The Counts 1.7 TD GSI nova

[Count Vaux Alot]

So here we go again lol

After much house related saving and being sensible I decided i was fed up of not having a nova to actually drive around in as my track car project is at a stand still for one reason or another so here is the latest project.

Some of you will recognise Craig Greens shell others wont but he decided to part company with it and i decided i could do something with it.

So the plans are to fit a 1.7td engine out of a cavalier, add a front mounted intercooler, up the fuel up the boost and have some reasonably priced fun so here goes:

Up to now i have a 1.5td donor car that i have owned since 2004 that my brother has been borrowing for too long. He has now brought it to the end of its life body work wise, so i will be using a selection of parts from that to fit the cav td lump. Again i have already acquired the engine and several other parts.

Pics...


Collecting the car from CG

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD001.jpg

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD003.jpg

CG himself

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD002.jpg

All ready to go

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD004.jpg

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD006.jpg

Reasonably clean underneath

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD005.jpg

And its current resting place on the drive with the addition of a white bonnet to keep the engine bay a little less moist!

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD009.jpg

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD008.jpg

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD014.jpg


Some pre td engine bay shots

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD015.jpg

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD016.jpg

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD019.jpg

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD020.jpg

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD021.jpg

[Count Vaux Alot]

This o/s chassis leg will be changing a little to accept the td engine mount

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD017.jpg

I think im going to repair this boost pipe hole with bits from the donor

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD018.jpg

A very annoying dent

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD022.jpg

A heavily faded boot that needs some attention

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD013.jpg

I'm going to have the inside stripped out so the sound deadening had to go

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD010.jpg

Here are some goodies ready to go including a new gsi velo radiator and a frontera intercooler

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD023.jpg

One cavalier 1.7td donor car looking very sorry for its self

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD040.jpg

And the 1.7td engine out and ready to be stripped and rebuilt - turbo removed ready for an upgrade as the original IHI unit is tiny :d more details to follow!

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD037.jpg

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD063.jpg

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD025.jpg

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD026.jpg

[Count Vaux Alot]

As the shell has already had the rear arches turreted (see pics below)

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD011.jpg

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD012.jpg

I had no other option other than to fit a set of coil overs (thats my excuse anyway lol) so when a set of Gaz came up at a reasonable price locally i was more than pleased to take them off the guy.

The fronts have seen some use but the rears are almost new, apparently the rears had only been on the car in the body shop when it was being painted as they fouled the tyres so he removed them - bonus!

Here is how they looked when i collected them

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD075.jpg

Grubby but serviceable fronts

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD055.jpg

VGC rears

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD047.jpg

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD057.jpg

Me being me i wasn't happy with the state of the fronts so they came apart for a clean up.
One side came to bits with little hassle the bottom spring seat was a stiff but turned the other side was sized to fook!

Most bits dissembled

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD067.jpg

The one offender that wouldn't move for sh!t

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD031.jpg

So out came the saw - ha ha now it was off

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD059.jpg

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD061.jpg

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD056.jpg

Ready to be cleaned

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD071.jpg

In the degreaser then the hot was (the bodies didn't go in the hot was before anyone starts!)

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD068.jpg

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD044.jpg

[craig green]

Ooh hello, good to see a start James! Very interesting project IMO. So glad she will live on.

[Count Vaux Alot]

Once the bits were dry and free of grease it was time to tape them up ready for blasting!

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD078.jpg

The bodies were done by hand in the hand shot (very fine sand)

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD073.jpg

They came out rather well - one done one to go for comparison

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD043.jpg

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD035.jpg

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD039.jpg

Both sorted

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD060.jpg

The rest of the bits went in the big shot blaster (stainless steel shot)

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD069.jpg

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD054.jpg

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD029.jpg

Then it was time to get everything masked, primed (with acid etch) and painted.

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD041.jpg

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD062.jpg

I did all the bits and bobs in black

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD074.jpg

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD048.jpg

And the bodies in red as thats what was on offer for free

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD051.jpg

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD065.jpg

[Count Vaux Alot]

Only the beginning CG much more to follow when i get some more time on the net lol

[John]

wow! Top project! I'm sure, knowing you, it'll be excellent!

[Connor]

1.7td Gsi
Now thats what i am talking about :cool:

[craig green]

1.7td Gsi
Now thats what i am talking about :cool:

DSi

[comptoncj]

looks like an interesting project chap, gimme a shout when your working on it and il pop round and have a look :)

[Balley]

Wow, a fellow Derv,... I will be watching this one

[Mattman]

good work so far mate, looking forward to the progress

[Benn]

Awesome dude! Glad to see you getting back in to the Nova, Damn nice shell you've picked up. If you need any bits give me a call.

[muzzy]

Nice project, very interesting that you are going with a diesel engine. Have considered doing the same a few times now.

[peester]

be nice to learn diesel tuning specs .. so game on

[Edd]

Good to see Craig's shell living on

[Nobby]

nice to see summat different! good luck!

[Count Vaux Alot]

Cheers chaps like I said more to follow that's already been done plus this weekends activities

[Jackroadkill]

Very interesting that you are going with a diesel engine. Have considered doing the same a few times now.

Me too - looks like it will be a bit different, mate. Good luck.

[burgo]

lush project james :D takes lots of pics of the chassis leg mod

[discoinferno]

good project :)

[Count Vaux Alot]

lush project james :D takes lots of pics of the chassis leg mod

Cheers burgo - your wish is my command, chassis leg pics ahoy! lol

[Angus Closier]

sounds good mate! keep up the good work, this will be a good one!

[dj_wudgey]

good work mate not so shure about the derv though lol

[Adam]

Good project. Started with a sound shell too! :)

[Count Vaux Alot]

Here are last weekends activities

Another donor car looking very sorry for its self - shes a real pear!

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD081.jpg

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD088.jpg

What i really need is under there and i was hoping the o/s chassis leg wasn't too far gone

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD082.jpg

The strip down begins, with the head lights and grill out of the way you can see the state the shell is in

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD099.jpg

When i took the wing off this corner basically crumbled

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD098.jpg

wiring and pipe work on its way out

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD102.jpg

And the chassis leg its self

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD100.jpg

I was getting fed up of the slam panel so cut that out complete as i will probably use it later on - i hadn't realised it before even after owning this nova for so long but the slam is partially removable anyway! (see the pics above the black bit towards the back of the slam panel unbolts i assume its because its a td and that was for access to the turbo?)

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD104.jpg

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD105.jpg

I was beginning to be able to see what was going on now - rad out then bumper off, look at the state of the front panel many previous repairs here.

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD107.jpg

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD108.jpg

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD109.jpg

Once all the wiring and pipe work was out of the way it was time for the trusty seat belt and engine crane

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD113.jpg

Car up in the air

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD114.jpg

Mmmm covered in cement

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD115.jpg

[Count Vaux Alot]

And on to some very substantial stands, no halfrauds crap here!

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD116.jpg

Engine and gear box oils out, suspension etc off

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD117.jpg

Then out with the engine its self - this is the best bit about the car its a good runner still with no smoke etc if any ones interested?

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD118.jpg

And how it was left last saturday night

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD123.jpg

So i started a fresh sunday morning with the grinder in hand :d

One very cripsy looking chassis leg but the important engine mount section is still in good order

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD125.jpg

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD127.jpg

And the section needed to repair the old boost pipe hole in the new red shell - on the td the coolant header tank sits on this side.

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD128.jpg

The n/s corner i said crumbled on wing removal lol

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD138.jpg

Grinder out

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD140.jpg

a few careful incisions later

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD141.jpg

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD142.jpg

I cut the other turret out

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD144.jpg

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD145.jpg

[Count Vaux Alot]

I took both turrets as they were in surprisingly good condition and thought they might be worth something to some one - they are up for sale as of now if anyone is interested?? They have now been blasted and primed (see further pics)

Here is what was left of the o/s chassis leg and inner arch/splash guard

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD143.jpg


I gave the front panel a twist to see how easy it was to move and it folded straight over!

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD148.jpg

Moving my concentration from the engine bay to the rest of the car i salvaged as much as possible for the new shell. This included the wiring loom (very important lol) the dash, wind screen, door cards etc etc.

N/s side door forcibly removed then dash coming out while Mr grinder had a rest

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD129.jpg

Screen out

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD130.jpg

a collection of more debris

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD131.jpg

dash out

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD132.jpg

Loom on its way out

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD134.jpg

Loom gone along with the passengers seat - the passengers is in reasonable condition wear wise but is grubby if anyone wants it for beer money? - the drivers was fooked as the adjuster etc had died and it had multiple rips so i didn't think it was worth saving...

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD135.jpg

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD139.jpg

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD149.jpg

With my attention now on the rear it was tailgate off, fuel tank and filler neck off, and axle off, rear lights out

More debris

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD146.jpg

Leaving the poor old girl on her belly after some heavy abuse

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD150.jpg

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD152.jpg

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD151.jpg

[Mattman]

If no one takes the full engine does it have working starter as mine just recently gave up :(

[Count Vaux Alot]

Sunday over i had what i needed, now it was time to get the bits chopped into shape and cleaned up

So back at work i degreased, hot washed and paint stripped the n/s turret as it needed less chopping up

cleaned

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD122.jpg

painted stripped

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD124.jpg

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD153.jpg

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD154.jpg

Blasted - most of the crispyness left is the inner wing material not the actual turret.

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD155.jpg

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD156.jpg

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD157.jpg

so a little more chopping and cleaning needed

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD168.jpg

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD167.jpg

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD166.jpg

Much better! Acid etch primer finishes things off nicely - ready for a new owner to fettle and fit it!

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD171.jpg

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD170.jpg

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD169.jpg

Finishing n/s i moved to the o/s chassis leg and turret, as you can see they were still as one so needed more of Mr grinders attention.

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD158.jpg

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD159.jpg

[Count Vaux Alot]

Much better more manageable chunks

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD160.jpg

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD161.jpg

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD162.jpg

and some further neatening up

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD163.jpg

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD164.jpg

I will be removing the diesel fuel filter mount from this turret

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD165.jpg

Once things were the size i wanted them it was time to degrease, wash and paint strip again before blasting.

Here is the post blasting results.

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD091.jpg

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD090.jpg

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD085.jpg

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD083.jpg

I then primed everything again ready for fitment (pics to follow)

[comptoncj]

Been busy then, looking good chap

[Count Vaux Alot]

More to follow later lol

[Cormac]

Fantastic bit of butchering lad!! Will be gluded to this thread!!

[Mattman]

Not sure if you would see my post amongst all your pics so requoted while the pic whoring has calmed down....lol


If no one takes the full engine does it have working starter as mine just recently gave up :(

would probably take other decent condition engine bits too, again only if no one wants the full engine and you are just going to scrap it.

[Connor]

Good work Count, turrets came out really good :d
Lmfao at the td shell made out of cookie crumbles lol

[Count Vaux Alot]

Not sure if you would see my post amongst all your pics so requoted while the pic whoring has calmed down....lol



would probably take other decent condition engine bits too, again only if no one wants the full engine and you are just going to scrap it.

Lol sorry for all the pics ive been saving them up - i did see your post and if the engine doesn't go as a whole then it will be sold in bits :thumb:

[peester]

lol start with a piece of rust n build a car around it eh lol

[Mattman]

Lol sorry for all the pics ive been saving them up - i did see your post and if the engine doesn't go as a whole then it will be sold in bits :thumb:

:thumb: just give me a shout when you know mate

[Count Vaux Alot]

During the week this turned up after a prolonged search - its a corsa b 1.7 N/A isuzu engined inlet manifold (for those who don't know) it fits directly to the td and makes the routing of boost pipework from the intercooler much easier as the original manifold is a pain in the @rse!

It arrived in a grubby mess

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD174.jpg

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD175.jpg

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD172.jpg

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD177.jpg

So it was in real need of a clean :thumb:

here it is after i split the two half's and gave it the degrease and hot wash treatment

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD173.jpg

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD176.jpg

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD178.jpg

Surprisingly enough once it was clean i taped up the manifold to head mounting surfaces (to stop them getting roughed up by the blast media) and gave it a blasting, again good results were achieved

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD243.jpg

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD242.jpg

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD238.jpg

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD241.jpg

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD240.jpg

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD239.jpg

We have some bits at work going to be bead polished again so i might be lucky and get this polished as well :d

Todays progress to follow after i've eaten my fish and chips.

[muzzy]

With the N/A inlet, is the intercooler piping the only benefit from it or is it a different design?

[dj_wudgey]

fook me that donor car was a pear lol good work though buddy!!

[Cle]

fair play that inlets looking sweet, look forward to seeing this done :thumb:

[Benn]

Funk me dude, dont mess about a.

[Rickyb]

SUBSCRIBED.com

[craig green]

How many lunch hours do you get in a day, James?

[burgo]

With the N/A inlet, is the intercooler piping the only benefit from it or is it a different design?much better internal design as well imo

exactly work as per usual james :d

[John]

fantastic stuff!

[Southie]

Well looking forward to another build mr vauxalot I do enjoy the thorough cleanliness and thought that go into your builds, also your photos make one hell of a wip also the daily progress updates make me jelouse :cool:

Looks a cracking shell cg sold you for the build and that 1.5 derv may it rip as it was a shiiter lol

Ohhhh yeah subscribed :)

[Pistol Pete]

Looking good so far. You attention to detail and doing things right makes me happy!

[scott.parker]

Well this is a surprise mate, looks a nice new project, i like what your doing, and dam your lucky you landed that job, eh?!

Scott

[Count Vaux Alot]

Thanks to everyone for all the positive comments so far it makes the effort worth while!

Benn - i would like it to see the road for the summer shows so time is short and there is lots to do.

CG - i have been staying after hours to get bits finished

Muzzy - the cooler pipe work advantage is enough of a reason in its self to fit the manifold imo. As said already the manifold allows much easier routing of the pipe work and reduces all the bends and twists the original pipework had - i will post a pic of the original manifold once its off the engine :thumb:
As burgo said its generally a less restrictive flowing design.

Scott - yep the job is ace!

Anyway here are today's efforts:

The primed o/s chassis leg and o/s turret pics that i missed earlier

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD179.jpg

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD180.jpg

The td leg against its petrol equivalent

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD181.jpg

Slam panel marked ready for removal

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD182.jpg

And out

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD184.jpg

The old bits from the td slam will be cut up to replace the red slam so it will be removable.

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD183.jpg

Then i positioned the rad were i wanted it, marked out were the new holes needed to be and hole sawed away. The rad has been centralised and moved further forward to allow for turbo clearance and access.

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD186.jpg

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD187.jpg

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD185.jpg

Here is the cooler balanced in position lol for marking purposes

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD188.jpg

Lower panel marked

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD189.jpg

And cut

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD190.jpg

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD194.jpg

[Count Vaux Alot]

Scab central on the back side

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD191.jpg

Once i was happy with the shape of the cut out it was time to cut a piece of metal to suit, so out came the home sized guillotine very useful

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD195.jpg

chop chop

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD196.jpg

Turning my attention back to the front panel i started to have a further clean up with the grinder and sanding disc

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD197.jpg

This bottom edge looked grubby as fook to so it had to go

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD198.jpg

A little better

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD200.jpg

I shaped the new metal to suit the aperture with the grinder

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD201.jpg

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD202.jpg

Gave the aperture a clean up with some sand paper and busted some primer in there and on the back face of the new metal - i will stone chip it later.

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD203.jpg

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD204.jpg

Tacked it in

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD205.jpg

Then welded up the top edge

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD206.jpg

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD207.jpg

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD208.jpg

[Count Vaux Alot]

Followed by the bottom edge

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD209.jpg

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD210.jpg

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD211.jpg

Here is the drive way come the afternoon lol refreshments time...ham rolls and salt and vinegar crisps GO!

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD212.jpg

Once lunch was over it was time to clean up the front panel

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD213.jpg

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD214.jpg

I then turned over the lip at the bottom of the bottom panel and welded that up too, a little over kill perhaps but it made me feel better, this was a pain in the ass due to the rust.

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD215.jpg

Leaving that to cool off i turned my attention back to the o/s chassis leg, giving it a further trim and clean up leaving it looking quite respectable

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD216.jpg

On to the car its self i cut the petrol mount off the o/s chassis leg as i couldn't see any real reason to keep it. Then i cleaned it up with the sanding disc.

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD217.jpg

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD218.jpg

Time to overlay the old with the new

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD219.jpg

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD220.jpg

Allowing me to cut straight through them both meaning the new section is going to be very similar to the hole

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD221.jpg

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD222.jpg

[djbrowney]

awsome project buddy !

[Count Vaux Alot]

I found some rot lurking in the process

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD223.jpg

old and new side by side

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD224.jpg

And the rough cut hole in the chassis leg in need of some further fettling

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD225.jpg

I was happy as it wasn't a bad fit for a first time try with no alterations though

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD226.jpg

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD227.jpg

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD228.jpg

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD229.jpg

the seam full of rust needs some repair so i gave that a quick sand down to see the full extent of the situation and cleaned up the hole ready for the td mounts insertion

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD230.jpg

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD231.jpg

As early evening approached it was time to set down the grinder and clean up, so i gave the front panel a quick prime over to keep the moisture off

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD232.jpg

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD233.jpg

And chopped up a bit of Ali to blank the original brake servo mounting point (craig had already fitted a corsa b servo and MC)

Marked

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD234.jpg

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD235.jpg

And cut, it needs to be finished off later

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD236.jpg

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD237.jpg

Thats it until tomorrow

[Southie]

Another good update :)

It's amazing how the innerwings still had rot hidden behing them, well actually not surprised though as it's a nova lol

Do you do all the work on your own or do you have helping other helping hands onboard?

[dj_wudgey]

some good progress there mate!!

[scott.parker]

Crikey, i now see what CG mean about his old shell and why he wanted a new one, but looks like it's in safe hands to Be resurrected.

Good going mate.

Scott

[Count Vaux Alot]

awesome project buddy !

Cheers Boss :thumb:


Another good update :)

It's amazing how the inner wings still had rot hidden being them, well actually not surprised though as it's a nova lol

Do you do all the work on your own or do you have helping other helping hands onboard?

Thanks Southie - i do all the work on my own other people tend to just get in the way and not everyone does things to my standards either lol

[Southie]

Don't EVER lower your standards, your wip would be cr@p lol
I've got more respect for you knowing that the effort is all yours. :thumb:

[Count Vaux Alot]

Crikey, i now see what CG mean about his old shell and why he wanted a new one, but looks like it's in safe hands to Be resurrected.

Good going mate.

Scott

Yep the shell has some issues - anyone got a pair of rear quarters?? lol

[muzzy]

The welding on that front panel looks top notch. Interesting information for future reference regarding the N/A inlet.

[Connor]

Cracking progress Count
Keep it up :thumb:

[Lee]

I will be quietly watching this, as i do all your threads. Inspiring stuff.

[burgo]

i proper funking love your threads James. no nonsense crack on and get it done and to a high quality, how they should all be

*edit* voted

[Plug]

wish i had the know how for all this.

good update

[Edd]

I always thought that Craig's shell was solid up front.

Looks like this is going to be a very interesting project.

[Benn]

Damn your welding is good! Where is the car?

Love the work so far, gimme a call if you need bits i'm sure i can sort you most of them..

[Count Vaux Alot]

Benn - the car is in Bedfordshire :( as we wont be moving in to our new house for another 8 weeks or so meaning yet more travelling back and forth at weekends but hay ho lol

I will be needing a gasket fit for the engine along with a cam belt and some other bits if you can sort that sort of stuff through work?

Rain is holding off play out side atm which is really pi$$ing me off, if i mean the person who ordered rain this weekend they are going to get it!

[Count Vaux Alot]

Anyone on here know anyone who does fly wheel machining and balancing?

[sport]

Top work will be an intresting build.

[Benn]

Anyone on here know anyone who does fly wheel machining and balancing?


Yes there's a place in Cadum (juc1) that did mine.

I can get a gasket set yes.

[LEWI007]

Loving this thread, Are you putting a BOV on the TD ?

[Count Vaux Alot]

Are nova td drive shafts the same as the gsi's 22 splined ones?

And no i wont be fitting a BOV as they are a waist of time on a diesel.

[John]

Are nova td drive shafts the same as the gsi's 22 splined ones?

And no i wont be fitting a BOV as they are a waist of time on a diesel.

Some are, some aren't james, just pot luck i guess. Whip the boot off an count em.

[comptoncj]

IIRC yes they are, GTE early GSI and TD are 22 spline

[John]

IIRC yes they are, GTE early GSI and TD are 22 spline

I once bought a 1.5 td with 28 splines in. :thumb:

[Nobby]

quality project mate makes me even more gutted about mine! Pictures are always the best way! ;)

[comptoncj]

I once bought a 1.5 td with 28 splines in. :thumb:

Was it a late TD? on the cv's there is a choice of two (for a gsi) 89-93 or 92-93 the late ones were 28 spline.

[Count Vaux Alot]

28 spline ffs ive just checked...the car was on a J plate 1992.

Looks like its big block shafts and hubs then lol

[comptoncj]

What gearbox you going to use then ?

[Benn]

J i think i still have some 22 spline shafts...

[Count Vaux Alot]

So my alarm goes off at 8am I open my eyes and I felt really positive about what i had got to do today thats until i look out the window and its was pi$$ing it down how annoying!

I pace around for a bit in frustration and prayed it would stop whilst thinking of all the jobs i couldn't do in the rain (welders and rain don't mix
), once i had eaten breakfast the rain had eased off some so out side it was.

Rain

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD245.jpg

A couple of pics of the eps from Edd cheers bud

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD247.jpg

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD246.jpg

As rain was still a threat i decided to strip the suspension down as for some unknown reason i took it off the car in one

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD248.jpg

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD249.jpg

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD250.jpg

Some spannering later, ready to be cleaned

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD251.jpg

The weather was on the change for the better

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD252.jpg

out came the welder but it was short live, I had enough time to do a bit of repair work befor i got wet.

The o/s inner wing were the boost pipe used to run needed some attention, but first i had to repair the repair section lol

Repair section

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD253.jpg

Grot

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD254.jpg

The boost pipe hole to be filled

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD255.jpg

A bit like this

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD256.jpg

I cut the grot out and marked out a new section to go it

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD257.jpg

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD258.jpg

[Count Vaux Alot]

And welded her home - not the best job but it will do as it had started to spit by now

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD259.jpg

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD260.jpg

Cleaned it up all ready to be welded in next week

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD261.jpg

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD262.jpg

And cut out some more rust to be replaced

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD263.jpg

I also cut this small section out of the new td chassis leg so i could get at the second skin when welding it in

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD264.jpg

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD265.jpg

I will weld the cut out back in

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD266.jpg

It was now raining heavily so back inside it was and on with stripping the engine

The old inlet

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD267.jpg

Cavalier heater hoses and engine loom off

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD268.jpg

Inlet off

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD269.jpg

[Count Vaux Alot]

Marked up the injector pipes to save later confusion and removed them

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD270.jpg

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD271.jpg

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD272.jpg

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD273.jpg

Leak off pipes off and injectors out

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD274.jpg

Along with the oil cooler

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD275.jpg

Then i boxed a selection of bits up ready to be cleaned at work - job done for today

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD277.jpg




J i think i still have some 22 spline shafts...
Cheers mate i will keep that in mind, i'm not sure what i'm going to use yet. The 22 spline stuff might get destroyed by diesel torque thats if the gear box doesn't die first :d


What gearbox you going to use then ?
F18 to start with as i already have two unless anyone has any better suggestions?

[bmw156]

some awesome progress.

keep at it :)

i think diesel is the new petrol

[The Simps]

Good to see you pulling your finger out for a change! ;)

x

[Balley]

Well done for the fast work am impressed

[Count Vaux Alot]

Cheers chaps

[Benn]

Did you get my txt?

[Count Vaux Alot]

Few bits done at lunch/after work today

Here it what needed cleaning (its all i could get my hands on to bring back with me but its a start)

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD278.jpg

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD279.jpg

It all went in the degreaser

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD280.jpg

Then the hot wash - slightly at capacity

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD281.jpg

Once i'd dried everything off there were a few bits that i didn't want to blast, they had come up well anyway

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD282.jpg

Then the rest of it went in the blaster

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD284.jpg

Whilst that was doing i taped up the injector pipes

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD283.jpg

And gave them a clean

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD286.jpg

The leak off pipe got the same treatment

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD287.jpg

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD288.jpg

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD289.jpg

The rack washed up quite well too as it was proper grubby - I still need to finish this properly

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD290.jpg

The track rod ends were still seized though lol so out came the gas

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD291.jpg

And a quick wrestle later

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD292.jpg

[Count Vaux Alot]

By that time the bits in the blaster were just about done

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD293.jpg

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD294.jpg

Some bits that are awkward shapes need a little longer or finishing in the coarse hand shot.

I cant decide whether to machine this down or not as i only need to run one belt

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD295.jpg

The plastics washed well

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD296.jpg

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD297.jpg

A couple of bits in primer too, but the rest is still to do :thumb:

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD301.jpg




Did you get my txt?
Yes mate sorry been rather busy - were are those bits from?? FAI?

[Adam]

So handy having access to a shot blaster, amazing how well it cleans things up!

[Benn]

That's cool, they a re Payne stuff.

[comptoncj]

looking good chap

[craig green]

Is it an auto blaster or summat? You leave parts to blast..

[Mazz]

Can't believe how well all those parts have come up, they look almost new

[Mattman]

lovely and shiny, just how I like em'

Good work so far mate

[novacabrio]

Its going to be to clean for an oil burner!!

[Count Vaux Alot]

Is it an auto blaster or summat? You leave parts to blast..
The large blaster is auto as such, in that you set the timer and it gets on with it but we also have a coarse hand shot blaster and a fine hand shot blaster both of which are completely manual :thumb:


Its going to be to clean for an oil burner!!

Were did you chirp up from lol

[bmw156]

.

[Rysee]

.
That's two bolts in either side not one bent one

Edit... i see what you did there

[peester]

if only u can clean the missus eh, stick her in the blaster lol

[bmw156]

if only u can clean the missus eh, stick her in the blaster lol

i like em dirty :d

[burgo]

my brother is very keen to see what you do about the turbo. he has done the usual N/A inlet, front mount and up'd the ful and boost to 24 psi so needs a next step

[Count Vaux Alot]

Any pics of said vehicle burgo? What box and clutch is he on?

Turbo details to follow in the near future as i've already started working on it but i'm not quite finished yet - and there are a couple of options :)

[krobinson]

Great work, most interesting thread of the year so far!

[vaughanmc]

Should be very well done going by the XE Saloon and the 3dr track weapon

[Count Vaux Alot]

Evening all here is a small update on my progress in preparation for the long weekend - enjoy :thumb:.

The last of the bits out of the blaster needed blowing out and tapping

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD312.jpg

The lower arms had some hard to get areas so i had to use the coarse hand blaster to sort them out

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD313.jpg

blasting in progress

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD309.jpg

Then i finished all the nuts and bolts by hand in the fine hand shot

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD308.jpg

And put them in a bag with some lite grease to stop them from rusting in the mean time

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD307.jpg

The engine mount got the same treatment - it came out looking brand new

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD303.jpg

Then i primed up all the other bits

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD306.jpg

Started to get some colour on them

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD311.jpg

All done thank fook!

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD304.jpg

[Count Vaux Alot]

Great work, most interesting thread of the year so far!



Should be very well done going by the XE Saloon and the 3dr track weapon

Cheers Chaps :d

[Benn]

Good work dude, get my cv joint price txt.

[L14MNP]

Just sat and read this mate. Can't believe I hadn't seen it before.

Awesome work as usual, and great to see CG's shell being given a new lease of life after how much graft he put into saving it!

You have some handy toys to play with. lol :thumb:

[Count Vaux Alot]

Thanks boys

Benn - yer i did i'm waiting for my shafts from Let nova to turn up before i know which ones i actually need then i will let you know

L14MNP - the toys are very handy indeed

[novacabrio]

So will you be offering mail order cleaning service then for my rebuild parts! Looking good, get plenty pics of the epas being fitted as ive got the gear here to do mine!

[Count Vaux Alot]

If you want bits cleaned then i work for Lolly pops ;) lol

[burgo]

Any pics of said vehicle burgo? What box and clutch is he on?

Turbo details to follow in the near future as i've already started working on it but i'm not quite finished yet - and there are a couple of options :)
as far as im aware hes on standard clutch and box still. he is dyno'ing it this weekend so will see what its putting out :d

ebay special intercooler :D

http://sphotos.ak.fbcdn.net/hphotos-ak-snc3/hs122.snc3/16967_277689099036_692054036_3415380_878678_n.jpg

N/A inlet and original crap intercooler lol

http://sphotos.ak.fbcdn.net/photos-ak-snc1/v2569/211/97/692054036/n692054036_1530164_2681218.jpg


he has a trooper turbo which he was going to try but gonna wait and see what you do first. for now hes gonna get another head which i can work me magic on :d

[Count Vaux Alot]

Thanks for those burgo i will be interested to find out what power he makes, i would like to see the 120bhp mark but we will see lol

I'm also after trying something different with the clutch and flywheel - do you have any idea which fly baxter used on his td?

[burgo]

baxter used the 1.5td one i believe so he could keep the small block shafts and hubs.

I asked my brother about his clutch aswell and his is standard but apparently when thrashing it it does slip. so i can see you having issues. only thing i can think is measure the friction plate and then get an uprated petrol one thats a similar size

[Adam]

The clutch on my astra slipped a bit too, it wasnt exactly brand new though.

[burgo]

The clutch on my astra slipped a bit too, it wasnt exactly brand new though.my brothers is brand new and still slips lol

[Spudly]

I also had slippage issues when giving mine big beans, usually when carrying a load up a slope or a hill, mine was only boosting at 19psi though but i imagine they dont take well to the extra torque upped fuel and boost produces, mine was a new clutch aswell, but only did it to me a handful of times and behaved after that lol

[Count Vaux Alot]

I know I will have issues as my 1.7td corsa slipped after some left foot down and that clutch had only done a few thousand miles hence the reason for the hunt for another option.
The standard friction plate has a diameter of 200mm which is the same as a 1.6 16v or very close iirc which is tiny for the 200 odd lb ft of torque I plan on putting through it ( the c20xe's friction plate is 220mm wide iirc and they only produce 149lb ft or what ever it is) so I'm going to see if I can machine my Td flywheel to suite an xe clutch and use an updated one.

Also didn't Baxter have an f28 fitted??? So what fly would he have used for that??

[craig green]

Baxter, F28? LOL.

[Count Vaux Alot]

Baxter, F28? LOL.
That was kinda my point lol

[burgo]

looking at that flywheel i cant see any reason why you cant machine it so that its basically a copy of an XE flywheel :) and i think it was the supercharged x16xe he planned to fit an f28 to

[Andy]

I also had slippage issues when giving mine big beans, usually when carrying a load up a slope or a hill, mine was only boosting at 19psi though but i imagine they dont take well to the extra torque upped fuel and boost produces, mine was a new clutch aswell, but only did it to me a handful of times and behaved after Andy set the cable properly ;)

Great build,this will be spot on.Nice attention to detail aswell

[Adam]

Baxter just had a std box afaik.
F28 would take some messing about to fit, because the size of the input shaft(bigger than f16/f20 etc) means you would have to spend hours looking for clutch part catalogues looking for a suitable friction disc.

[Benn]

I have an LUK book at home if you wanna borrow it..lol

[SRimon]

I meant to comment on this the other day.

A, its really good to see Craigs shell living on!
B, love the fact its going to be different! Didn't baxter have nearly 200BHP out of his 1.7TD?

[Count Vaux Alot]

Thanks Simon

According to baxters sig on vxON it was 212 with an f28

see here:

file:///C:/DOCUME%7E1/Tracy/LOCALS%7E1/Temp/moz-screenshot-3.pngfile:///C:/DOCUME%7E1/Tracy/LOCALS%7E1/Temp/moz-screenshot-4.pnghttp://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/untitled.jpg

[discoinferno]

either machine your flywheel for an xe setup, but use a c20let pressure plate this will give the clamping force required but the splines for an f16/18/20 box etc

of if your feeling flush speak to ttv racing and they will make you a billet item

[John]

if there's enough face and the clutch will bolt up ok, machine the fly.

[Count Vaux Alot]

Todays activities began with the removal of the rear axle (it was craigs disk axle and he sold it on so it had to go) - nice to meet you btw Chris.

Back end in the air

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD316.jpg

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD317.jpg

Axle off

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD318.jpg

Luckily i had a spare anyway so i slipped that on

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD319.jpg

Axle swap...done!

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD320.jpg

Whilst i was messing around with that i found the MOT failure of the day - just another repair!

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD321.jpg

Putting that to one side i focused back on the main task in hand - the engine bay modifications and repairs

This needed sorting

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD322.jpg

So i fashioned this repair section

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD324.jpg

like a glove

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD323.jpg

Gave it a clean up

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD325.jpg

Along with the inside of the chassis leg

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD326.jpg

Tacked it in

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD329.jpg

And welded it in fully (this was a pain in the ass due to the amount of crispiness all over the surrounding material)

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD330.jpg

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD331.jpg

[Count Vaux Alot]

After giving that a quick clean off and a prime i started to tidy the leg up as i wanted all the cutting and grinding to be done before i welded the td engine mount in.

This is how i left it

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD327.jpg

Crispy

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD328.jpg

A little cleaner with primer

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD333.jpg

Then i went on to do some marking of more unwanted material, so i had some clean metal to weld to

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD332.jpg

chop chop

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD335.jpg

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD336.jpg

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD337.jpg

Getting there

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD338.jpg

Doesn't that look better

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD339.jpg

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD340.jpg

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD342.jpg

Once i was happy here it was time for the boost pipe repair section

I gave this some further fettling ready for its insertion

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD341.jpg

Clamped it to the car and cut through it

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD343.jpg

Another hole!

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD344.jpg

[Count Vaux Alot]

I cleaned the edges and some other rust holes/patches

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD345.jpg

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD346.jpg

Then turned my attention to the engine mount its self

drilled some holes for puddle welding the bottom edge to the cars outer chassis leg

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD334.jpg

Tacked in

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD347.jpg

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD348.jpg

And began to weld it in

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD349.jpg

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD350.jpg

The chassis leg its self needed quite a lot of cleaning to find clean metal hence the gap around the td leg section, i will probably weld it all up then clean the welds up V them out again then cap them to finish them off properly.
I was unable to get any further today due to important house buying related commitments so hopefully there should be some more progress to follow tomorrow :thumb:

[muzzy]

Should look pretty much factory once the welds are ground back and painted, very neat work. :thumb:

[scott.parker]

It's quite worrying where rot can hid on shell even if you think there clean and rot free..

But looks like your well on top of it now mate, fair play for doing all this.
Keep it up.

Scott

[Benn]

I'm sitting in a damp patch.

[peester]

u even had sunshine.. i mean blimmey..

[kent14sr]

Looks great James!!

[mk1nova_rich]

looks a good project, and the standard of your work is excellent :thumb:

[Count Vaux Alot]

u even had sunshine.. i mean blimmey..

No such luck today though :(

[Dervy]

hay i recognise that astra, and that garage looks very familiar, hang on a minute thats my astra lol :), can`t wait to c this nova finished, im hoping to get the astra dyno`d at pv :)

[Ernie]

onca again stunned by your builds mate.Keep it up James.

[CorsaBBoomer]

Nice work James, will keep an eye on this :thumb:


Although it makes me miss my TD... :cry: :cry: :cry:

[Adam]

Youve got some skills James! Impressive work

[Count Vaux Alot]

As Sunday was a was out i was determined to get at least something done on monday what ever the weather!

Fortunately the sun was out to begin with so i cracked on

I ground back the welds on the newly inserted td chassis leg section, then V'd them out to take a final cap off

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD351.jpg

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD352.jpg

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD353.jpg

V'd out

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD354.jpg

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD355.jpg

Then just as i was about to lay the first line of weld it started to pissit down ffs, i thought funk this its time for some sort of circus gypsy tent as so

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD356.jpg

This kept the rain off everything thank funk. Anyway it was a short shower so onwards with the welding

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD357.jpg

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD358.jpg

Happier with that i moved on to the small section i had cut out to get at the inner skin

Held in place with a magnet while a tacked it home

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD359.jpg

Tacked

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD361.jpg

And done (not the prettiest admittedly lol)

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD362.jpg

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD363.jpg

Moving swiftly on I welded up the top edge of the chassis leg insert

First below the turret

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD360.jpg

[Count Vaux Alot]

Then all the way down the top of the leg, yes there was fire and it popped and spattered like a bastid!

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD364.jpg

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD365.jpg

Now it was jigsaw time as i needed to do something with the large hole were the rotten metal used to be

First and easiest repair section tacked in place

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD366.jpg

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD367.jpg

Then i began at the back of the hole below the turret with the first of my home made repair sections, the section in question is directly above my earth return clamp in the pic below.

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD368.jpg

I crafted this shape after some careful measuring

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD369.jpg

Cleaned up the weld behind the repair section

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD370.jpg

Manipulated the metal into shape

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD371.jpg

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD372.jpg

Getting there but a little more needed

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD374.jpg

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD375.jpg

Tent time again, fecking rain!

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD373.jpg

Once i was happy with the final shape i drilled some holes were the repair section meets the chassis leg lip so i could puddle weld it in later on

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD376.jpg

And tacked it in to position - not to bad a fit

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD377.jpg

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD378.jpg

[Count Vaux Alot]

Moving down the leg i was getting frustrated with yet more rust so out came some more metal

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD379.jpg

Giving me the perfect opportunity to douse the inside of the chassis leg with acid etch primer

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD380.jpg

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD381.jpg

While the primer was drying i cut up some more metal to fill the hole

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD382.jpg

welding it in good and proper

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD383.jpg

This gave me a much better base to build the rest of the repair off of

Metal cut

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD384.jpg

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD385.jpg

Bent

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD386.jpg

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD387.jpg

And tidied in to shape

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD388.jpg

Tacked in ready for the next section - i thought small sections would be easier....

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD389.jpg

The beginnings of the next section

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD392.jpg

Fettled

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD393.jpg

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD394.jpg

Inserted

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD395.jpg

[Count Vaux Alot]

On to the next

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD396.jpg

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD397.jpg

Looking a little better

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD398.jpg

Another small section

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD399.jpg

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD400.jpg

finally the last piece of the puzzle

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD402.jpg

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD403.jpg

Frankenstein's monster is complete

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD404.jpg

Happy that i was getting there i began to weld the sections in permanently

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD405.jpg

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD406.jpg

The section above the current return clamp was a right t w a t to do as it kept trying to destroy itself

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD407.jpg

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD408.jpg

But i got there in the end

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD409.jpg

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD410.jpg

[Count Vaux Alot]

You may think WTF has he done but after a clean off with the sanding disc it began to look better

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD411.jpg

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD412.jpg

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD413.jpg

More sanding to blend the edges

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD414.jpg

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD415.jpg

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD416.jpg

Smoother still but much more to do

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD418.jpg

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD419.jpg

I had to call it a day here unfortunately as i was due to make the joyous journey back down south so i welded up the bottom of the td chassis leg section and slapped some primer on it to keep the weather off it, even now the leg doesn't look to bad with some paint on it

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD421.jpg

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD420.jpg

I then sealed the front panel - job done!

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD422.jpg

[peester]

aye.. good skills.

[Graeme]

Excellent fab skills as all ways James

[Count Vaux Alot]

Cheers Chaps hopefully next weekend will see the appearance of something other than this fcuking chassis leg and you will have something more interesting to look at lol

[comptoncj]

Keep up the good work buddy!

[Benn]

Funk dude, your fab skills/work is awesome. Great work.

[Spudly]

Lols until the last few pics it looked like you were patching the leg up with bits of giant mechano lol

[John]

Top fab skills fella!

[Connor]

Great Work Count

[Count Vaux Alot]

Lols until the last few pics it looked like you were patching the leg up with bits of giant mechano lol
lol too true i don't think it looks too bad now though right? lol

[Pistol Pete]

Pic heavy but thats what makes a good WIP thread IMO. Top skills. Loving the toys (parts blaster/cleaner etc) you have access too aswell.

[Edd]

top work, you dont hang about do you ?! lol

[SRimon]

Lovely welding, I need to do a welding course!

[Grey]

Jeeez! lol 118 get your number! shiza your good at welding

[Balley]

You would not believe how much insperation your giving me for my project, My chassis legs are in a state too and need some similar work before I drop a 1.7 in :(

Keep it up fella :D

[burgo]

stunning work sir. i love the vision you have, "looked" a right mess yet you knew and could see the end result.

[Southie]

Love the fact you take so many pictures to keep us glued to your thread :cool:

Excellent fab work as ever :)

[Nick J]

Top work fella........ your wip's are always a pleasure to watch! :)

Nick.

[Dervy]

thats some nice fabrication going on there :)

[nova ian]

Alright James, check you out saving yet another nova. Top notch work as always.

Should be a good powered little car, love my van with the 1700td lump.

Hopefully catch up soon

Ian

[Spudly]

lol too true i don't think it looks too bad now though right? lol



Not at all mate its looking sterling now bud:cool:

[craig green]

HOLY FUNK!

impressed.

[Count Vaux Alot]

Thanks everyone it makes the effort worth while after Reading all your comments!

This weekend all being well should see the bay finished off and the engine build on it's way!


Ps. Any one got a red bonnet and grill for sale??

[craig green]

Red grille..... £20 delivered?

[Count Vaux Alot]

Oh and mirrors??

[Ernie]

ive got a set of mirrors but there not painted mate.Your welcome to them toward the build if thats any help.

[Count Vaux Alot]

Thanks for the offer Chris i think i have some red ones but i will let you know :thumb:

[MK999]

I've got a load of mirrors kicking about if you wanna have a look when you're here for those hubs, none in red though.

[Cormac]

Nice work!!

[Ron]

keep up the good work liking the look of you engine mount and patch work

[Count Vaux Alot]

Evening!

I managed to crack on with a few bits at work this weeks so thought i would fill you all in...

Here is the steering rack that i had previously cleaned but hadn't finished looking particularly fury

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD290.jpg

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD440.jpg

After i had removed the gaiters i taped her up and gave it a blast, here is the same section as above post blasting. Its heavily pitted were the Ali has corroded but is still serviceable.

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD431.jpg

And the rest of the rack

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD439.jpg

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD436.jpg

Once it was cleaned the track rod ends needed some attention

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD444.jpg

So it was out with the die (M12 x 1.5 for reference)

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD443.jpg

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD438.jpg

Much better

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD437.jpg

And i polished this shaft up too lol

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD430.jpg

Prep done, next primer

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD390.jpg

Then paint....classic black

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD391.jpg

[Count Vaux Alot]

Here are some other filthy bits i removed from the donor 1.5td as these bits are different to their 1.7 td counter parts (only slightly different as in angles etc but it will make it easier for fitting the 1.7 lump to the nova)

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD423-1.jpg

To the wash tank then the hot wash

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD424.jpg

And finally the blaster - as you can see they look like sh!t still

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD441.jpg

Corrosion was an issue again due to the ends being submerged in coolant for so long. They were heavily pitted so i decided to smear some liquid metal over the pitting to level the surface, you can see this in the pics below

Pitting

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD433.jpg

Filled

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD428.jpg

Hopefully this will help to seal the pipes but if not its back to the drawing board as i can't imagine its too easy to get these bits any more!

Next issues was the mounting surface faces which were suffering from corrosion also as seen below

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD432.jpg

On to the linisher

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD426.jpg

much better

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD434.jpg

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD427.jpg

Blasted, primed, and painted this metal coolant pipe

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD425.jpg

I wire wheeled these bits too - shiny!

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD429.jpg



Thanks for looking :thumb:

[Spudly]

Awesome work as always bud, will be good to see this done, its going to be immaculately clean for a weasel motor lol

[Count Vaux Alot]

Diesels don't have to be dirty they need love too lol

[Spudly]

I think this ones going to be cleaner than any other, even brand new ones fresh from the facotry aint this clean lol

[novacabrio]

So your going to have the bonnet open with pride at shows?? lol

[Count Vaux Alot]

Too funking right i am! And i will make sure i'm close to that sport your building so people can compare lol

[burgo]

i would love to have the access to all the tools you do lol

[SRimon]

Envious at the shot blasting, such an easy way of cleaning stuff up, some of us would be there for hours with the wire wool lol!

[muzzy]

Attention to detail on all these parts is brilliant.

[peester]

wow more clensing of sins

[thedjse]

Excellent work mate just read the full thread lol

[dj_wudgey]

Envious at the shot blasting, such an easy way of cleaning stuff up, some of us would be there for hours with the wire wool lol!
Thats how i have to do it lol good work though bud!

[maddogdaz666]

i admire your attention to detail. top build!

[Benn]

Good work on cleaning all the bits up.

[Lewis.]

this is an awesome project, i've got a lot of love for the dervs :d
your attention to detail puts me to shame too lol
hav some rep :thumb:

[Count Vaux Alot]

Cleaned yet more bits during the week, first on the list was the bonnet stay

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD445.jpg

Then the big block shafts arrived so i got on with them, These are the M tech variety that have been joined i'm a little weary of these - any one like to put money on when they will break?

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD449.jpg

Took the boots off

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD448.jpg

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD451.jpg

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD452.jpg

Cleaned them up

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD450.jpg

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD459.jpg

Hand shot the splines with the fine hand shot

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD462.jpg

Taped them up and blasted them

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD455.jpg

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD461.jpg

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD454.jpg

Then i wasn't quite happy with the mating surface on the water way housings so i decided to mill it flat

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD457.jpg

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD464.jpg

Better

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD456.jpg

[Count Vaux Alot]

This bring us to today - as the weather was complete toss i decided to start on the engine properly as its inside in the dry.

Starter off

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD465.jpg

Rocker cover off

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD466.jpg

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD470.jpg

Cam belt and pulley

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD468.jpg

Off

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD469.jpg

Head off

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD471.jpg

Looking ok so far

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD472.jpg

Looking very grubby

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD473.jpg

So out came the degreaser

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD475.jpg

The weather had improved slightly so to save the mess getting every were inside i dragged the engine outside - the light was better too!

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD476.jpg

A couple of pics for reference

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD477.jpg

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD478.jpg

IIRC this fuel pump support bracket needs swapping with the one from the 1.5td as it doesn't stick out was much

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD479.jpg

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD480.jpg

[Count Vaux Alot]

Upside down for the last bit of cleaning

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD482.jpg

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD485.jpg

Once most of the dirt was off i decided to take he sump off

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD486.jpg

It was at this point when, what was going to be a simple strip down, clean up and replace a few gaskets turned in to a full rebuild as disaster had struck

Were did that come from ffs...can you see it?

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD487.jpg

Swarf....BOLLOX!

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD489.jpg

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD491.jpg

The engine ran fine, looked fine and showed no other signs of wear or failure but i had come this far and didn't want to risk it so (even though i'm not sure if i can get the nuts, studs, and bearings)

It had to come apart

Second half of the sump off along with the oil pick up pipe

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD488.jpg

rods and pistons out

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD493.jpg

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD495.jpg

Block looks nice and clean now though

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD496.jpg

Main caps coming out (back inside as it was pissing it down again)

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD498.jpg

Crank pulley off

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD499.jpg

Oil pump and crank out

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD500.jpg

[Count Vaux Alot]

Annoyingly everything is as it should be ffs - note the piston oil squirter!

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD501.jpg

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD503.jpg

Now i was left with this lot apparently a waisted effort

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD505.jpg

After a further clean everything still looked ok

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD508.jpg

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD509.jpg

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD510.jpg

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD511.jpg

Last of all i began to paint the block this is how i left it - its having a new water pump btw.

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD506.jpg

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD507.jpg

[burgo]

yes the 1.7td support bracket hits the steering rack. :d

those internals look facking mint

[Count Vaux Alot]

yes the 1.7td support bracket hits the steering rack. :d

I thought so :thumb:

Anyone any idea on were i might be able to source the rebuild parts i need? big end bearings, main end bearings, piston rings main bolts and con rod nuts??

[burgo]

not a clue, i would assume a normal motorfactors. ive heard the rods are the weak link but they look funking huge

[Count Vaux Alot]

Tried my local motor factors they are usually really good i got a full cam belt kit, and full gasket kit and head bolts but no chance of the other bits :confused:


The rods are huge much bigger than xe stuff...

[novacabrio]

Motor factors would be my suggestion, have you tried some of the bigger ones? We have Andrew Page up here don't know who you have down there but a larger one may be better than a local one?

[Rysee]

Con Rod bearings at the bottom

http://www.vauxhall-car-parts.co.uk/acatalog/Cavalier89_Other_Engine_Parts.html

[burgo]

Tried my local motor factors they are usually really good i got a full cam belt kit, and full gasket kit and head bolts but no chance of the other bits :confused:


The rods are huge much bigger than xe stuff...exactly my thinking, what power have xe rods been proved to?

[Count Vaux Alot]

Con Rod bearings at the bottom

http://www.vauxhall-car-parts.co.uk/acatalog/Cavalier89_Other_Engine_Parts.html

I think thats the GM 1.7 by the engine code

[Count Vaux Alot]

exactly my thinking, what power have xe rods been proved to?

200 bhp is safe for xe rods with arp's possibly more

[MK999]

Swarf looks to me like a collet, dunno if these actually exist anywhere in these engines or it's just mashed up into the shape one, kinda looks like one to me is all lol

[novacabrio]

are the rod bolts not the same as an XE or anything? Not got EPC on my computer at the moment but could be worth a check?

[Lee H]

200 bhp is safe for xe rods with arp's possibly more


I'd say more than that as LETs have the same rods and run phase 2 with no problems.

[burgo]

maybe its the nuts that are the weak link then :s. find out what thread size and pitch they are count as my mate has various arps laying around which i could check for you

[Benn]

J i'd have thought i can get the bearings.

[Count Vaux Alot]

Evening I thought would share my progress from sunday with you

So here goes

Other side of the engine masked and painted

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD512.jpg

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD515.jpg

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD516.jpg

And got the conversion shafts primed and painted silver

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD513.jpg

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD543.jpg

As that lot was drying and the weather wasn't wet i decided to move operations outside again to crack on with the engine bay prep

Began to rub the bay down

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD517.jpg

pretty much there

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD519.jpg

I think the chassis leg mods look ok here

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD520.jpg

Once i was as happy as i could be assed to be masked up

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD521.jpg

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD522.jpg

And primed the area

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD523.jpg

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD524.jpg

After 3 coats i flatted it back and seam sealed it up going over all the fresh welds to stop much or water getting in anywhere

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD525.jpg

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD526.jpg

[Count Vaux Alot]

While the sealer was drying i moved on to the front panel

Flatted back

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD527.jpg

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD529.jpg

A couple of coats of primer

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD530.jpg

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD531.jpg

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD540.jpg

Sealer primed

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD532.jpg

Now sorry for all the pics here but i thought i would show you the chassis leg and surrounding repairs from various angles now they are all primed up

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD533.jpg

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD534.jpg

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD535.jpg

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD536.jpg

Nearly looks factory

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD537.jpg

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD538.jpg

Would you know it wasn't meant to be there if i had showed you the pic below at the start?

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD539.jpg

Anyway back to the front panel

Flatted back, blown off and panel wiped down

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD544.jpg

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD545.jpg

[Count Vaux Alot]

Then the first coat of colour

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD546.jpg

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD547.jpg

And after a couple more coats

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD550.jpg

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD551.jpg

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD553.jpg

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD552.jpg

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD554.jpg

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD555.jpg

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD556.jpg

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD557.jpg

This is were i ran out of paint

Its only out of a rattle can so the finish wasn't going to be amazing but its not bad, I still need to lacer it. Besides no one will even see most of it lol

I'm not back at my parents for a couple of weeks so i had to de mask the car so the tape didn't stick like sh!t to a blanket but that did mean could take some comparison pics of the wings and the front panel.

I know the suns in a sh1t place here but you get the idea...

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD563.jpg

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD561.jpg

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD564.jpg

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD565.jpg

[Count Vaux Alot]

This brings us nicely to today and there very crusty machined big block hubs and carriers (cheers MK999 nice to meet you btw)

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD578.jpg

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD575.jpg

So hubs out

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD573.jpg

washed and dried then in the blaster (old bearings left in place to protect bearing boars)

Clean as fook!

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD574.jpg

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD577.jpg

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD572.jpg

Old bearings pressed out

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD582.jpg

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD568.jpg

Boars cleaned up

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD579.jpg

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD569.jpg

Cir clips cleaned

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD566.jpg

New bearings ready to go

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD580.jpg

Clips and new bearings fitted

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD570.jpg

Finally all degreased, taped up and acid etch primed

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD576.jpg

That is all

[Plug]

cracking update as normal :thumb:

[craig green]

Quality.

[SRimon]

Enjoyable read!

[MK999]

Pff they aren't mine, no way the ones I gave you would come out that clean lol

[burgo]

i can see im gonna have to send some bits to you to refurb lmao. the chassis leg / inner wing now just look like you have seem welded and then sealed which = epic repairage imo

[muzzy]

Great work, you would hardly notice that mount isn't a factory fitted item. Loving the attention to detail and the amount of cleaning that's happening too!

[Count Vaux Alot]

Thanks chaps!

[NOVANICK]

just read it all, very inspiring!

[Damo]

Good thread this count keep it up mate.

[Lee]

Looking great! Theres something about seeing old crusty stuff come out of that blaster like new!

[scott.parker]

Looks ace, love how clean the stuff comes out the blaster, very satisfying indeed, and as for paint match, dam thats close for rattler cans!

Scott

[Balley]

Very nice,

Two questions...
Have you sourced any rebuilb parts for the engine, if so where from?
And what are the shafts off (are the welded ones) , what Gearbox you using?

Keep up the good work !

Dan

[Count Vaux Alot]

Thanks again for your kind words everyone - putting crusty old crap in the blaster and seeing it come out spotless still hasn't lost its appeal lol

Dan yes i have managed to source all the rebuild parts but they weren't cheap

The bearings ~( an engine set of bigs and mains), piston rings, and thrust spacers cost £108 from a local engineering company we use through work (Robinsons engineering in ferndown dorset)

Then for the fixings i had to go to vauxhall (Robinsons advised me to go to vauxhall as thats the only place that supply them ie they aren't available n the after market)

The Main bearing cap bolts are re usable according to auto data (which is a spot of luck as vauxhall don't list them as they are supposed to be reused so arn't available at all according to vaux parts dept) so i only got the con rod studs and nuts (8 or each) for £45

I was going to go ARP but they are a strange size some thing like M9 super fine so i thought OEM for now.

BTW i also enquired with vauxhall about the bearings and they come in pairs at £27 a pair!! :eek:

[trackdaynova]

you living back in MK gayboy?

[Count Vaux Alot]

No mate only on weekend visits atm until we are in our new house (hopfully soon) nice to see you making an apperance is all ok?

It would be nice to catch up soon

[Count Vaux Alot]

Craig have you still got the red grill?

[craig green]

yeah mate.

[Benn]

Painting looks good.

[Count Vaux Alot]

Cheers boss like I saidits only rattle can

[Count Vaux Alot]

Few more bits done today

Hubs hand shot with the fine grade

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD597.jpg

And polished up

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD584.jpg

Hub carriers painted up

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD604.jpg

More bits cleaned ready to be blaster

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD589.jpg

They cam out spanking as usual

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD599.jpg

Especially the upper half of the sump

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD600.jpg

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD606.jpg

Primed the filler neck and lower half of the sump (the pan if you will)

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD601.jpg

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD596.jpg

Oil strainer and oil pump degreased and hot washed

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD586.jpg

No swarf left in here now :roll:

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD594.jpg

Oil pump stripped and cleaned - by hand this time i will add

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD612.jpg

Starter cleaned off

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD610.jpg

[Count Vaux Alot]

Then on to the head - which was filthy

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD592.jpg

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD593.jpg

I made sure i gently removed the injector washers first (there are two per injector)

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD585.jpg

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD603.jpg

For reference the small washer goes this way up in the hole

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD587.jpg

In the degreaser

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD591.jpg

Looking better after a rinse

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD595.jpg

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD602.jpg

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD611.jpg

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD598.jpg

Then after a dry off with the brake cleaner and air line i lubed up the cam and followers

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD605.jpg

Some new goodies arrived to day as well

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD609.jpg

:thumb::thumb:

[novacabrio]

Why didnt the head go in the hot wash?

[Count Vaux Alot]

Why didnt the head go in the hot wash?

Ran out of time so i just did a quick clean off until i get the time

[novacabrio]

You need to put £15 in the meter to run the machine?

[Count Vaux Alot]

Evening everyone i have a small update for you

There was a slight issue with the hubs i got off MK999, that issue being one looked like this

Normal

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD607.jpg

The other one looked like this

Unwell

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD588.jpg

Someone appears to have tightened a nut on to the cv joint with out the washer and mangled it so on to the lathe

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD618.jpg

The first run to remove the large bur

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD621.jpg

Tiding up the damaged splines

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD620.jpg

Getting there

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD615.jpg

All done and looking a lot neater - much better

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD619.jpg

Then from the lathe to the press

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD617.jpg

Finally the hubs reunited with the carriers, job done.

http://i248.photobucket.com/albums/gg167/Count85/Nova%20TD/Nova%20TDI/NovaTD623.jpg

[MK999]

Uh oh, supplying dodgy goods :eek: lol Not giving you a refund though :p

[bmw156]

good work, i love the daily updates :)

[craig green]

Wicked updates again James.

[Benn]

Nice lathing. Rears didnt need taking down then...

[Count Vaux Alot]

Nice lathing. Rears didnt need taking down then...

What? if you mean the part of the hub that presses into the bearing then no they had already been done (badly i will add lol)

[Will F]

Did you paint the flanges after you bead blasted them matey?

Pretty sure they will go rusty immediately if you didnt! lol