Project: Gold Snowplough Turbo [Archive] - Page 5 - Performance Nova Group

Nova_Tek

04-05-12, 08:24 PM

Continuing on from yesterday...

I had a spare few hours in the early afternoon to try get some stuff done.

First up was cutting off the lug on the gearbox. Whipped out the diamond metal cutting wheel (This bad boy again... not made from diamond lol )
https://images2.imgbox.com/6c/9a/uyGY5Ijt_o.jpg

http://img269.imageshack.us/img269/7640/1003183z.jpg
A few minutes and 25,000 rpm later it was off :)
https://images2.imgbox.com/ad/f9/xMx41ose_o.jpg
http://img52.imageshack.us/img52/4129/1003184a.jpg

I took it right back as far as I could. I then gave it a quick rub down and coated that bit in Hammerite too.

I then took the bolt which I was going to use as a sump bolt for the diff pan and chopped that to size. Great thing is that the hex head is 19mm just like the oil sump bolt so one socket for both.
http://img801.imageshack.us/img801/2183/1003185l.jpg

I then wanted to give the diff plate some oil resistant lacquer to protect the paint as I had left it as a matt black.
https://images2.imgbox.com/72/dc/cWdeXEbb_o.jpg
http://img607.imageshack.us/img607/1894/1003188w.jpg

All that is left is the gearbox seals and I think I'll need to organise driving down to the other side of the Thames to hand over the LET to be put together.

:thumb:

Nova_Tek

14-05-12, 10:43 PM

UPDATE

After working 9 days straight, today was a day off... Kinda woke up a bit late lol

I got these in the post

Fly wheel cover
https://images2.imgbox.com/95/d8/R4GkI7IK_o.jpg
http://img208.imageshack.us/img208/757/1003193a.jpg

Long wiper linkage as mine was too worn to hold on to the ball joint
https://images2.imgbox.com/f9/8a/UTW009f2_o.jpg
http://img705.imageshack.us/img705/3131/1003192r.jpg

Then made a trip to my second home.... Vauxhall!

Got what I've been looking for... oil filter pick up
https://images2.imgbox.com/50/5e/U5dWMT9n_o.jpg
http://img535.imageshack.us/img535/4686/1003191z.jpg

Then went over to Halfords to get some washers with the trade card.
http://img641.imageshack.us/img641/7209/1003190q.jpg
https://images2.imgbox.com/e9/d2/LPhQTAdU_o.jpg

Smaller pack was £3.99 and the large washer pack was £9.99. Got the lot for £7 on trade :)

Gave the wiper linkage a coat of black to stop it from rusting and for it to make the rest of the linkage that I sprayed up before. Just need the weather to ease up so I can sort stuff out.
https://images2.imgbox.com/81/bc/7B5Myodb_o.jpg

Benn

14-05-12, 11:03 PM

Wiper bit wont rust, but good work.

Nova_Tek

15-05-12, 05:08 PM

Cheers Benn, I know they don't rust as such but they still go manky and dirty which is why I painted it.

Here it is anyway all dry
http://img855.imageshack.us/img855/2655/1003200m.jpg

Got these in the post also... some misc M6 & M7 hex bolts
https://images2.imgbox.com/c8/73/YuZmwnry_o.jpg
http://img27.imageshack.us/img27/7453/1003199q.jpg

Sun came out so I jumped into the garage to get the gearbox gaskets on... started off with the cluster and forgot to take a picture. I then did the end plate gasket and made sure I took a picture :)
https://images2.imgbox.com/79/eb/0WsaB2RR_o.jpg
http://img826.imageshack.us/img826/7738/1003194o.jpg

I then moved on to the selector housing gasket and forgot to take a picture again, typically remembering that I didn't as I was doing up the bolts lol

Wanted them to dry completely before I turned it upside down to do the diff cover... so I moved on to the seals. Thought I was on to a winner when trying to remove the o-ring seal but I only took of the metal ring :(
https://images2.imgbox.com/54/7d/D9bzslai_o.jpg
http://img19.imageshack.us/img19/7987/1003197k.jpg

Then came out the hammer. I tried to prise it out with the hammers forks underneath the seal with another hammer persuading it off. I felt it started to give but it didn't budge hmm.....
http://img833.imageshack.us/img833/4982/1003195m.jpg

One bent hammer :(
https://images2.imgbox.com/31/9b/QsaU3dYM_o.jpg

And one half chewed up seal
http://img607.imageshack.us/img607/6351/1003198r.jpg
https://images2.imgbox.com/d8/fc/yn486ULJ_o.jpg

Then started the thunder and hail. Off I went in.

Is there not a better way to take these out apart from butchering them?

I also realised that the oil filter pick up screw I got yesterday is not the right one... it is the correct one for the LET but won't work with my sandwich plate. It's too short for it to actually fix the sandwich plate to the pump and give enough thread for the filter to screw on to, but too long to use the sandwich plate's own extender pick up thread. I should've got a non-oil cooler pick up screw like off a SEH or XEV etc.

Shall have to order one.

Iain

15-05-12, 05:33 PM

I remove the shaft seals from behind with a punch and they come out fairly easily, although not overly useful unless you're willing to take them out/drop the diff out.

There's a spring behind the rubber part so make sure that hasn't fallen off into the gearbox casing during your butchering.

Nova_Tek

15-05-12, 05:37 PM

I had my mate change the diff recently, totally forgot to tell him to get the seals off ( I was at work so wasn't involved with it). I know that these seals no matter where they are, pretty much need to get ripped out for them to come off but this one didn't shift with all that force. May need to make up some sort of pulling device.

Nova_Tek

17-05-12, 10:05 PM

UPDATE

Another couple hours of free time today so I decided to have another go at removing the seals.

Raided the garage to see what I could find to help me... then found my trusty crow bar

Just managed to fit it into the hole and gave it a few whacks with the hammer (a different one ). Then removed the crow bar and put the hammer underneath the seal. A couple jerks and off it popped
https://images2.imgbox.com/b0/3e/nzxJaXvw_o.jpg

Cleaned up the area
https://images2.imgbox.com/28/b6/BBIAQMVz_o.jpg

and gave the bearings a good covering/packing of LM bearing grease.

The seals I took off had a bit of gasket type sealant around it so I did the same with the new ones. Took out my largest socket to 'persuade' the seal in and ended up butchering it

Got the other one out and tried to use a different tactic... nope still messed it up. Need a much bigger socket in order to uniformly apply pressure around the outer most edge and not the middle of the metal section of the outer part of the seal (which is what had bent while trying to fit it). So contacted the ebay seller that I got the seals off to see if I can buy some more.

I then removed the diff oil filler plug to clean it up and found this inside it
https://images2.imgbox.com/c9/28/WxdmdtNW_o.jpg

Tis a magnet! IIRC this isn't standard issue right? Either way I kept it and gave it a good clean. So I've gone and delayed myself due to butchering the new seals so will be getting that sorted in the week when the new ones arrive.

On the look out for a quality scuttle cover as I hate the standard noisy, thin, cheap cover that covers the heater blower motor.

Benn

18-05-12, 05:43 PM

That's the level plug, filler is the breather on the top. Never seen one with a magnet on before.. Wont really do much being up there either... Seals are a night mare too fit. I use a bit of 2.5" exhaust tubing to tap them home.

Make a scuttle cover, they are easy as.

Andy

18-05-12, 06:28 PM

I use a 30something mm socket to fit the seals,acting as a drift.
I also fill mine via the selector housing hole,much easier imo.

Nova_Tek

18-05-12, 08:20 PM

See all the mechanics that I've seen fill a Vauxhall diff with oil is via this plug as when it overflows it means it's got the correct 1.8/1.9 litres of oil. Apparently the selector housing hole it just a breather. either way works so don't really bother me.

May be something I will just make when everything is sorted as it's not urgent.

I had a 32mm socket but that only covered the inner metal section of the seal and bashing it bent that section. May have to find a metal pipe like you said Benn.

Nova_Tek

18-05-12, 08:31 PM

UPDATE

Nothing major but I've sorted out the sandwich plate. The oil pick up threaded tube I got was the wrong type (that was to use with the standard sandwich plate). So on the phone to Autovaux yesterday ordering a standard non-oil cooler threaded tube and it arrived today... swift!
https://images2.imgbox.com/dd/7b/X817y7Ph_o.jpg
http://img109.imageshack.us/img109/7895/1003205f.jpg

And all the relevant bits now fitted to the oil pump... yay!
http://img13.imageshack.us/img13/3302/1003206m.jpg

That is all for now...

Nova_Tek

24-05-12, 05:20 PM

UPDATE

Busy week at work... keep forgetting to arrange a day to drop the engine off to my mechanic mate :( and now I have man flu... feel totally bushed!

I got this today dropped off by the courier guy
http://img262.imageshack.us/img262/6024/1003207.jpg
https://images2.imgbox.com/b6/ff/yFt2bWyT_o.jpg

Millers Fully synthetic 10w-40 for the LET. I got it together with an aluminium portable Toshiba 500GB hard drive for £11 lol (thank you Amazon e-voucher!)

Still waiting for the oil seals to arrive for the gearbox... at least the weather is starting to get better (now that I'm ill :( )

BRoadGhost

24-05-12, 05:33 PM

My gearbox plug is like that too. When I first removed it there was some pickup on it :)

Iain

24-05-12, 05:41 PM

Yeah that magnet in the level plug is normal. Being at the top of the fluid level I guess it picks up anything metal that floats? Filling via the breather hole and checking the level with that plug is easy really.

Nova_Tek

25-05-12, 08:24 PM

Cool... infact if you remove the breather nipple from the selector housing you can fill the box up quicker ;)

Nova_Tek

06-09-12, 09:56 AM

UPDATE

It's been a while so I thought I'd just update everyone on what's happening right now.

I've slowly been doing the usual parts look out for little bits and pieces I need for the build. Being married for 4 years, priorities change to which they have. Decided that buying a house is one of the most important things currently... so I've been saving as much of my wage up as possible to be able to afford a down payment for my first place. This has no doubt slowed the project down.

Work has been full on, which I actually don't mind as it gets me closer to affording a place and in this day and age more work isn't a bad thing. I did actually manage to have a few days off in a row back in July, which I arranged to go down to south London to drop the engine off to a good mate to get it built (like I mentioned in the last few updates). I was certainly feeling good and excited. Got the LET in bits into my brothers Cav and headed down. Took 50 mins to get there lol

Met up with the fella and he come to sort out some details with what was what etc. He took one look and the block and started shaking his head. He said that the bores had uneven wear and would be better off getting it re-bored or changed. To say I was p*ssed off is an understatement, as I said to the engine shop to let me know what was needed. They said a 'light hone' would be fine. The mechanic did say that he could quite easily rebuild it in its current state and it will run ok for a short while but it would use up oil like nothing else and that I'd be back in not much time after. He felt very uncomfortable knowing the condition and for him to go ahead and rebuild it. He had a couple of his colleagues take a look just to get other opinions.

Decision time:

Change block? or Re-bore?

I've opted to go for re-bore and oversized pistons as I didn't wanna risk buying another block and for that to need honing or boring etc.

40thou rebore (1mm) to increase to 87mm together with 87mm pistons. Looking at pistons, there isn't a substantial difference in price between 86.5mm & 87mm. Boring of the block costs the same for both sizes. Spoke to my other mate who spoke to his mate who owns the engineering shop that did the honing. He had a 'word' with his staff lol and said that he'd deduct the price of the hone off the re-bore - result!

Block is at the shop, which I dropped off before I went on my holiday for it to be checked out. I'm just waiting for the Omega pistons to arrive for me to take it to the shop so they can start on the re-bore. Only problem I have is I need to try return the 86mm Mahle piston rings back to AutoVaux.

That's where the project stands...

Nova_Tek

19-09-12, 01:46 PM

UPDATE

A bit more productive this time...

Went and met Steveboyslim in the morning to pick up my new pistons... we're about 5 miles apart so to save time and postage fees a quick trip to him was best.

He's a top bloke with plenty of knowledge and sense... picked up these beauties
https://images2.imgbox.com/46/4e/Fb0JVCg4_o.jpg

https://images2.imgbox.com/16/af/KXADkTkN_o.jpg

http://imageshack.us/a/img207/1127/imag0621i.jpg
https://images2.imgbox.com/94/3f/BbgOhbYT_o.jpg
http://imageshack.us/a/img850/8783/imag0620n.jpg

Pure engineering Pr0n- 4 new Omega pistons with rings, pins and clips.

Then went and had a spot of breakfast and dropped the pistons to the engine shop to measure up and bore to the exact size.

Should get the block back in the next few days...

brainsnova

19-09-12, 02:48 PM

Does Steve look like his brother fatboyslim

Nova_Tek

19-09-12, 07:07 PM

lol not quite

Paul

19-09-12, 07:53 PM

Looks like chips dad...

Balley

19-09-12, 11:03 PM

The diff plate is a nice little touch

Nova_Tek

19-09-12, 11:13 PM

Cheers dude... should be very handy and a practical solution :)

novacabrio

10-11-12, 08:16 PM

Any updates??

Nova_Tek

11-11-12, 03:26 PM

UPDATE

Just for the record I got my block back a few weeks ago, all re-bored to 87mm. Have tried to get the engine down to my mates shop but he's been away or I've been working a full week

Have had trouble finding enough free worth while time to actually get any real progress done

Now that I had bought myself an impact gun, I could finally attack the calipers and change the front brakes... unfortunately it wasn't as easy as that! Even with the gun at full trigger it wouldn't budge. Tried WD40 but still, then tried a wrench and a big ol' mallet. Still seemed impossible. A trip to Halfords found a can of 'Shock & Unlock' - a penetrating fluid which shock cools the nut/bolt and allows it to free off. This time I made myself a make-shift breaker bar from different tools and hollow tubes so I could angle away from the arch/wing.

After much force I heard a snap! Still very difficult to undo but that's where the impact wrench did the rest... Finally the caliper was off!!!

Next problem was the fact that the little brake disc retaining screw was bent and was a nightmare in itself to take off. Eventually got the disc off, hub looking good and less dirty/rusty that I guess it would be.
https://images2.imgbox.com/14/26/CcqwisEH_o.jpg

Gave the disc shield a good old clean and gave it a coat of stone chip. I had to also bend the shield back a few mm's as the larger discs would obviously foul the shield.

Trial fit the disc to make sure it cleared the shield.

https://images2.imgbox.com/52/9a/vjFLkTCV_o.jpg

Now it was time to fit the calipers
https://images2.imgbox.com/37/fe/9wyj1pPR_o.jpg

Totally easy to fit which was a breath of fresh air as everything else leading up to it was a bit of a pain. Then fitted the brake lines.

During my last visit to Haldfords I got a litre of DOT 5.1 brake fluid for £5.39 (normally £13 - thank you trade card). Bled the front brakes thanks to the £2.99 bleed kit from ebay. There is good pedal feel, nice and firm but I want to bleed the rears as the old fluid is the really old DOT 4 from about 4 years ago. Still need to fit the new Goodridge rear lines but no doubt once fitted and the rears bled there should be an even better feel.

Was my birthday last weekend... got the usual pressies like clothing, money and smellies but also got two things which would be really useful. One of them would be this:

Prosport PSi Boost Gauge
https://images2.imgbox.com/cf/fc/aRmlZePf_o.jpg

https://images2.imgbox.com/82/a5/m3U1NlLS_o.jpg

Comes with everything you need to get them to work, they can be daisy chained so you only need to wire one in and the rest will run off the other. This model is setup by a touch sensitive control switch, multiple colour display and have warning beep or peak light which can be setup to desired value.

Here's how it should look when on as when they are off the dial face is almost blacked out
https://images-na.ssl-images-amazon.com/images/I/61iuy12wkZL._SY355_.jpg

The other gift on it's way - it's a vernier pulley to help dial in the XE inlet cam when it is fitted.

I'm trying my best to get this project finished but time is definitely of a finite abundance at the moment.

Benn

11-11-12, 07:34 PM

Ooo the gauge is very nice.

Nova_Tek

12-11-12, 10:36 PM

They are Benn ;) This one, which is top of the range is only £60

Nova_Tek

09-12-12, 12:50 PM

UPDATE

Been real busy... unfortunately not on the Nova :(

Busy with work as usual taking on more responsibility and work as my manager was away for a whole month thus me having to take care of as much as I could. Worked solid 6 days a week, but not going to complain though as it's miles better than being unemployed so I can only be grateful. This does mean that the Nova is still on hold, and to be honest I can't see anything further happening until things go back to 'normal' after christmas & new year.

I have got a couple more new bits to add to it, but just to give you an idea of how much time I don't have... I got these bits almost 3 weeks ago. Compared to how quickly I used to update my thread before this is dire!

Anyway got a friend for the boost gauge:
https://images2.imgbox.com/ab/ba/pjplxg2V_o.jpg
http://img14.imageshack.us/img14/573/1003211e.jpg

And got these as well:
https://images2.imgbox.com/da/57/NydPEuv0_o.jpg
http://img819.imageshack.us/img819/5344/1003210t.jpg

Brake disc securing screw. Only needed one but Vauxhall only sold them in 25's lol

Hoping to get more bits 'n bobs over xmas/new year to add.

Really need to get this project in to gear (pardon the punn) after the new year... I am beating myself up for the big project slow down but such is life.

Benn

09-12-12, 03:11 PM

I got one of them pillar pods, but ordered the wrong one. If you still want one i have a mk1 fit one here.

Nova_Tek

10-12-12, 10:26 AM

Is it black in finish? 2 pods? How much on trade? lol

Benn

10-12-12, 05:23 PM

Carbon, single...

Nova_Tek

17-12-12, 10:48 PM

Ahhh, I need a double pod :( thanks anyway

TonySR

29-10-13, 02:06 PM

Any updates?

Edd

06-04-15, 05:58 PM

What happened to this?

scott.parker

08-04-15, 09:25 AM

Good question.. So many good bits bought..

Benn

08-04-15, 12:58 PM

He's not signed in in over a year... So prob dead.

Southie

08-04-15, 01:50 PM

He's not signed in in over a year... So prob dead.
The car I hope you mean Ben :eek:

ben doodar

08-04-15, 08:43 PM

Shame I liked this project.

Benn

08-04-15, 11:32 PM

The car I hope you mean Ben :eek:

lol sorry yes i do.

Christ, did a bit of stalking. As he hadn't filled in his name in his profile here, i googled his email addy, that took me to his Mig account, which had his name in it.
Found the same name on a twitter account and that he is First team manager at Ware FC.
I know his name, but dont know what he looks like to know if its the same dude...

brucer

09-04-15, 07:12 PM

Sure he worked in telecoms and abroad...may be wrong.

Southie

09-04-15, 07:16 PM

Stalker alert Ben lol

Benn

10-04-15, 01:32 PM

Got to be done.

ben doodar

10-04-15, 10:00 PM

"I have is a particular set of skills"

Southie

24-09-15, 07:47 PM

So as I know he's alive I'll be looking forward to an update Mr Tek ;)

Nova_Tek

04-05-20, 08:13 PM

Here's a partial update for you all 7 years, 4 months & 3 weeks since my last one... thanks for waiting!

I first need to re-host the billion photos on to somewhere better than imageshite I mean shack, before I re-start the project. This will help me get back on track of what's been done and what I was last doing as my mind has been off the project for many years (obviously).

I've recently moved in to my new home and I've started prepping the garage for receiving the Nova and half of the engine, which is at my parents garage (once social distancing allows).

scott.parker

05-05-20, 08:22 PM

Yes! Man, about time you showed up! Lol

uh60

06-05-20, 12:26 PM

Looking forward to seeing it again. I for instance use Imgur and Flickr but the last ones interface is a pain in the back.

Nova_Tek

24-05-20, 12:01 AM

Evening all... hope all you old boys are doing well ;)

It's taken me 2 and a half weeks to re-host the 900+ images. Not surprising that I ended up with a few images missing but not many. For anyone that's interested I'm hosting them on imgbox.com - free, unlimited storage and simple really :cool:

Anyway, now that it's done, I'm up-to-date (again) on what I had done with the project, where I got up to etc. Back all those years ago, the aim of the project was to have a powerful but reliable daily to use, however, that's now not the case. The daily is now currently an Astra G GSi and if all goes well I'll be retiring that for a more grown up family car (with some poke of course :d ). So the Nova really is now going to be a weekend toy and a bit of fun. This means that certain things may be revisited when the project restarts. Will need to see how much time I can spare on it, now that I'm a family man. Either way I'm looking forward to resuming the project.

Just don't ask me when I'll finish it, please lol

Things I'm considering doing in addition to what's been done so far (in no particular order)

- Bigger brakes (256mm was last fitted)
- Bigger wheels (something different maybe 17")
- LSD
- Uprate the conrods (currently standard)
- Headwork while it's out
- Chipped ECU to make use of the engine work.

One thing that won't change is my level of OCD and making everything shiny and new looking :d

I do need to go arrange picking up the other half of LET as I've got bits at my parents (where the Nova is currently laid up) as soon as 'rona allows us.

Until the next update :thumb:

The Simps

24-05-20, 08:24 AM

Great to see another project resurrected, well in principle anyway - pics or it never happened! [emoji13][emoji23]

Looking forward to seeing how she’s looking after all these years [emoji106]

Nova_Tek

24-05-20, 11:11 PM

Great to see another project resurrected, well in principle anyway - pics or it never happened! [emoji13][emoji23]

Looking forward to seeing how she’s looking after all these years [emoji106]

Sorry Simps, I'm a little rusty, I forgot about the pics or gtfo rule.

Before the Nova and any of bits can be brought back, I wanted the garage to be a place best suited for it's purpose.

A few things need to be done:
- rubber matting/flooring to be laid
- suitable shelving to store bits, pieces, tools etc
- upgrade the lighting as the developer thought a 5.5w light bulb is sufficient for a 20 metre sq. area :confused:

Rubber matting arrived recently and was fitted the other day.

Before
https://images2.imgbox.com/cd/32/FXOlZtDI_o.jpg

78 kilos of rubber later
https://images2.imgbox.com/f6/27/mnE4czO7_o.jpg

Shelves should be arriving soon, then I can start gathering all the bits together.

The Simps

24-05-20, 11:32 PM

Thats better ;)

Nova_Tek

24-05-20, 11:48 PM

Thats better ;)

:thumb:

nova_niek

25-05-20, 11:32 AM

Nova_Tek

25-05-20, 10:36 PM

Hey Tek, good to have you back on here. Threads like this give me much needed inspiration to get my finger out and start on my GSi that has been sitting for almost 20 years now. Looking forward to updates. Also liking your rubber floor. Any good with regards to potential oil spills and other abuse?

20 Years!? Sheesh has it been that long? Makes me feel a little better I must say :) You just need to find your motivation. For years I totally forgot that the Nova was sitting there because of the many priorities and responsibilities I had to deal with, but I needed to get back my hobby to be able to chill and let the mind relax. I'm sure you'll come to a point where you'll want to resume it. Obviously having some disposable income to be able to fund the project is always very helpful. And look at it this way, 20 years of not driving, less miles on the chassis and other components, less moisture and salt, less chance for rust and now they're rarer ;)

From what I recall the rubber floor is non-porous and non-absorbent so should be fine with any small oil spills, better than it staining the fresh concrete.

Nova_Tek

30-05-20, 10:56 PM

Received a box of goodies this week

https://images2.imgbox.com/52/31/BLcsEzS7_o.jpg

Got it off eBay, direct from Germany for £45. Just over an hour and they were ready to go

https://images2.imgbox.com/c8/e8/2nPAWQXx_o.jpg

Apparently they can hold over 800kg each which is impressive, though I won't be trying that out anytime soon. Need to arrange picking up my tool cabinet and as much as the Astra can carry in engine parts!

Nova_Tek

07-06-20, 09:55 PM

UPDATE

Nothing exciting at the moment (for those reading) - Had the opportunity to go collect bits and pieces from my parents place yesterday. I already had about 35% of the LET, so it was a matter of collecting the rest and picking up the engine stand and tool cabinet. Good old Astra dealt with the load with relative ease with the seats folded down.

Got home and unloaded the Astra and started organising all the bits. Shelving ended up pretty much rammed full of engine parts and chemicals!
https://images2.imgbox.com/a4/a4/bqhRTJbc_o.jpg

Got the block on the engine stand ready for some overdue work.
https://images2.imgbox.com/05/4c/ZVLT0eGT_o.jpg

Will be going through parts to see exactly what I've got making sure there's nothing missing, and anything which isn't needed put it up for sale to help fund new bits :d

Need to check out the turbo and see what state it is. Also want to check the ECUs to see if there are any issues with them.

The Simps

08-06-20, 08:47 AM

Let the real work begin!

Nova_Tek

08-06-20, 12:12 PM

Let the real work begin!

;)

Nova_Tek

16-06-20, 10:44 PM

Update

Found a couple hours to start going through stuff, and then realised that a couple hours in the garage passes by in 30 mins.

I came across a few things that I need to double check as it's been way too long to remember vital details, so I was hoping I could get some input from the big brains on here.

First up were the XE cams, part number shows as 90322027 - this one is the shorter inlet one
https://images2.imgbox.com/84/5b/rAma5wpb_o.jpg

And the other longer exhaust one has 2091358 072 stamped on it and nothing else.
https://images2.imgbox.com/f9/1d/QrgoPPaS_o.jpg

Searching the web yields some varying results for the first (inlet) cam but the 2nd one (exhaust) seems to always result in an XE item. Unfortunately ecat no longer exists and that would've given a definitive answer, whereas 7zap catalogue doesn't narrow down the part number. Can anyone confirm if the top cam is an XE cam?

I have another pair of cams which were fitted to the LET as it arrived - 90423011 & 90423010 These part numbers come up as LET cams

Next up was the drive shafts. Originally I bought the first pairs which were 22 spline but it turned out to be 22 spline on both ends, which if I recall correctly are for the Corsa B. I then bought a pair off a fellow PNG user. Having counted the splines it's 28 splines on both sides. The shafts fit the inner CV's I bought which in turn fit the F20 box, but I'm wondering which CVs I'd need for outers? Also, anyone know what the 22 spines Corsa shafts are used for? e.g. big block Corsa B conversion or Corsa GSi etc? Need to get them sold ;)
https://images2.imgbox.com/49/b2/zQzTbg5T_o.jpg

Finally, I cracked open the ECUs (I have 2 of them) to see what's what as I hadn't done any investigating on what I bought when I first got them.

This one was the ECU which looked like it was previously opened
https://images2.imgbox.com/b6/41/aApCoWXy_o.jpg

As you can see I found a pair of Superchips installed. I've since read many varying reviews of Superchips and most tend to lean towards negative than positive. Not sure how useful these will be in my build. I have set myself a target of 300bhp for my build, but based on reviews I doubt these chips will be useful. Can't really get much info on these based on the numbers on the chip. Any ideas? Again, if they're of no use, I'll put them up for sale.

The other ECU was untouched
https://images2.imgbox.com/0d/28/H9lTaRQt_o.jpg

Planning to do some more work over the weekend if things go to plan.

The Simps

17-06-20, 09:26 AM

I've of absolutely no help with your questions but good to see another bit of progress, no matter how small.

Will F

17-06-20, 09:54 AM

Superchips will be the equivalent of Phase One - so 240 ish. Courteney used to supply them

Nova_Tek

17-06-20, 11:31 AM

Cheers Will F, I'll probably get rid of them. I doubt they'd make use of the work on the LET. Chips seem to be hard to get hold of so might go down the route of a re-map if I can fond someone who can reprogram the standard chips. I'd rather have a custom map or a top notch chip. But this is probably the last thing I'd need to do and I'll decide when I'm closer to it lol

Will F

19-06-20, 10:25 AM

Yeah - i'd only go with genuine EDS chips with the switches tbh

Nova_Tek

19-06-20, 09:03 PM

Yeah - i'd only go with genuine EDS chips with the switches tbh

Yeah I'm asking a mate of mine who had a Calibra DTM, he had a chip and switchable map, but he doesn't recall who did them. I see EDS still do these for 599 euro, however.

Nova_Tek

21-06-20, 12:08 AM

Update

Had a bit of time to myself today (about 8 minutes worth :roll:), continued with checking things out to get a handle on things that may be needed.

Had a look at the head
https://images2.imgbox.com/5b/c8/USkEzm6b_o.jpg

Checked the inlet ports
https://images2.imgbox.com/10/bf/8fLgPzdp_o.jpg

And the exhaust port
https://images2.imgbox.com/58/ec/t2cccsXG_o.jpg

Is it me or has this been ported? When comparing the exhaust port to the inlet port, the inlet deffo looks untouched and this looks like it's been modified.

Next was the turbo, I never took it apart so I had to see what state it was in. It took hours to remove the manifold nuts, and even once they were all off it was fused to the manifold, I had to use brute force to get it off.
https://images2.imgbox.com/3b/f2/kS8TYK13_o.jpg

Let's just say it's not in a useable condition lol The turbine doesn't freely spin, seems to grind against the heat shield shroud and sounds very crusty. There's also some end float so it needs a desperate freshen up. Anyway here's the rest:
https://images2.imgbox.com/e8/9a/y5XkV4tl_o.jpg

https://images2.imgbox.com/cb/04/T3ZynEGH_o.jpg

https://images2.imgbox.com/94/e5/oA2E8Zef_o.jpg

https://images2.imgbox.com/65/f6/ak4UdW8J_o.jpg

Problem I can see is trying to find the correct/quality refurb parts for the turbo, or just get a replacement. Need to raid the web for info. The budget won't stretch to a different turbo and a new/custom manifold at the moment. If in the years to come I do, then internals will be able to handle it, but until then it'll be the K16.

The shopping list is now:

- Turbo (replacement/refurb)
- ARP fastenings (flywheel/head studs & nuts/rod bolts)
- Oil squirters and block modification... as well as the bits I mentioned earlier:

- Bigger brakes (Vectra B 308mm)
- Bigger wheels (something different maybe 17")
- LSD
- Uprated rods
- Headwork while it's out (if needed)
- EDS chips.

I'm also considering ceramic coating on the standard manifold and turbo housing, have read good reviews about it.

When it comes to head gaskets, I already have a Victor Reinz composite head gasket and the rest of a head set, but will it be able to handle power of 300 bhp? I don't need to lower compression in any way as the pistons are 1mm oversized and low comp.

totalnova

21-06-20, 11:20 AM

That exhaust port definitely looks like its has some type of sanding drum down it, although nothing major as you can still see the casting mark's.
Nick

Nova_Tek

21-06-20, 09:58 PM

That exhaust port definitely looks like its has some type of sanding drum down it, although nothing major as you can still see the casting mark's.
Nick

Cheers totalnova, yeah I wasn't sure how effective it was, for the reasons you said. I've never attempted a port or polish, so not sure about doing it in order to finish off what has been started. Would be great to learn but don't feel like looking for another head (due to bodging it), especially after this one has had some prior work done to it. Will need to find a reliable person to do the polishing.

While we're on the subject of port and polishing, any benefits to smooothing out ports on the manifold? I've seen in the past people (yanks) doing this on boosted engines. I have 2 manifolds so wouldn't mind having a go on that especially if it helps even in the smallest way.

steveboyslim

03-07-20, 07:45 AM

I have only just seem your message, still supplying parts, still building engines, still have the same phone number.
I have replied to your message (three weeks late)
The most reliable specification is bored, skimmed, oil jetted block, skimmed pressure tested head oil gallery sleeved if not coscast, uprated single valve springs,INA lifters, set of my Omega pistons which you have, steel rods, arp head stud kit, arp main cap stud kit, arp flywheel bolts, TTV billet flywheel all cleaned checked and rebuilt with new gaskets, bearings, belt kit and water pump, after that cams and vernier pulleys, but if on a budget, leave the cams and verniers put the money towards and aftermarket ecu and engine loom, something like MBE or DTA

Thanks

Steve

Nova_Tek

03-07-20, 02:44 PM

Hi Steve,

Thanks for getting back to me (I got your PM). I'll give you a call over the weekend regarding what I'd like to get done.

:thumb:

steveboyslim

05-07-20, 07:07 PM

Any time you like.

Steve

Nova_Tek

23-12-20, 09:10 PM

Howdy all, hope everyone is well. It's been a few months I know, but I deliberately left updates to be done in bulk otherwise they'd be one photo posts and a bit boring!

A few things have been done over the last few months to progress the project forward. First up was the block. There was plenty of signs of rusty crustiness in it, so I had to try make it better. It started out in this way:

https://images2.imgbox.com/bd/7a/Gd167dw6_o.jpghttps://images2.imgbox.com/83/2c/VSfq4Pm5_o.jpg

It was pretty much like this all over
https://images2.imgbox.com/c8/d0/f62WOlDG_o.jpg

https://images2.imgbox.com/c1/25/6AZgOIgg_o.jpgz
You can see the crust around the top of the waterways as well as get a glimpse of the rusty material in the block itself. Some might say leave it as is, but I'm likely to opt for waterless coolant seeing as the there is no trace of water in the system at all, it's a perfect time. Granted, it'll need a proper flush out but it's worth getting as much out whilst dry.

This is how it looked after a going over it with a sanding cone and the dremmel, didn't want no harsh grinding which the grinding stone would've done. Tried to get in there as deep as possible... it eventually looked like this:

https://images2.imgbox.com/7e/42/QtdHIhFf_o.jpg

https://images2.imgbox.com/92/91/Y2VRs6tw_o.jpg

https://images2.imgbox.com/bf/0b/6Ar2TZbj_o.jpg

Far better.

Turned the block over to get and loose bits out
https://images2.imgbox.com/c3/f4/TL5hTkBr_o.jpg

Having seen all this I had to clean it out with something, so I decided to get the block flushed with some distilled white vinegar, which most of us will know has some rust clearing abilities.

Got the block plugged up and sealed:
https://images2.imgbox.com/05/4c/ZVLT0eGT_o.jpg

Who knew that Cavalier mk3 rear shock rubber mounts are a perfect fit to plug the block?
https://images2.imgbox.com/af/4a/ZGvnrCFh_o.jpg

Then filled it up with the vinegar
https://images2.imgbox.com/83/1b/lCKHOjyJ_o.jpg

I actually left it for a couple days and emptied the block, ran some more vinegar through it allowing it to come out from the water pump aperture. Thought I snapped more pics but this was the only one I actually took... none-the-less from starting off very crusty, the vinegar dissolved most of the crust
https://images2.imgbox.com/f6/5a/KiSR9UKV_o.jpg

After allowing the block to dry off with the help of a hairdryer, there was a fair bit of residue on the silver paint. Seeing as it was already masked up, I thought I'd recoat it in high temp block paint, but this time in gloss black.
https://images2.imgbox.com/1d/dd/1cCBC7cx_o.jpg

https://images2.imgbox.com/8c/a9/UMws27K4_o.jpg

Certainly prefer it in black...

The Simps

23-12-20, 10:13 PM

All clean and shiny [emoji4]

What?s next?

Nova_Tek

23-12-20, 10:32 PM

The following day, once the paint had properly dried, it was time to fit the new core plugs on the rear of the block.

https://images2.imgbox.com/e6/51/gNvBjUmZ_o.jpg

Opted to smear them with some Loctite 5940 sealant
https://images2.imgbox.com/fe/c5/SAmE9BlF_o.jpg
Less than a 5 min job
https://images2.imgbox.com/96/3d/2kHKK8I2_o.jpg

After going through all the bits for the project out from storage, aka my parents garage, I came across the new offside engine mount and thought I'd give them the Polyurethane sealant treatment and stiffen them up a little bit.

https://images2.imgbox.com/73/3c/45uxKfZq_o.jpg

Stiff as funk once cured
https://images2.imgbox.com/fa/9c/P6zDipac_o.jpg

Then I focused my attention on the gearbox, which was still in place. After a lot of faffing about, I got it out
https://images2.imgbox.com/60/3d/348uqp8o_o.jpg

This gave me a chance to get the rear and nearside gearbox mount out to benefit from some the stiffening up treatment. I was pleasantly surprised at their condition, they barely look used aside from some dust and dirt.
https://images2.imgbox.com/05/12/j4wEMGIv_o.jpg

Now that the gearbox was out, had a good look underneath to see if there was any rot... everything looks sound! Really happy with the condition. This made me think about sealing any vulnerable areas i.e. the entire car lollol:lollol After a few mins of deliberation, I decided that it'd be worth going round everywhere which had a seam or overlapping panel and properly seal it. I'll likely only use the Nova in the dry, but even then, prevention is better than cure.

I started off with the drivers front wheel well. Lots of overlapping panels, gaps and holes which mud, dirt, water will love. So out came the seam sealer:
https://images2.imgbox.com/aa/fc/12yX9O93_o.jpg

https://images2.imgbox.com/01/90/8nXx8MIJ_o.jpg

Let this dry as is and will re-visit and apply liberal amounts of stonechip/waxoyl or like protective coating. Of course there's a ton of other areas like this that need the same treatment, but given how cold the weather is I'll wait until its not as cold and humid.

In the meantime, I contacted Steveboyslim and had a good long chat over the phone, and then face to face. Top bloke, says it how it is which is what I prefer to hear. Fortunately, he lives a 10min walk from me. So with the block in one hand and the head in the other, I walked over to his.... no I didn't! Drove there in the daily and discussed what was going to get done.

Block is having the oil jets put in as all else is a-ok.

The head on the other hand was going to get a once over to ensure it's all good, and this was what was on the to-do list:
- remove snapped heat shield studs
- repair thread on one exhaust stud (last firm 10 years ago replaced a broken stud with an oversized one)
- GM head porous mod
- Head skim
- uprated single valve springs

Handed the bits to Steve to start the work, during which I got a call to say that the valves currently fitted were not sodium filled or GM items. This made some sense... for those that remember, the old pistons had some visible surface damage from valve interference, so it seems that last owner had replaced the many bent valves with an incorrect set. Fortunately, Steve had a set of proper GM sodium filled LET valves to hand, which were re-lapped and fitted (the set which were removed were originally re-lapped and the head had new valve seats fitted 10 years ago).

Eventually, picked up the head and will be picking up the block in the new year (Cheers Steve!).
https://images2.imgbox.com/74/aa/o5Oa5Eom_o.jpg

Only things needed to source are the turbo, rods, fastenings, and also need to think about what oil pump route to take.

Steve recommended a zLET/H pump with a modded pickup pipe for better oil pressure, only issue is getting a good 2nd hand original pump, as aftermarket ones are poor quality.

Either that or opt for a LET pump with both internal pump gears replaced with strengthened items. Apparently oil pressures still won't be much improved.

So some thinking to do, but will get there.

Nova_Tek

23-12-20, 11:29 PM

My time was then consumed by the daily which kept bugging me as the front bumper was peppered with stone chips, I couldn't take it anymore, so I decided to sort it out.

As it took much of my time, I'll post it up

Looks good from far
https://thumbs2.imgbox.com/1b/1f/txs42CGA_t.jpg

But the bumper was far from good :(
https://thumbs2.imgbox.com/b6/da/WZbuEeSU_t.jpg

https://thumbs2.imgbox.com/2c/65/Rho9VHgb_t.jpg

https://thumbs2.imgbox.com/26/f5/qy351EPx_t.jpg

https://thumbs2.imgbox.com/34/a7/F7VXSZxN_t.jpg

https://thumbs2.imgbox.com/a9/7b/pswbnnMu_t.jpg

https://thumbs2.imgbox.com/d6/d0/rzXhjGhm_t.jpg

Over many weeks that followed it slowly got better. It took a while to get done as I was doing it bit by bit during lunch breaks from work, the odd couple hours I had over a weekend etc...

https://thumbs2.imgbox.com/d0/09/elELMemG_t.jpg

https://thumbs2.imgbox.com/5b/53/W27omkZY_t.jpg

https://thumbs2.imgbox.com/f5/d0/TRgVH3Bs_t.jpg

https://thumbs2.imgbox.com/14/89/vXWtGfLD_t.jpg

Nova_Tek

23-12-20, 11:54 PM

Despite all this rubbing down, there remained many stone chips still, so I had a bit of a brainwave and decided to blob on some filler primer on to remaining chips...

https://thumbs2.imgbox.com/72/5b/M9PWZQXF_t.jpg

https://thumbs2.imgbox.com/2c/4e/gYtb01jy_t.jpg

This worked well and cut down the time on rubbing down. Then it was down to the deep scratches with some proper filler
https://thumbs2.imgbox.com/6d/75/937XSf6W_t.jpg

https://thumbs2.imgbox.com/3b/c5/rQlzQ2eh_t.jpg

https://thumbs2.imgbox.com/98/c7/AUhyC1oS_t.jpg

https://thumbs2.imgbox.com/15/88/7yIv8CGI_t.jpg

https://thumbs2.imgbox.com/f1/16/bgnVFe3L_t.jpg

After lots of hand action, dropped some filler primer which was white, rubbed that down and dropped some further high build primer

https://thumbs2.imgbox.com/04/ae/AfhgznCa_t.jpg

Then came some stopper (fine filler) for the small imperfections and the stubborn stone chips that still hadn't disappeared (which were still a lot lol)
https://thumbs2.imgbox.com/3b/40/9GQlFWTB_t.jpg

https://thumbs2.imgbox.com/17/3d/GH4tzVuJ_t.jpg

Then came some final coat of filler primer, rubbed down smooth and then plastic primer

https://images2.imgbox.com/b7/29/y7uraEt1_o.jpg

[IMG]https://images2.imgbox.com/97/01/UJtGcVlr_o.jpg

https://thumbs2.imgbox.com/7b/2b/bX30VgiA_t.jpg

Far too cold in the garage to lay the top coat and clear coat, so for the time being it'll stay like this until the weather becomes milder.

nova_niek

24-12-20, 04:27 AM

The Simps

24-12-20, 10:37 AM

I replied too soon! You have been busy!

So what's next? lol

Nova_Tek

24-12-20, 11:24 AM

Oooh lots of elbow grease here! Impressive work.

Word of warning: I've always been told primer is hygroscopic. You might want to check into this before laying down any base coat and clear coat.

Verstuurd vanaf mijn SM-A505FN met Tapatalk

Cheers fella!

Checked the can for any info, no warnings were given. It's been on for a couple months with no ill effects. If it goes Pete Tong no biggie, won't take long to reapply. Trust me, I spent so much time perfecting that bumper that I'll doubly make sure everything is top notch before doing the top coat lol Really don't want to have to re-do everything after the time it took.

I replied too soon! You have been busy!

So what's next? lol

Next up Simps, is to return everything I bought for Christmas so I can get the rods, turbo and fastenings lmao.

On a serious note, I've got to get the rest of the underside/wheel wells etc seam sealed, get the bottom track control arms over to someone to weld the strengthening plates in, final parts - Headgasket, headbolts, rods, in order to be able to start putting the motor together, and also need to consider getting an LSD and get it fitted while the gearbox is free.

torquey

24-12-20, 12:52 PM

Looking good love a gsi mk4. Engine looking sweet too.

Nova_Tek

24-12-20, 08:11 PM

Cheers Torquey, you wouldn't think she's done 169k miles! They're great motors.

Yeah it's getting there slowly but surely.

torquey

24-12-20, 09:23 PM

Would love one maybe one day.

Nova_Tek

03-01-21, 09:29 PM

First update of the year...

Picked up the block from Steveboyslim which has had the BMW oil jets installed.

https://images2.imgbox.com/72/f3/qQmI64Wv_o.jpg

https://images2.imgbox.com/8a/3c/W4T7Fl0W_o.jpg

https://images2.imgbox.com/ad/4d/V2UHBPvO_o.jpg

https://images2.imgbox.com/4c/27/b9nPnbRz_o.jpg

Need to go over the block and clean the flash surface rusting that's occurred and make sure there are no bits of swarf that will cause havoc later on, but with that being said I'm pleased with the job, very tidily done. Cheers Steve!

Need to source some forged rods next.

Also need to look at cleaning the screw threads all round the block, what do you chaps suggest for the thread cleaning?

House

03-01-21, 10:12 PM

Did Steve bore it?? If he did I'd send that back mate!!

Steve can do better than that!!

Nova_Tek

03-01-21, 10:23 PM

No he didn't bore it, just did the oil jets.

It probably as the camera was set to supermacro, everything looks mental in that mode!

House

04-01-21, 08:27 AM

I'm sure it's fine, just a shame it wasn't kept oiled!!

Nova_Tek

04-01-21, 11:04 PM

those hone marks are not visible to the naked eye in that way and feels smooth uniform across the cylinder wall. The block has been to a few people for some work in the past to get it to this point and no one has raised concern :)

Nova_Tek

05-06-22, 12:24 AM

Evening to you all.

I know it's an all too familiar occurrence of this project losing momentum, but rarely do plans actually happen as I hope. I can't believe it's been nearly a year and a half since I did an update!

Unfortunately, I've been dealing with a divorce since autumn last year. The ex-wife pulled that one out of no where. This, of course, has consumed most of my energy, emotions and funds, and so the Nova has been put on the back burner... again!

My plans haven't changed, and I aim to pick up where I left off soon as this mind-f*ck is over.

Anyway, chaps (and chapettes) I look forward to giving you all a better update!

Stay frosty!:thumb: :thumb:

bazil

05-06-22, 09:01 AM

Sorry to hear this mate, at least once the divorce is over you’ll have this as a distraction to move on.

bazil

05-06-22, 09:02 AM

Sorry to hear this mate, at least once the divorce is over you?ll have this as a distraction to move on.

Nova_Tek

05-06-22, 10:44 PM

Sorry to hear this mate, at least once the divorce is over you’ll have this as a distraction to move on.

Thanks bud. Any hobby to distract the mind is a good thing, in any situation... so yeah, it will certainly help. Frankly I look forward to it lol

Nova_Tek

05-06-22, 10:44 PM

loldouble post!

Benn

06-09-22, 11:52 AM

Sorry to hear the news. Hope your sorted soon

House

08-09-22, 02:53 PM

Chin up fella.

scott.parker

09-09-22, 05:03 PM