user/hillclimbescort/media/009_zps6e19b7f6.jpg.html)

http://i285.photobucket.com/albums/ll66/hillclimbescort/010_zps06f6c05e.jpg (http://s285.photobucket.com/user/hillclimbescort/media/010_zps06f6c05e.jpg.html)

http://i285.photobucket.com/albums/ll66/hillclimbescort/011_zps070bebba.jpg (http://s285.photobucket.com/user/hillclimbescort/media/011_zps070bebba.jpg.html)

And the new rear calipers have arrived from the USA;

http://i285.photobucket.com/albums/ll66/hillclimbescort/007_zps0bd9ab9d.jpg (http://s285.photobucket.com/user/hillclimbescort/media/007_zps0bd9ab9d.jpg.html)

http://i285.photobucket.com/albums/ll66/hillclimbescort/006_zps0e3127dc.jpg (http://s285.photobucket.com/user/hillclimbescort/media/006_zps0e3127dc.jpg.html)

http://i285.photobucket.com/albums/ll66/hillclimbescort/005_zpsea3f3f7e.jpg (http://s285.photobucket.com/user/hillclimbescort/media/005_zpsea3f3f7e.jpg.html)

[mowgli]

re the O-rings, I'd imagine any decent bearing/seal stockist, or hydraulic shop will be able to supply them

[novarally]

A friend of mine has kindly 'volunteered' to take the Nova into his workshops for a week in a push to get it mostly finished off. There's quite a list of things to be done, not least of which are;

Wiring and plumbing the engine to cooling and fuel systems
Wiring in the new instruments, switches and fuse box
Fitting the pedal box and plumbing in the brakes
Making brackets for front and rear brake calipers
Making/modifying an exhaust system to fit
Repainting and repairing various bits of bodywork
Sorting out the clutch
Getting hold of a gearbox to use, and a replacement LSD (this one more tricky as it requires actual cash)

In an effort to raise some funds I have various bits from this car which are now surplus to requirements listed on EBAY;

http://www.ebay.co.uk/sch/hillclimbescort/m.html?item=310952737913&ssPageName=STRK%3AMESELX%3AIT&rt=nc&_trksid=p2047675.l2562

The carbon fibre bonnet, front bumper, front wings and splitter will also be appearing on EBAY soon (and probably the fibreglass tailgate too)

[Benn]

Love the angle on the rad, will you be ducting it like Lee has? So the air is forced thru and out the top?

Love those calipers too. Look mega sexy.

[Peredur]

Hi,

Did anything come of the lotus pedal box you tried to use?

Thanks

[novarally]

Hi,

Did anything come of the lotus pedal box you tried to use?

Thanks

No, nothing happened with that.

The clutch pedal on the Elise is completely straight, compared to a Nova pedal which has a significant 'kink' in it to go around the steering column. So without moving the steering column or modifying the Elise pedal significantly, I couldn't come up with a way to make it fit.

I still have the pedal box, was planning to put it on EBAY soon!

[novarally]

The carbon fibre bonnet, front bumper, front wings and splitter will also be appearing on EBAY soon (and probably the fibreglass tailgate too)

Carbon front end and bonnet are now on EBAY;

http://www.ebay.co.uk/sch/hillclimbescort/m.html?item=310965275096&ssPageName=STRK%3AMESELX%3AIT&rt=nc&_trksid=p2047675.l2562

Tailgate will be joining them soon

[Southie]

Whys that Colin? What's replacing them then?

Are you planning any outings in this; this year? Would love to see you giving it a thrashing.

[novarally]

Whys that Colin? What's replacing them then?

Are you planning any outings in this; this year? Would love to see you giving it a thrashing.

News on the revisions to the front end will be posted on here next week I hope.

I will be out racing this year IF (and it's a big 'if') I can find the money to pay for a new LSD...about £600. Money is very tight, and there are more pressing things than an LSD, unfortunately.

But I do want to race this season, so fingers are crossed that I can raise the funds.

[Southie]

Where you looking at now with living in a different area?

[_Jake]

News on the revisions to the front end will be posted on here next week I hope.

I will be out racing this year IF (and it's a big 'if') I can find the money to pay for a new LSD...about £600. Money is very tight, and there are more pressing things than an LSD, unfortunately.

But I do want to race this season, so fingers are crossed that I can raise the funds.

not being rude but if it was me id be looking to save for an lsd rather than buying random carbon items, whats lighter than carbon? ...nothing. i.e rather than having that carbon thing in the footwell, have nothing at all! cheaper and lighter

[novarally]

not being rude but if it was me id be looking to save for an lsd rather than buying random carbon items, whats lighter than carbon? ...nothing. i.e rather than having that carbon thing in the footwell, have nothing at all! cheaper and lighter

Fair comment, but racing is not the be all and end all for me.

Building and developing the car probably gives me more satisfaction than the actual driving.

[joshy]

Fair comment, but racing is not the be all and end all for me.

Building and developing the car probably gives me more satisfaction than the actual driving.


I can relate to that

[novarally]

not being rude but if it was me id be looking to save for an lsd rather than buying random carbon items, whats lighter than carbon? ...nothing. i.e rather than having that carbon thing in the footwell, have nothing at all! cheaper and lighter

So, the question was...........'What's lighter than carbon?'

And the answer is, even lighter carbon!;

http://i285.photobucket.com/albums/ll66/hillclimbescort/imagesPATW5NA9_zps3f3abc55.jpg (http://s285.photobucket.com/user/hillclimbescort/media/imagesPATW5NA9_zps3f3abc55.jpg.html)

[mowgli]

now that looks interesting.

ps. want a carbon splitter??? lol

[_Jake]

Fair comment, but racing is not the be all and end all for me.

Building and developing the car probably gives me more satisfaction than the actual driving.

100% agree with that mate fair play. hope to see it out soon :)

[scott.parker]

Colin, is that the front end from that foreign drag car let engine nova?

[novarally]

Colin, is that the front end from that foreign drag car let engine nova?

It is indeed, although it had an XE engine, not an LET.

It's the UPG Corsa from Bulgaria.

[novarally]

http://i285.photobucket.com/albums/ll66/hillclimbescort/images_zpsac1cbf8e.jpg (http://s285.photobucket.com/user/hillclimbescort/media/images_zpsac1cbf8e.jpg.html)

http://i285.photobucket.com/albums/ll66/hillclimbescort/imagesGM71VYLB_zpsd05a53d3.jpg (http://s285.photobucket.com/user/hillclimbescort/media/imagesGM71VYLB_zpsd05a53d3.jpg.html)

http://i285.photobucket.com/albums/ll66/hillclimbescort/imagesWG1XG23E_zps0764e028.jpg (http://s285.photobucket.com/user/hillclimbescort/media/imagesWG1XG23E_zps0764e028.jpg.html)

http://i285.photobucket.com/albums/ll66/hillclimbescort/imagesCB3PNHP0_zps4e04b8ec.jpg (http://s285.photobucket.com/user/hillclimbescort/media/imagesCB3PNHP0_zps4e04b8ec.jpg.html)

[scott.parker]

Nice!
:)

[turbojolt]

thought that nova sold for 20 odd grand

[Kev Turbo]

Enough of this "I have no money talk" You have carbon and titanium all over that garage of yours.

Did you buy UPG?

Great work as always Colin.

[novarally]

thought that nova sold for 20 odd grand

No, it didn't sell complete, they broke it up into parts.

[novarally]

enough of this "i have no money talk" you have carbon and titanium all over that garage of yours.

Did you buy upg?

Great work as always colin.

;)

i

[turbojolt]

ohhh I see. good news for you then

[Jonlem]

Nice purchase, the UPG car certainly was a bit of an eye opener for me, those panels are superlight

[novarally]

Nice purchase, the UPG car certainly was a bit of an eye opener for me, those panels are superlight

Thanks again James, looking at paying a visit to you this coming week.

[Jonlem]

No problem. Forgot to measure it but will sort that asap.

[novarally]

No problem. Forgot to measure it but will sort that asap.

Thanks - I'm not sure if it will go in a Vito van. Failing that I might be able to borrow my mates enclosed car trailer.

[Southie]

Well this will transform the weight and looks of your car Colin, it's ideal for you though on weight saving. Are you going to reproduce that front end though incase god forbid you have an off?

[novarally]

Well this will transform the weight and looks of your car Colin, it's ideal for you though on weight saving. Are you going to reproduce that front end though incase god forbid you have an off?

It will knock about 3kg off the car, which is worth having. But mostly it looks great IMO!

It has crossed my mind to have a mould taken from it, although I don't know who I would get to do it, or how much it would cost. It's also honeycomb-reinforced, so it's not a simple thing to replicate.

I'm also still harbouring a strange desire to have the front clam made in transparent Lexan (like a RC car bodyshell) - although again I don't know who to approach for getting such work done, and no doubt the cost would be stupendous.

[Southie]

In all fairness how much difference would fibreglass be for a similar setup? Can't be that much and you'll still have decent strength of the panels.

[mowgli]

I'm also still harbouring a strange desire to have the front clam made in transparent Lexan (like a RC car bodyshell) - although again I don't know who to approach for getting such work done, and no doubt the cost would be stupendous.

http://www.cnc-arena.com/en/forum/vacuum-forming-thermoforming-etc--291 you might find someone on here that can help.

[novarally]

http://www.cnc-arena.com/en/forum/vacuum-forming-thermoforming-etc--291 you might find someone on here that can help.

Thanks Mike, I will definitely put up a plea for help on there.

[Mike]

It has crossed my mind to have a mould taken from it, although I don't know who I would get to do it, or how much it would cost. It's also honeycomb-reinforced, so it's not a simple thing to replicate.

Anyone that deals in pre preg Colin. If you want it replicating with a core it cant be done via a wet method (ie, infused or a wet lay laminate) Well, I say it cant, it could, but the core soaks up all the epoxy & it'll weight as much if not more then grp copy.

I hope you got incredibly deep pockets though if your planning on replicating it lol

And just to add, GRP isn't exactly strong what so ever if your looking for a lightweight part. Hit a GRP bonnet with a hammer itll go straight through it. Hit a well made carbon panel with a hammer itll bounce straight back at you. FACT.

[novarally]

Monday's journey to collect the front end from Cambridgeshire;

http://i285.photobucket.com/albums/ll66/hillclimbescort/001_zpsff04233b.jpg (http://s285.photobucket.com/user/hillclimbescort/media/001_zpsff04233b.jpg.html)

http://i285.photobucket.com/albums/ll66/hillclimbescort/002_zps21237e22.jpg (http://s285.photobucket.com/user/hillclimbescort/media/002_zps21237e22.jpg.html)

http://i285.photobucket.com/albums/ll66/hillclimbescort/003_zpsc1b37662.jpg (http://s285.photobucket.com/user/hillclimbescort/media/003_zpsc1b37662.jpg.html)

http://i285.photobucket.com/albums/ll66/hillclimbescort/004_zps6e7debed.jpg (http://s285.photobucket.com/user/hillclimbescort/media/004_zps6e7debed.jpg.html)

Oh, and the tailgate to match!;

http://i285.photobucket.com/albums/ll66/hillclimbescort/005_zpsfa4641d7.jpg (http://s285.photobucket.com/user/hillclimbescort/media/005_zpsfa4641d7.jpg.html)

[Jonlem]

Careful that doesn't put you overweight ;) lol

[novarally]

Careful that doesn't put you overweight ;) lol


Big thanks to James (jonlem) and Relentless Performance for taking delivery of the panels for me and storing them for a while.

Photos to follow shortly of the new front-end mocked up on my car............

[novarally]

http://i285.photobucket.com/albums/ll66/hillclimbescort/006_zpsf99dd234.jpg (http://s285.photobucket.com/user/hillclimbescort/media/006_zpsf99dd234.jpg.html)

http://i285.photobucket.com/albums/ll66/hillclimbescort/007_zps56dca716.jpg (http://s285.photobucket.com/user/hillclimbescort/media/007_zps56dca716.jpg.html)

http://i285.photobucket.com/albums/ll66/hillclimbescort/009_zps9977d3d3.jpg (http://s285.photobucket.com/user/hillclimbescort/media/009_zps9977d3d3.jpg.html)

http://i285.photobucket.com/albums/ll66/hillclimbescort/010_zps2c3bc81a.jpg (http://s285.photobucket.com/user/hillclimbescort/media/010_zps2c3bc81a.jpg.html)

http://i285.photobucket.com/albums/ll66/hillclimbescort/011_zps0941ebea.jpg (http://s285.photobucket.com/user/hillclimbescort/media/011_zps0941ebea.jpg.html)

http://i285.photobucket.com/albums/ll66/hillclimbescort/012_zps91c563e8.jpg (http://s285.photobucket.com/user/hillclimbescort/media/012_zps91c563e8.jpg.html)

http://i285.photobucket.com/albums/ll66/hillclimbescort/013_zpsad72d795.jpg (http://s285.photobucket.com/user/hillclimbescort/media/013_zpsad72d795.jpg.html)

Just got to fabricate a framework to attach it all to the car now.

[novarally]

And just about to start the 'new' engine up, most of the (temporary) wiring has been done, just need a feed to the fuel pump and the ignition, and it should be running..........noisily without an exhaust;

http://i285.photobucket.com/albums/ll66/hillclimbescort/014_zps13523cd4.jpg (http://s285.photobucket.com/user/hillclimbescort/media/014_zps13523cd4.jpg.html)

And the STACK dash is now in, so more wiring to do;

http://i285.photobucket.com/albums/ll66/hillclimbescort/015_zpsb5ae1264.jpg (http://s285.photobucket.com/user/hillclimbescort/media/015_zpsb5ae1264.jpg.html)

[turbojolt]

**** yes!

[Jonlem]

Spot on. Looks great and it's certainly on the right car. Sounds like you had a busy weekend.

[Mazz]

holy-funking-****balls :) Almost as sexy as Stuart!

[toymex]

Looking good Colin

[bazzap8389]

Nice purchase there colin!

[L14MNP]

Fantastic machine that just keeps evolving for the better.

[SGA33]

Oooooooooooooooooooof....................:)

[boffer8]

Really nice Colin, should be a massive weight saving. Shame about the size of the arches, as in how close they are to the circumference of the wheel, will create quite a lot of drag in those, shame you can't do some 'air curtain' work like a lot of new BMW's to reduce it a bit.

[8valve-craig]

Looks pretty serious. I can't remember what trailer you have, will it still fit on?

[novarally]

Looks pretty serious. I can't remember what trailer you have, will it still fit on?

I have a Brian James A-Max, with a 6' 5" bed width, so it will be fine.

[Kev Turbo]

Love this!

Car has just stepped up another notch or two on the awesomeness scale - congrats!

[Southie]

pooorn

It needs a massive PNG logo on the bonnet ;)

[8valve-craig]

I have a Brian James A-Max, with a 6' 5" bed width, so it will be fine.

Just seen it on the last page, not quite sure how I missed that, but yes its plenty wide enough ey.

[Benn]

front looks mega mean now, nice buy on that and the boot.

What's going on with the drivers door? Looks riveted on and like it hangs very low at the bottom..

[Connor]

Wow, looks fantastic!

[novarally]

front looks mega mean now, nice buy on that and the boot.

What's going on with the drivers door? Looks riveted on and like it hangs very low at the bottom..

The door was reversed into by a fellow racer whilst it was open!

I do have some fibreglass doors to go on, but they're not really light enough for my liking.

Now I have so much carbon on the car I want to get some nice 'weave showing' carbon doors made for it. One day.

[Benn]

Ah i see, that was good of them.... The bugs bitten you now hasn't it....

[Mike]

Now I have so much carbon on the car I want to get some nice 'weave showing' carbon doors made for it. One day.

Some nice visual doors too. Look tidy that will.

You defo got the carbon bug Colin lol

[mowgli]

ffs colin, that looks amazing, and a little scary, actually a lot scary..

do you need to space the front wheels out????

[M Sutton]

Looks good with the new front end! Very mean!

[novarally]

ffs colin, that looks amazing, and a little scary, actually a lot scary..

do you need to space the front wheels out????

Thanks, I'm really pleased with the way it looks and fits. It will be nice to get the carbon tailgate on as well, but that is going to be bonded into place, so I need to relocate the fuel filler as that's currently inside the boot.

As for the front wheels, the ones that are on the car in the photos are my narrower 'wet weather' ones, so I think the arches will look more filled out when it's got the 7.5" or 8" wide wheels I use on the front in dry weather.

But there is an option to space out if necessary.

[novarally]

Some nice visual doors too. Look tidy that will.

You defo got the carbon bug Colin lol

I need someone to make them though Mike.............can you help?

[novarally]

A fair bit of effort has allowed me to shift the pedal box as far as is possible to the right;

http://i285.photobucket.com/albums/ll66/hillclimbescort/037_zpsd771c098.jpg (http://s285.photobucket.com/user/hillclimbescort/media/037_zpsd771c098.jpg.html)

http://i285.photobucket.com/albums/ll66/hillclimbescort/036_zpsc5064976.jpg (http://s285.photobucket.com/user/hillclimbescort/media/036_zpsc5064976.jpg.html)

This has made the placement of the pedal box as close to perfect as it's possible to get, given the fixed location of the inner wheel arch.

It also means that I'm reasonably confident that the carbon fibre false floor and clutch footrest can be persuaded to fit in there, with a little bit of adjustment;

http://i285.photobucket.com/albums/ll66/hillclimbescort/034_zps885455e2.jpg (http://s285.photobucket.com/user/hillclimbescort/media/034_zps885455e2.jpg.html)

http://i285.photobucket.com/albums/ll66/hillclimbescort/035_zps4ca63f33.jpg (http://s285.photobucket.com/user/hillclimbescort/media/035_zps4ca63f33.jpg.html)

http://i285.photobucket.com/albums/ll66/hillclimbescort/033_zpsca1a0910.jpg (http://s285.photobucket.com/user/hillclimbescort/media/033_zpsca1a0910.jpg.html)

[toymex]

Looks good Colin ,I like the carbon floor

[therealnovaboy]

Surely the carbon floor is dead weight? I cant see you having much time to rest your foot.

can you not just fit some skateboard grip tape to the floor to stop your heels sliping about.

[Benn]

Is the clutch foot rest not a bit far forward?

[novarally]

Is the clutch foot rest not a bit far forward?

Yes, that's why it needs to be modified!

It's not dead weight if it gets my feet into the right position to be comfortable in the car. My feet need to be raised, so tape on the floor won't do that.

I think people underestimate just how important it is to be sat in the perfect position, for safety, weight distribution and of course ultimately car control.

I doubt I will use the clutch footrest on a hillclimb, but this was the best quality carbon fibre false floor I could find, at a good price, and it happened to have a footrest built in.

Who knows, if I ever do a trackday it might be useful.

[Benn]

Ah sorry didn't see that bit. Should be to hard to be moved by a lamonator (sp?)

[8valve-craig]

Yes, that's why it needs to be modified!

I think people underestimate just how important it is to be sat in the perfect position, for safety, weight distribution and of course ultimately car control.

I completely agree. A Nova floor slopes downwards into the tunnel, so a correctly fitted pedal box see's your left heel considerably lower than your right. Unless you have very big feet that also means that your toes are lower on the clutch pedal and will be working your leg muscles harder.

I spent weeks getting mine right, but can say with confidence that it is absolutely perfect for me.

[novarally]

Ah sorry didn't see that bit. Should be to hard to be moved by a lamonator (sp?)

I'm just going to cut a section out of it so it can slide around the pedal box, which will push the clutch footrest right up to the bulkhead (or thereabouts).

[novarally]

I completely agree. A Nova floor slopes downwards into the tunnel, so a correctly fitted pedal box see's your left heel considerably lower than your right. Unless you have very big feet that also means that your toes are lower on the clutch pedal and will be working your leg muscles harder.

I spent weeks getting mine right, but can say with confidence that it is absolutely perfect for me.

Wise words indeed.

Mine is going to be 95% perfect, if I could it would go a little bit more to the right, but I cannot do that because the wheel arch intrudes into that space.

But it's a hundred times better than it was with the original pedal box that came with the car.

[novarally]

Not an update on my car, but after a 7-year absence from motorsport, it was great to welcome back Kevin and Ian Plummer today at Gurston Down hillclimb;

http://i285.photobucket.com/albums/ll66/hillclimbescort/008_zps0ca5b333.jpg (http://s285.photobucket.com/user/hillclimbescort/media/008_zps0ca5b333.jpg.html)

http://i285.photobucket.com/albums/ll66/hillclimbescort/010_zps34f4ccb7.jpg (http://s285.photobucket.com/user/hillclimbescort/media/010_zps34f4ccb7.jpg.html)

http://i285.photobucket.com/albums/ll66/hillclimbescort/009_zps67519227.jpg (http://s285.photobucket.com/user/hillclimbescort/media/009_zps67519227.jpg.html)

http://i285.photobucket.com/albums/ll66/hillclimbescort/007_zpsdecb2ca7.jpg (http://s285.photobucket.com/user/hillclimbescort/media/007_zpsdecb2ca7.jpg.html)

http://i285.photobucket.com/albums/ll66/hillclimbescort/006_zps34e7cd70.jpg (http://s285.photobucket.com/user/hillclimbescort/media/006_zps34e7cd70.jpg.html)

A very successful return it was as well. The car previously used a 2.0 XE, but following the rebuild it has a 1639cc smallblock 16v engine with an XEL head, couple to an F20 Quaife SCCR gearbox with ATB.

Note the wheels - ex-works Astra 16" magnesium in ET49. Looks great.

[toymex]

Very nice Colin ,I love it

[8valve-craig]

I was on my way up, but decided not to at the last minute as we would have arrived just before lunch time. Wish I had now.

Note, Note.... Wheels have fixing threads in them for the super rare brake cooling fans. Those would have been on either the Works Mk3 Astra or the Opel Calibra.

[novarally]

Very nice Colin ,I love it

Hi Jezz.

The owner of this car lives about 5 minutes from you........I will introduce you to one another.

Colin

[novarally]

I was on my way up, but decided not to at the last minute as we would have arrived just before lunch time. Wish I had now.

Note, Note.... Wheels have fixing threads in them for the super rare brake cooling fans. Those would have been on either the Works Mk3 Astra or the Opel Calibra.

Shame you didn't make it Craig, it was a good day.

Yes, they did have the cooling fans, unfortunately Kevin didn't get them with the wheels, and like you say, they are incredibly rare now.

[toymex]

Hi Jezz.

The owner of this car lives about 5 minutes from you........I will introduce you to one another.

Colin
Please do Colin ,I would love to take my engine builder to see them and talk about the engine

[novarally]

Please do Colin ,I would love to take my engine builder to see them and talk about the engine

Kevin built this engine himself (with input from Steve at SBD), and he's done a brilliant job on it.

Very good power and excellent torque on standard cams, and there's potential for more yet (I won't post the numbers on here!).

I will pass on your number to Kevin so you can get together.

BTW - with reference to our Mad'In split rims, I have now found out that Gotti centres are the same bolt pattern, and therefore interchangeable. Might be useful info for you.

[novarally]

The carbon fibre tailgate from UPG in Bulgaria;

http://i285.photobucket.com/albums/ll66/hillclimbescort/007_zps537760dc.jpg (http://s285.photobucket.com/user/hillclimbescort/media/007_zps537760dc.jpg.html)

This is going to be bonded into place, so it won't be removable in future. Which is a problem as my fuel tank filler currently resides in the boot.

So, I either need to relocate the fuel filler position, or move the tank completely. I think this is my preferred option, so I picked up this 3.5 litre tank to experiment with;

http://i285.photobucket.com/albums/ll66/hillclimbescort/003_zpsa0ca8c71.jpg (http://s285.photobucket.com/user/hillclimbescort/media/003_zpsa0ca8c71.jpg.html)

It fits rather neatly above the gearbox;

http://i285.photobucket.com/albums/ll66/hillclimbescort/001_zpsd4c7a8b7.jpg (http://s285.photobucket.com/user/hillclimbescort/media/001_zpsd4c7a8b7.jpg.html)

http://i285.photobucket.com/albums/ll66/hillclimbescort/002_zps56e19b9e.jpg (http://s285.photobucket.com/user/hillclimbescort/media/002_zps56e19b9e.jpg.html)

It will mean I need to remove the one-piece front end every time to fill the tank, but it does away with all the pipework inside the car, saving a fair bit of weight.

[Benn]

Could you not make the front flip forward?

[novarally]

Started work on making the rear caliper mounts - as luck would have it I can just weld 2 captive nuts direct to the axle!;

http://i285.photobucket.com/albums/ll66/hillclimbescort/002_zps05c88c71.jpg (http://s285.photobucket.com/user/hillclimbescort/media/002_zps05c88c71.jpg.html)

http://i285.photobucket.com/albums/ll66/hillclimbescort/001_zps7cba2610.jpg (http://s285.photobucket.com/user/hillclimbescort/media/001_zps7cba2610.jpg.html)

http://i285.photobucket.com/albums/ll66/hillclimbescort/003_zpsf633a9a5.jpg (http://s285.photobucket.com/user/hillclimbescort/media/003_zpsf633a9a5.jpg.html)

http://i285.photobucket.com/albums/ll66/hillclimbescort/004_zps079a6074.jpg (http://s285.photobucket.com/user/hillclimbescort/media/004_zps079a6074.jpg.html)

and a rather neat packaging solution to mating the fuel pump to my new tank;

http://i285.photobucket.com/albums/ll66/hillclimbescort/005_zps43c4ed11.jpg (http://s285.photobucket.com/user/hillclimbescort/media/005_zps43c4ed11.jpg.html)

Just need to make up new fuel lines for that and sort out a tank breather.

A friend of mine has machined up some alloy brackets to mount the front calipers, they should be arriving on Monday so I will post up some pictures.

[burgo]

That rear brake set up is the bollocks

[fearless]

Other than possible bleeding problems (pressure bleed or remove to Bleed) that looks like a nice easy modification :)

[dgbnova#1]

Please see some of my FAO posts

[Benn]

How come you're mounting the caliper at the bottom?

[boffer8]

A very successful return it was as well. The car previously used a 2.0 XE, but following the rebuild it has a 1639cc smallblock 16v engine with an XEL head, couple to an F20 Quaife SCCR gearbox with ATB.

Note the wheels - ex-works Astra 16" magnesium in ET49. Looks great.

Do you know if that is a Z16XEL or X16XEL head Colin? The cam cover is Z16 but that doesn't elude to below ;-)

[stt]

Any updates Colin?

[L14MNP]

I heard he bought a carbon fibre spoiler and it won't fit.

[dgbnova#1]

lol lol lol ^

[rallypvc]

Any progress Collin

[Stuart]

For whatever reasons, Colin appears to have vanished from the site... Be that personal problems, or business issues etc. So I wouldnt expect any updates for a while

[Mazz]

Last Activity : 19-08-14 05:42 PM

[novarally]

A little bit of progress to report, I got the rear axle all built up and installed, there's still a load of jobs to do, but it's nice to at least have the back end sat on the floor again;

http://i285.photobucket.com/albums/ll66/hillclimbescort/003_zps7403a4f4.jpg (http://s285.photobucket.com/user/hillclimbescort/media/003_zps7403a4f4.jpg.html)

http://i285.photobucket.com/albums/ll66/hillclimbescort/002_zpseded978f.jpg (http://s285.photobucket.com/user/hillclimbescort/media/002_zpseded978f.jpg.html)

http://i285.photobucket.com/albums/ll66/hillclimbescort/001_zpsa74f6471.jpg (http://s285.photobucket.com/user/hillclimbescort/media/001_zpsa74f6471.jpg.html)

http://i285.photobucket.com/albums/ll66/hillclimbescort/005_zps4a5a41b6.jpg (http://s285.photobucket.com/user/hillclimbescort/media/005_zps4a5a41b6.jpg.html)

http://i285.photobucket.com/albums/ll66/hillclimbescort/004_zpscc672278.jpg (http://s285.photobucket.com/user/hillclimbescort/media/004_zpscc672278.jpg.html)

http://i285.photobucket.com/albums/ll66/hillclimbescort/006_zps399117e6.jpg (http://s285.photobucket.com/user/hillclimbescort/media/006_zps399117e6.jpg.html)

http://i285.photobucket.com/albums/ll66/hillclimbescort/007_zps52f9e86d.jpg (http://s285.photobucket.com/user/hillclimbescort/media/007_zps52f9e86d.jpg.html)

http://i285.photobucket.com/albums/ll66/hillclimbescort/008_zps06d5f85c.jpg (http://s285.photobucket.com/user/hillclimbescort/media/008_zps06d5f85c.jpg.html)

http://i285.photobucket.com/albums/ll66/hillclimbescort/009_zps821a125f.jpg (http://s285.photobucket.com/user/hillclimbescort/media/009_zps821a125f.jpg.html)

http://i285.photobucket.com/albums/ll66/hillclimbescort/010_zpsfa302054.jpg (http://s285.photobucket.com/user/hillclimbescort/media/010_zpsfa302054.jpg.html)

[Southie]

Rear assembly looks very nice Colin, was it straight forward to bleed up?

[novarally]

Rear assembly looks very nice Colin, was it straight forward to bleed up?

Time will tell on the bleeding, as I haven't finalised the fitting of the master cylinders and fluid reservoirs yet.

But if it's a problem I think I have sufficiently long brake hoses to remove the caliper and lift it up.

[Benn]

That looks awesome!

[novarally]

Subframe manufactured to support the one-piece carbon fibre front clamshell;

http://i285.photobucket.com/albums/ll66/hillclimbescort/003_zpsdc270444.jpg (http://s285.photobucket.com/user/hillclimbescort/media/003_zpsdc270444.jpg.html)

http://i285.photobucket.com/albums/ll66/hillclimbescort/002_zps67c26298.jpg (http://s285.photobucket.com/user/hillclimbescort/media/002_zps67c26298.jpg.html)

And I'm about to start playing with the location and mounting for the radiator;

http://i285.photobucket.com/albums/ll66/hillclimbescort/001_zps05198afc.jpg (http://s285.photobucket.com/user/hillclimbescort/media/001_zps05198afc.jpg.html)

[toymex]

Looking good Colin,is the carbon front end really that much longer than a normal nova that you can mount the rad like that ?

[novarally]

Looking good Colin,is the carbon front end really that much longer than a normal nova that you can mount the rad like that ?

Yes, it is a lot longer, I had no idea that was the case until I got it fitted. I guess the guys at UPG in Bulgaria did that deliberately to create more room for there engine install.

Where that flat steel bar is at the front of the subframe is where the clamshell nose comes to.

[toymex]

Loads of extra room then ,easy to duct the air in and out

[Benn]

Will give nice ducy/routing for air flow in too and thought the rad...

[novarally]

I'm now modifying the subframe for the clamshell front, as it was a bit fiddly to get on and off. It will now be more 'quick release';

http://i285.photobucket.com/albums/ll66/hillclimbescort/001_zps898b32bc.jpg (http://s285.photobucket.com/user/hillclimbescort/media/001_zps898b32bc.jpg.html)

And I have acquired some new rear calipers, which are lighter (half the weight of the Wilwood go kart calipers), and were very cheap, so I may end up re-doing the rear brakes yet again! These ones came off a Mini hillclimb car, but originate from a GP motorcycle;

http://i285.photobucket.com/albums/ll66/hillclimbescort/002_zps47fe4451.jpg (http://s285.photobucket.com/user/hillclimbescort/media/002_zps47fe4451.jpg.html)

http://i285.photobucket.com/albums/ll66/hillclimbescort/003_zpsa6894375.jpg (http://s285.photobucket.com/user/hillclimbescort/media/003_zpsa6894375.jpg.html)

But for a little while there will be no progress on this car, as it's about to be put into storage whilst I take delivery of a high-spec. Nova circuit race car. More details on that to follow soon..........so my Nova goes off with standard front suspension and alloys, just to get it rolling;

http://i285.photobucket.com/albums/ll66/hillclimbescort/004_zps3e0c222e.jpg (http://s285.photobucket.com/user/hillclimbescort/media/004_zps3e0c222e.jpg.html)

[novarally]

As per my post about hydraulic clutches in the 'Mechanical' section, I am now searching for a Daewoo gearbox (from a smallblock Daewoo), complete with the clutch slave cylinder, so if anyone can help on that, please let me know. My local breakers yard doesn't have anything.

[8valve-craig]

The White wide arched one by any chance?

[toymex]

The White wide arched one by any chance?
My one is going no where Craig ,it takes a lot of time and effort to get mine to where it is ,I do know the car Colin is talking of though

[8valve-craig]

Oh no no, I never meant yours. I meant the RWD Zetec one?

http://i995.photobucket.com/albums/af79/smith9051/Mobile%20Uploads/5206d38a-5126-4b8c-9909-a19f74b6ba74_zpsef5f15ac.jpg

[toymex]

No it's not that one ,I do need that body kit though :)

[novarally]

Oh no no, I never meant yours. I meant the RWD Zetec one?

http://i995.photobucket.com/albums/af79/smith9051/Mobile%20Uploads/5206d38a-5126-4b8c-9909-a19f74b6ba74_zpsef5f15ac.jpg

Is that one still for sale (or maybe for sale again)? I haven't seen it advertised recently.

[eggy]

As per my post about hydraulic clutches in the 'Mechanical' section, I am now searching for a Daewoo gearbox (from a smallblock Daewoo), complete with the clutch slave cylinder, so if anyone can help on that, please let me know. My local breakers yard doesn't have anything.

Theres a breakers local to me that has 3 Daewoo Lanos in that have the small block GM engines in. There website is www.stockautobreakers.com.

James

[novarally]

Theres a breakers local to me that has 3 Daewoo Lanos in that have the small block GM engines in. There website is www.stockautobreakers.com.

James

Thanks James, much appreciated.

Anyone in that area fancy earning a few quid removing one and taking it away?

I could get it picked up from you.

[eggy]

Im going there in the next couple of weeks as they have a couple of novas there and typicaly the land has been sold and they have got to be gone by the end of january.

If you want to speak to them and see if they have what you want. They will take it off for you and Ill collect one or if need be Ill take one off.

Its an old school beakers where your still aloud to go and climb about on the cars. None of the health and saftey crap like the salvage yards you now get :)

James

[novarally]

Im going there in the next couple of weeks as they have a couple of novas there and typicaly the land has been sold and they have got to be gone by the end of january.

If you want to speak to them and see if they have what you want. They will take it off for you and Ill collect one or if need be Ill take one off.

Its an old school beakers where your still aloud to go and climb about on the cars. None of the health and saftey crap like the salvage yards you now get :)

James

Cheers James, that's very good of you. I'll give them a call.

Colin

[novarally]

Theres a breakers local to me that has 3 Daewoo Lanos in that have the small block GM engines in. There website is www.stockautobreakers.com.

James

James.

I rang them this morning and they reckon there's no Lanos's left now! Apparently they've been having a clearout. Gutted.

[Southie]

PM'd Colin.

[novarally]

This spaceframe Integra I just spotted for sale is rather inspirational, very neat packaging of the engine and ancillaries in particular;

http://racecarsdirect.com/listing/57105/tube_chassis_drag_integra.html

[novarally]

I've just found a Daewoo Lanos less than 2 miles from me which I have bought for £120. Seemed like the easiest way to get the complete gearbox with hydraulic clutch mechanism.

It's got a 1349cc Vauxhall-based 8v engine, I haven't done any research yet, but this seems like an odd engine size compared to what was fitted into Vauxhalls.

[novarally]

The silly things we do for our Novas......buy a complete Daewoo Lanos (horrible) just to get the gearbox for my clutch conversion;

http://i285.photobucket.com/albums/ll66/hillclimbescort/015_zps6529202c.jpg (http://s285.photobucket.com/user/hillclimbescort/media/015_zps6529202c.jpg.html)

http://i285.photobucket.com/albums/ll66/hillclimbescort/016_zps8ca3a5b5.jpg (http://s285.photobucket.com/user/hillclimbescort/media/016_zps8ca3a5b5.jpg.html)

http://i285.photobucket.com/albums/ll66/hillclimbescort/017_zps8644b73a.jpg (http://s285.photobucket.com/user/hillclimbescort/media/017_zps8644b73a.jpg.html)

[bazzap8389]

Haha disgusting car lol

[novatracker]

I did that with a a3 for the rear brake setup to be fair was cheap cheap and got cash back with parts sold and scapping it. Score

[novarally]

My Xmas present to myself for the Nova;

http://i285.photobucket.com/albums/ll66/hillclimbescort/064_zpsadc312ff.jpg (http://s285.photobucket.com/user/hillclimbescort/media/064_zpsadc312ff.jpg.html)

A box of interesting looking carbon fibre bits from the Jordan F1 team.

[BRoadGhost]

Definitely some kinda tie bar setup in there

E-Tec just kicked in yo

[novarally]

Definitely some kinda tie bar setup in there

E-Tec just kicked in yo

No tie bars unfortunately.

At the top of the photo are carbon/aluminium water pipes. and at the bottom of the photo they are described as 'side impact bars' - not quite sure exactly where these would have been used in an F1 car.

In the rest of the box there are also some carbon fibre straps for supporting silencers (I think) and some bits called 'nose inserts', which are solid carbon fibre, about 2.5cm long and about 10p sized diameter. Again I'm not sure what the function of these was, but they look ideal for drilling through and using as spacers/bushes.

[novarally]

Change of plans on the engine, and the gearbox. Long term I'm still planning to get my 1000cc turbocharged engine rebuilt, and use that, but in the meantime I've acquired a slightly more modified 16v motor.

Previous engine comes out;

http://i285.photobucket.com/albums/ll66/hillclimbescort/001_zps786aba0f.jpg (http://s285.photobucket.com/user/hillclimbescort/media/001_zps786aba0f.jpg.html)

While the replacement waits to go in;

http://i285.photobucket.com/albums/ll66/hillclimbescort/003_zps279f94b0.jpg (http://s285.photobucket.com/user/hillclimbescort/media/003_zps279f94b0.jpg.html)

At the same time I'm revising the fuel delivery system, and will probably go through with my plan to re-locate the fuel tank to the front of the car, to keep thing simple;

http://i285.photobucket.com/albums/ll66/hillclimbescort/002_zps46b1b147.jpg (http://s285.photobucket.com/user/hillclimbescort/media/002_zps46b1b147.jpg.html)

As for the gearbox, I've decided to go back a step, at least for the moment.

When the car last raced I was using a Quaife F15 SCCR 'box with the straight cut 4.5 CWP, and a Tran-X plated LSD. The 4.5 was never quite suited to the hillclimbs I was doing, but there was no other option available from Quaife, and being the F15 single-piece pinion shaft, getting something custom made was ridiculously expensive.

So I'm going back to an F13 SCCR Quaife gearbox, and then I've got the option of using any of the standard CWP's from the F10/F13 range of gearboxes.

A 4.1 FD was what I always used to use, so that's what's been installed ready for next season, if I ever get the rest of the car ready.

And I'm going back to a Quaife ATB LSD, although I may decide to change to a 3J Driveline plated LSD if I feel the need. I was never entirely comfortable with the Tran-X LSD, it made the car very unfriendly to drive.

[Andy]

Its all go!
Much to do before first meeting colin?
When is first meeting of the season?

[novarally]

Its all go!
Much to do before first meeting colin?
When is first meeting of the season?

The hillclimb season starts in early April, and there's a huge amount to be done, but I'm determined to be out there competing again, after 2 years + enforced absence.

The car is totally untested and undriven since my big crash in June 2012, and will have different brakes front and rear, plus the new 'spaceframe' front-end, as well as a different engine.

Just need to make the time to get it all ready now.

[nova_stee]

If you spent half the time racing this than just changing things you might get somewere