Czech it out Nova Rallyx

[phunkynova]

The car started as a 1.4SR Endurance rally car. Having payed for the car and then driving it from England to Plzen in the Czech Republic I started to change it into a Rallycross car as per the reg's for the Rallycross club here in Domazlic. A 1.6 GSI motor was fitted but I had too many problems with senors and then I fitted it with R1 Bike carbs plus pump and no more problems. A small Fuel tank was fitted to save weight the rollcage was improved a 90%LSD was fitted strengthened lower arms. Car all ready had Bilsten Shocks and a good sump guard . Polycarb windows were also done and now its go and take on them there Czech boy's on home ground:thumb:http://i995.photobucket.com/albums/af71/phunkferret/MyNovarallycrosscar099.jpghttp://i995.photobucket.com/albums/af71/phunkferret/MyNovarallycrosscar098.jpghttp://i995.photobucket.com/albums/af71/phunkferret/MyNovarallycrosscar103.jpghttp://i995.photobucket.com/albums/af71/phunkferret/MyNovarallycrosscar104.jpghttp://i995.photobucket.com/albums/af71/phunkferret/MyNovarallycrosscar096.jpghttp://i995.photobucket.com/albums/af71/phunkferret/MyNovarallycrosscar094.jpghttp://i995.photobucket.com/albums/af71/phunkferret/MyNovarallycrosscar101.jpg

[daverobson]

i like it =)
like where the washer bottle has been re-located too lol

[phunkynova]

need to see how much I have left in during the race bad news to run out just at the wrong time. lol

[vauxluva]

Nice car mate wat are your plans with her ..?

[16v Nova Kev]

love the petrol tank.

[phunkynova]

The car will be used at a local rallycross track near Plzen in the Czech Republic they run a 10 race season. I will be in class 3 which is up to 1599 cc engine's.Engine mods are unlimited so long you do not go over the engine size and a 1.4 times factor for turbos and superchargers is applied.

[phunkynova]

10L Gerry can dose the job just nice. lol

[16v Nova Kev]

what air filter did you use for the r1 carbs

[phunkynova]

pipercross air filter got the carb set up off SRJACK used but it all came from the Bogg bros in the first place

[16v Nova Kev]

cheers

[dj_wudgey]

looks good but its a shame its a good model!!

[phunkynova]

Well here is a up date on the car after the first race....... It's going to need a bit of tea-cutting and polish lol.
I must stop use my Nova as a battering ram to get pass slower cars (bloody slow Skoda driver's). Looks like a trip to the scrap yard for me for some parts.Dooh. P.S. I did win one race.http://i995.photobucket.com/albums/af71/phunkferret/MyNovarallycrosscar109.jpghttp://i995.photobucket.com/albums/af71/phunkferret/MyNovarallycrosscar110.jpghttp://i995.photobucket.com/albums/af71/phunkferret/MyNovarallycrosscar110.jpghttp://i995.photobucket.com/albums/af71/phunkferret/MyNovarallycrosscar108.jpg

[phunkynova]

If Anybody is interested how my first rallycross meeting went here it is:
So first time out in this car first time at this track and a very long time since I last drove on loose.
In the first race out of 4 I was in 2nd place and tried to make a move for 1st on the outside only to find a hidden big rock at the side of the track which bent the steering and I dropped back to 4th at the finish.
After jacking the steering arm straight I started the 2nd race I was in 2nd place when the steering arm broke and put me out of the run.
Missed the 3rd race as we were still fixing the car welding the arm back together and replacing the bust drive shaft.
made it out for the 4th race and came 1st in that one (yer).
And then to the final I had to start last dew to 2 DNF's made 3 places into the first corner and then got stuck behind a badly driven Skoda and no way past as the track was in a bad state by now and there was only one good line and he was on it tried to overtake put got bogged down in the very loose just off the race line. Then got pea-ed off with him and tried to run him out the way it did not work so tried ramming him also did not work so not so good finally and a low point scoring weekend. Ho well there's all ways the next meeting. lol

[MK999]

Wudgeys gonna cry! lol <insert popcorn eating animated image>

[phunkynova]

Yer sorry Wudgeys I will get it looking good again ok

[phunkynova]

Well here's a update I got the Nova back to about 90% as it used to be (that will make wudgeys a bit more happy).
And off I went to the 2nd race meeting of the year.
And this is what I came back with.http://i995.photobucket.com/albums/af71/phunkferret/busted%20car/MyNovarallycrosscar128.jpghttp://i995.photobucket.com/albums/af71/phunkferret/busted%20car/MyNovarallycrosscar126.jpghttp://i995.photobucket.com/albums/af71/phunkferret/busted%20car/MyNovarallycrosscar125.jpg
rad blow outhttp://i995.photobucket.com/albums/af71/phunkferret/busted%20car/MyNovarallycrosscar124.jpg
was hit so hard from behind the exhaust bent at 2 points
http://i995.photobucket.com/albums/af71/phunkferret/busted%20car/MyNovarallycrosscar122.jpg
IF ANY ONE CAN GIVE ME ANY TIPS ON HOW TO REPAIR THIS DAMAGE TO THE SILL much thanks
http://i995.photobucket.com/albums/af71/phunkferret/busted%20car/MyNovarallycrosscar119.jpghttp://i995.photobucket.com/albums/af71/phunkferret/busted%20car/MyNovarallycrosscar118.jpghttp://i995.photobucket.com/albums/af71/phunkferret/busted%20car/MyNovarallycrosscar117.jpghttp://i995.photobucket.com/albums/af71/phunkferret/busted%20car/MyNovarallycrosscar116.jpghttp://i995.photobucket.com/albums/af71/phunkferret/busted%20car/MyNovarallycrosscar115.jpghttp://i995.photobucket.com/albums/af71/phunkferret/busted%20car/MyNovarallycrosscar114.jpghttp://i995.photobucket.com/albums/af71/phunkferret/busted%20car/MyNovarallycrosscar113.jpghttp://i995.photobucket.com/albums/af71/phunkferret/busted%20car/MyNovarallycrosscar129.jpghttp://i995.photobucket.com/albums/af71/phunkferret/busted%20car/MyNovarallycrosscar112.jpg

[phunkynova]

http://i995.photobucket.com/albums/af71/phunkferret/busted%20car/MyNovarallycrosscar123.jpghttp://i995.photobucket.com/albums/af71/phunkferret/busted%20car/MyNovarallycrosscar121.jpghttp://i995.photobucket.com/albums/af71/phunkferret/busted%20car/MyNovarallycrosscar120.jpg

[fearless]

Are you sure your competing in Rally Cross and not Demolition Derby (Last car running wins - in case you didn't know) !!!! :)

Dave

[blue_peg_16v]

love the gerican petrol tank

[Rickyb]

you should be a banger driver haha

[phunkynova]

Here are some updates to the car. I've given up on the so called rally-cross
and have put the car back on the road as a club man rally car.
It is the only Vauxhall Nova Rally Car in the Czech Republic and maybe the only Nova/Corsa A rally car here in C.Z.


http://i995.photobucket.com/albums/af71/phunkferret/Updates%20to%20rally%20car/rallycar006.jpg


Painted the underside white

http://i995.photobucket.com/albums/af71/phunkferret/Updates%20to%20rally%20car/rallycar008.jpg


More white paint

Below you can just see the Kevlar fuel tank guard
http://i995.photobucket.com/albums/af71/phunkferret/Updates%20to%20rally%20car/rallycar012.jpghttp://i995.photobucket.com/albums/af71/phunkferret/Updates%20to%20rally%20car/rallycar016.jpg
http://i995.photobucket.com/albums/af71/phunkferret/Updates%20to%20rally%20car/rallycar009.jpg

New Camshaft Pulley

Below is the old standard gear box on the left and the new straight cut close ratio box on the right.

http://i995.photobucket.com/albums/af71/phunkferret/Updates%20to%20rally%20car/rallycar021.jpg

[phunkynova]

Here I had to grid the gear box out to fit the bigger 5th gear (marked in red)
http://i995.photobucket.com/albums/af71/phunkferret/Updates%20to%20rally%20car/rallycar022.jpg
http://i995.photobucket.com/albums/af71/phunkferret/Updates%20to%20rally%20car/rallycar024.jpg

Here are some photos from the new Tran-X L.S.D.
http://i995.photobucket.com/albums/af71/phunkferret/Updates%20to%20rally%20car/rallycar025.jpg

This is a hand tool I made up quickly to remove and refit the Diff.

http://i995.photobucket.com/albums/af71/phunkferret/Updates%20to%20rally%20car/rallycar042.jpg

Below is the bigger 5th gear in place.

http://i995.photobucket.com/albums/af71/phunkferret/Updates%20to%20rally%20car/rallycar046.jpg



The Diff in place.

http://i995.photobucket.com/albums/af71/phunkferret/Updates%20to%20rally%20car/rallycar048.jpghttp://i995.photobucket.com/albums/af71/phunkferret/Updates%20to%20rally%20car/rallycar049.jpghttp://i995.photobucket.com/albums/af71/phunkferret/Updates%20to%20rally%20car/rallycar051.jpg

Above the hand tool in use.

[dj_wudgey]

gutted was a awesome looking car this and its batterd now :(

[phunkynova]

Here one of the car in Action

http://i995.photobucket.com/albums/af71/phunkferret/Car%20in%20action/ak_a_319_shiel_1.jpg

[Andy]

good work with the tool you have made.
Keep it updated,will keep an eye on this,well done.
Thats a brilliant pic!!!!

[dj_wudgey]

looks cool side ways on that rally mate lol

[phunkynova]

gutted was a awesome looking car this and its batterd now :(
No it's back looking good see photo in action taken since the rebuild :thumb:

[dj_wudgey]

thats ok then matey lol

[mayhem]

http://www.pesch.cz/opel/opel-corsa-a

you might already know it, but who cares lol

[phunkynova]

http://www.pesch.cz/opel/opel-corsa-a

you might already know it, but who cares lol
Thanks for the info. I already know about them.
Thanks any way :thumb:

[boffer8]

Good to see you have put it back to being decent after the severe battering it seemed to have in that rallycross!

[phunkynova]

Hi all I've been doing some work on the car over winter. I was not happy with the suspension setup as I'm doing Tarmac rally's now and the car has a more off road setup.
First job play with the bottom arms. I wanted adjustable arms so I started by cutting the old inner rubber mounts off


http://i995.photobucket.com/albums/af71/phunkferret/Part%202%20updates/rallycarupdatesFeb2011005.jpg


http://i995.photobucket.com/albums/af71/phunkferret/Part%202%20updates/rallycarupdatesFeb2011006.jpg


http://i995.photobucket.com/albums/af71/phunkferret/Part%202%20updates/rallycarupdatesFeb2011008.jpg


Then I cut and welded a plate to the end

http://i995.photobucket.com/albums/af71/phunkferret/Part%202%20updates/rallycarupdatesFeb2011009.jpg


http://i995.photobucket.com/albums/af71/phunkferret/Part%202%20updates/rallycarupdatesFeb2011032.jpg


next drilled a hole and made a opening then fitted a threaded insert

http://i995.photobucket.com/albums/af71/phunkferret/Part%202%20updates/rallycarupdatesFeb2011034.jpg



http://i995.photobucket.com/albums/af71/phunkferret/Part%202%20updates/rallycarupdatesFeb2011012.jpg


A plate was cut and welded to the bottom of the arm for strength

http://i995.photobucket.com/albums/af71/phunkferret/Part%202%20updates/rallycarupdatesFeb2011013.jpg


http://i995.photobucket.com/albums/af71/phunkferret/Part%202%20updates/rallycarupdatesFeb2011015.jpg


Two holes were cut of the bolts


http://i995.photobucket.com/albums/af71/phunkferret/Part%202%20updates/rallycarupdatesFeb2011017.jpg

[phunkynova]

After a bit of a clean up and some paint

http://i995.photobucket.com/albums/af71/phunkferret/Part%202%20updates/rallycarupdatesFeb2011001.jpg


http://i995.photobucket.com/albums/af71/phunkferret/Part%202%20updates/rallycarupdatesFeb2011002.jpg


http://i995.photobucket.com/albums/af71/phunkferret/Part%202%20updates/rallycarupdatesFeb2011003.jpg


http://i995.photobucket.com/albums/af71/phunkferret/Part%202%20updates/rallycarupdatesFeb2011004.jpg

[phunkynova]

Next up where the Tie Bar mounts, out with the old rubber ones in with these Bad boys


http://i995.photobucket.com/albums/af71/phunkferret/Part%202%20updates/rallycarupdatesFeb2011022.jpg


http://i995.photobucket.com/albums/af71/phunkferret/Part%202%20updates/rallycarupdatesFeb2011021.jpg


A new set of top mounts come next


http://i995.photobucket.com/albums/af71/phunkferret/Part%202%20updates/rallycarupdatesFeb2011026.jpg


And least but not last a set of comp spec AVO adjustable coil overs


http://i995.photobucket.com/albums/af71/phunkferret/Part%202%20updates/rallycarupdatesFeb2011023.jpg



http://i995.photobucket.com/albums/af71/phunkferret/Part%202%20updates/rallycarupdatesFeb2011024.jpg


All my new toys in place


http://i995.photobucket.com/albums/af71/phunkferret/Part%202%20updates/rallycarupdatesFeb2011027.jpg



http://i995.photobucket.com/albums/af71/phunkferret/Part%202%20updates/rallycarupdatesFeb2011028.jpg



http://i995.photobucket.com/albums/af71/phunkferret/Part%202%20updates/rallycarupdatesFeb2011029.jpg



http://i995.photobucket.com/albums/af71/phunkferret/Part%202%20updates/rallycarupdatesFeb2011030.jpg


That's all for now. I hope you liked :thumb:.

[Dervy]

do you have to run the standard front brakes?

[phunkynova]

No just not got around to them yet lol
They don't over heat as the stages are not so long with a good time between stages to cool down.
That or I need to drive harder. lol

[Iain]

Nice work that setup looks cool. Are you planning on making the caster adjustable somehow?

[phunkynova]

The Castor can be set using the adjustable top mounts but i have also modified the strut house top so I get 4 degrees Castor now.
I'll try to get some photos of the strut top mount mods on here over the next few days.

[phunkynova]

A bit update to this old thread, as some of you now know the red nova shell was well and truly knacked at the end of last year helped along by me and a tree and a Wild Boar :eek:

http://i995.photobucket.com/albums/af71/phunkferret/Rallye%20Strela%202011/RallycrashRakovnik001.jpg


http://i995.photobucket.com/albums/af71/phunkferret/Rallye%20Strela%202011/RallycrashRakovnik011.jpg

And the Wild Boar handy work

http://i995.photobucket.com/albums/af71/phunkferret/Wild%20Boar%20damage/RallycrashWidBoar005.jpg


http://i995.photobucket.com/albums/af71/phunkferret/Wild%20Boar%20damage/RallycrashWidBoar001.jpg


The PIG :mad:

http://i995.photobucket.com/albums/af71/phunkferret/Wild%20Boar%20damage/2011-11-20115348.jpg



So after all this damage it was best to find a new donor car.
This little gem came my way :thumb:

http://i995.photobucket.com/albums/af71/phunkferret/Silver%20Corsa%20A/SilverCorsaA001.jpg

So it was written the Nova would become a Corsa A.

[phunkynova]

Work started on the Corsa A a full strip out :)

http://i995.photobucket.com/albums/af71/phunkferret/Making%20of%20the%20yellow%20rally%20car/NewShell001.jpg


http://i995.photobucket.com/albums/af71/phunkferret/Making%20of%20the%20yellow%20rally%20car/NewShell006.jpg

Still a bit more to take out but getting there.

Next up is to start welding in the strengthening kit and a bit of seam welding.
Don't laugh too much at the welding I'm not a weld I cut grass for a living lol

http://i995.photobucket.com/albums/af71/phunkferret/Making%20of%20the%20yellow%20rally%20car/NewShell012.jpg

http://i995.photobucket.com/albums/af71/phunkferret/Making%20of%20the%20yellow%20rally%20car/NewShell013.jpg

I made a this to help me

http://i995.photobucket.com/albums/af71/phunkferret/Making%20of%20the%20yellow%20rally%20car/NewShell014.jpg

Some weld in bits

http://i995.photobucket.com/albums/af71/phunkferret/Making%20of%20the%20yellow%20rally%20car/NewShell016.jpg

http://i995.photobucket.com/albums/af71/phunkferret/Making%20of%20the%20yellow%20rally%20car/NewShell017.jpg

more to follow :d

[phunkynova]

In the last photo is the rear sump guard mounting bracket.
So back to weld.

http://i995.photobucket.com/albums/af71/phunkferret/Making%20of%20the%20yellow%20rally%20car/NewShell018.jpg

http://i995.photobucket.com/albums/af71/phunkferret/Making%20of%20the%20yellow%20rally%20car/NewShell019.jpg


The sump guard bracket in place

http://i995.photobucket.com/albums/af71/phunkferret/Making%20of%20the%20yellow%20rally%20car/NewShell020.jpg


http://i995.photobucket.com/albums/af71/phunkferret/Making%20of%20the%20yellow%20rally%20car/NewShell022.jpg

http://i995.photobucket.com/albums/af71/phunkferret/Making%20of%20the%20yellow%20rally%20car/NewShell024.jpg


http://i995.photobucket.com/albums/af71/phunkferret/Making%20of%20the%20yellow%20rally%20car/NewShell025.jpg


IF ANYONE KNOWS WHERE THESE GO I WOULD LOVE TO KNOW :confused: :thumb:

http://i995.photobucket.com/albums/af71/phunkferret/Making%20of%20the%20yellow%20rally%20car/NewShell026.jpg

http://i995.photobucket.com/albums/af71/phunkferret/Making%20of%20the%20yellow%20rally%20car/NewShell028.jpg


http://i995.photobucket.com/albums/af71/phunkferret/Making%20of%20the%20yellow%20rally%20car/NewShell027.jpg

I will be putting update's on, over the next 4 week's or so until it's finished.
The next installment should be in a few days time. :thumb:

[Southie]

My words you don't mess about, nice shell btw... whens your first outing planned?

[phunkynova]

First event should be in April

[Southie]

You'll be able to build another then in that time lol

Is it cheaper than the UK for rallying in your neck of the woods then?

[Iain]

Nice shell prep mate, plating looks good. Think the triangle ones box the chassis legs to the crossmember, that kind of area?

[phunkynova]

You'll be able to build another then in that time lol

Is it cheaper than the UK for rallying in your neck of the woods then?

Yer a hell of a lot cheaper I couldn't do it in the UK any more.

[phunkynova]

Nice shell prep mate, plating looks good. Think the triangle ones box the chassis legs to the crossmember, that kind of area?

Thanks Iain I'll look at that tomorrow. :thumb:

[Iain]

Just found this for you:

http://img.photobucket.com/albums/v310/TheSimps/Nova/Nova%20Coupe%20Project/06-07-084.jpg

[phunkynova]

HO yer I also have a name for the new rally car "PIG KILLER 2" lol

[phunkynova]

Just found this for you:

http://img.photobucket.com/albums/v310/TheSimps/Nova/Nova%20Coupe%20Project/06-07-084.jpg

My two big plates cover that area so they are not for there and he's put the tie bar plate on wrong it should be on the under side.

[timbo1980]

Leftover plates go on the little ridge behind lower arm mount & goes to the floor but think your sump guard mounts may prevent you from fitting them

[phunkynova]

OK only a small update as I've been busy at work and away for a few days.
I've removed all the sound deadening material and cut out all the brackets that I don't need.

http://i995.photobucket.com/albums/af71/phunkferret/Making%20of%20the%20yellow%20rally%20car/NewShell029.jpg


http://i995.photobucket.com/albums/af71/phunkferret/Making%20of%20the%20yellow%20rally%20car/NewShell030.jpg

I will do more over the next few days.

[phunkynova]

Started to test fit the roll-cage and welding in the foot plates.

http://i995.photobucket.com/albums/af71/phunkferret/Making%20of%20the%20yellow%20rally%20car/NewShell036.jpg


http://i995.photobucket.com/albums/af71/phunkferret/Making%20of%20the%20yellow%20rally%20car/NewShell037.jpg

[Iain]

Cage looks sweet, is it a modified Safety Devices one?

[phunkynova]

Yes it is Iain and it will also be triangulated to the front struts.

[tom reid]

Looking good matey.

[Dayle_]

Looking a really tidy shell that Graham!

[phunkynova]

Thanks Tom and Dayle, it is one hell of a good shell :thumb:
I did a bit more on it today, I finished welding in the mount for the rollcage and made the front triangulation to the struts :).

http://i995.photobucket.com/albums/af71/phunkferret/Making%20of%20the%20yellow%20rally%20car/NewShell041.jpg


http://i995.photobucket.com/albums/af71/phunkferret/Making%20of%20the%20yellow%20rally%20car/NewShell042.jpg


http://i995.photobucket.com/albums/af71/phunkferret/Making%20of%20the%20yellow%20rally%20car/NewShell047.jpg


http://i995.photobucket.com/albums/af71/phunkferret/Making%20of%20the%20yellow%20rally%20car/NewShell048.jpg


http://i995.photobucket.com/albums/af71/phunkferret/Making%20of%20the%20yellow%20rally%20car/NewShell049.jpg

Some goodies I pick up while I was in England, I think the Seat will go well with the yellow and black colour scheme I have for the car.

http://i995.photobucket.com/albums/af71/phunkferret/Making%20of%20the%20yellow%20rally%20car/NewShell051.jpg

Some new 256mm :thumb:

http://i995.photobucket.com/albums/af71/phunkferret/Making%20of%20the%20yellow%20rally%20car/NewShell052.jpg

Carbon fiber wrap for the door cards

http://i995.photobucket.com/albums/af71/phunkferret/Making%20of%20the%20yellow%20rally%20car/NewShell054.jpg


More to come over the next few weeks ;).

[phunkynova]

I've been tiding up a few parts ready to go back in the car when the painting is finished. :thumb:

http://i995.photobucket.com/albums/af71/phunkferret/Making%20of%20the%20yellow%20rally%20car/NewShell055.jpg


http://i995.photobucket.com/albums/af71/phunkferret/Making%20of%20the%20yellow%20rally%20car/NewShell056.jpg


http://i995.photobucket.com/albums/af71/phunkferret/Making%20of%20the%20yellow%20rally%20car/NewShell057.jpg


http://i995.photobucket.com/albums/af71/phunkferret/Making%20of%20the%20yellow%20rally%20car/NewShell058.jpg


http://i995.photobucket.com/albums/af71/phunkferret/Making%20of%20the%20yellow%20rally%20car/NewShell059.jpg

Painted the dash black. I used MATT paint but some how it's come out with a shine to it :wtf:.

http://i995.photobucket.com/albums/af71/phunkferret/Making%20of%20the%20yellow%20rally%20car/NewShell060.jpg

http://i995.photobucket.com/albums/af71/phunkferret/Making%20of%20the%20yellow%20rally%20car/NewShell061.jpg


http://i995.photobucket.com/albums/af71/phunkferret/Making%20of%20the%20yellow%20rally%20car/NewShell063.jpg

I can't wait to start putting it all back together :).

[pie]

looking good buddy

[phunkynova]

Have your sunglasses ready :cool:
OK the car is now in paint but still a bit to do be for it's finished, the underside, wheel arches, inside. :)


http://i995.photobucket.com/albums/af71/phunkferret/Making%20of%20the%20yellow%20rally%20car/NewShell064.jpg


http://i995.photobucket.com/albums/af71/phunkferret/Making%20of%20the%20yellow%20rally%20car/NewShell065.jpg


http://i995.photobucket.com/albums/af71/phunkferret/Making%20of%20the%20yellow%20rally%20car/NewShell066.jpg


http://i995.photobucket.com/albums/af71/phunkferret/Making%20of%20the%20yellow%20rally%20car/NewShell067.jpg


http://i995.photobucket.com/albums/af71/phunkferret/Making%20of%20the%20yellow%20rally%20car/NewShell068.jpg


http://i995.photobucket.com/albums/af71/phunkferret/Making%20of%20the%20yellow%20rally%20car/NewShell069.jpg

So what do you think to the colour ?.

[mk1nova_rich]

Very nice mate, love the colour :thumb: wish I could afford to get mine repainted :(

[mk1nova_rich]

You not running a bias pedal box?

[phunkynova]

You not running a bias pedal box?
No I'm not I have some disability in my feet and leg's so I can't put too much presser though them so I need the servo to help me. :)
I have been keeping a eye on your thread it's looking good.:thumb:

[Royston]

Like the colour scheme:thumb:

Will the wild boar now see you coming and keep out of the way?

[phunkynova]

Like the colour scheme:thumb:

Will the wild boar now see you coming and keep out of the way?

I hope so Royston lol:thumb:

[billewizz]

yellow and black very works opel colours from the 70s !!! very nice

[phunkynova]

Yer that was in the back of my mind when i did it :d
Thanks billewizz :thumb:

[phunkynova]

Done a bit more at it put the Rollcage in and welded up the triangulation to the front struts :thumb:

http://i995.photobucket.com/albums/af71/phunkferret/Making%20of%20the%20yellow%20rally%20car/NewShell070.jpg


http://i995.photobucket.com/albums/af71/phunkferret/Making%20of%20the%20yellow%20rally%20car/NewShell071.jpg


http://i995.photobucket.com/albums/af71/phunkferret/Making%20of%20the%20yellow%20rally%20car/NewShell072.jpg


http://i995.photobucket.com/albums/af71/phunkferret/Making%20of%20the%20yellow%20rally%20car/NewShell073.jpg

http://i995.photobucket.com/albums/af71/phunkferret/Making%20of%20the%20yellow%20rally%20car/NewShell074.jpg

Put the fuel tank in.

http://i995.photobucket.com/albums/af71/phunkferret/Making%20of%20the%20yellow%20rally%20car/NewShell075.jpg

Strated to put the wiring loom back in.

http://i995.photobucket.com/albums/af71/phunkferret/Making%20of%20the%20yellow%20rally%20car/NewShell076.jpg

Had to cut a new hole for the loom as the triangulation uses the old wiring hole lol

http://i995.photobucket.com/albums/af71/phunkferret/Making%20of%20the%20yellow%20rally%20car/NewShell078.jpg


It coming together slowly :thumb:.

[Plug]

Looking good buddy :) cant wait to see it back in use :thumb:

[Southie]

:cool: as fook, love the colour... love the progress :)

[phunkynova]

It's starting to take shape now dash is in and most of the wiring has been done just some odd end to do and put in a extra fuse box and a tide up of the extra cables that went in to the car.
wipers are in brake servo and pedals and a few other bits and pieces are all so in.

http://i995.photobucket.com/albums/af71/phunkferret/Making%20of%20the%20yellow%20rally%20car/NewShell079.jpg

http://i995.photobucket.com/albums/af71/phunkferret/Making%20of%20the%20yellow%20rally%20car/NewShell080.jpg

http://i995.photobucket.com/albums/af71/phunkferret/Making%20of%20the%20yellow%20rally%20car/NewShell082.jpg


http://i995.photobucket.com/albums/af71/phunkferret/Making%20of%20the%20yellow%20rally%20car/NewShell084.jpg


Go on put your hands up if you spotted the big mistake I made :confused: Well look again it's there :wtf:


Yep I put a RHD rack in the car and there is a difference, I didn't spot it at first but the steering wheel has a slight angel to the rest of the column :eek: so a RHD one sit all wrong in a LHD car. lol So I must put the Opel one in.

http://i995.photobucket.com/albums/af71/phunkferret/Making%20of%20the%20yellow%20rally%20car/NewShell081.jpg

Ho yer the seat rails are in but my navigator Phil welded his in and I did mine :confused: is there a lack of trust between us :d.

[Spudly]

Lmao i was going to say your mistake was you fitted the wheel on the wrong side of the car lol




Looking fantastic, i really hope the wildlife and tree's stay well away from this one for you:thumb:

[phunkynova]

Thanks for the positive comment's so far guys. I did a bit more over the weekend, spent many hours but it dose not seam to be much, ho well here it is.
I put in the brake lines and the petrol line/fuel presser regulator/rear axle/engine cut off pull and a bit more on the wiring but still some to do on that front.

http://i995.photobucket.com/albums/af71/phunkferret/Making%20of%20the%20yellow%20rally%20car/NewShell088.jpg


http://i995.photobucket.com/albums/af71/phunkferret/Making%20of%20the%20yellow%20rally%20car/NewShell089.jpg


http://i995.photobucket.com/albums/af71/phunkferret/Making%20of%20the%20yellow%20rally%20car/NewShell090.jpg


http://i995.photobucket.com/albums/af71/phunkferret/Making%20of%20the%20yellow%20rally%20car/NewShell091.jpg


http://i995.photobucket.com/albums/af71/phunkferret/Making%20of%20the%20yellow%20rally%20car/NewShell092.jpg


http://i995.photobucket.com/albums/af71/phunkferret/Making%20of%20the%20yellow%20rally%20car/NewShell093.jpg

Tidied a few parts up with a quick coat of paint as well.

http://i995.photobucket.com/albums/af71/phunkferret/Making%20of%20the%20yellow%20rally%20car/NewShell094.jpg

[phunkynova]

Got some done on the rally car.
I had the Flywheel skimmed and lighted a bit

http://i995.photobucket.com/albums/af71/phunkferret/Making%20of%20the%20yellow%20rally%20car/NewShell098.jpg


Most of the front suspension is now in.

http://i995.photobucket.com/albums/af71/phunkferret/Making%20of%20the%20yellow%20rally%20car/NewShell099.jpg


Tie bar rose joints are in not easy to fit when you've done the plating as well !!! :mad:

http://i995.photobucket.com/albums/af71/phunkferret/Making%20of%20the%20yellow%20rally%20car/NewShell100.jpg

Rad is also in.

http://i995.photobucket.com/albums/af71/phunkferret/Making%20of%20the%20yellow%20rally%20car/NewShell101.jpg

Push to pass fitted .

http://i995.photobucket.com/albums/af71/phunkferret/Making%20of%20the%20yellow%20rally%20car/NewShell102.jpg

Loud Air horns lol They work really well :thumb:.

http://i995.photobucket.com/albums/af71/phunkferret/Making%20of%20the%20yellow%20rally%20car/NewShell103.jpg

http://i995.photobucket.com/albums/af71/phunkferret/Making%20of%20the%20yellow%20rally%20car/NewShell104.jpg

Auxiliary fuse box in for air horns/intercom/map light/fuel pumps/ and so on.

http://i995.photobucket.com/albums/af71/phunkferret/Making%20of%20the%20yellow%20rally%20car/NewShell108.jpg

Fuel pumps and lines done plus a box to put the pumps in .

http://i995.photobucket.com/albums/af71/phunkferret/Making%20of%20the%20yellow%20rally%20car/NewShell109.jpg


http://i995.photobucket.com/albums/af71/phunkferret/Making%20of%20the%20yellow%20rally%20car/NewShell110.jpg

http://i995.photobucket.com/albums/af71/phunkferret/Making%20of%20the%20yellow%20rally%20car/NewShell106.jpg

Two pumps fitted one is back up.
Gearbox ready to go in.

http://i995.photobucket.com/albums/af71/phunkferret/Making%20of%20the%20yellow%20rally%20car/NewShell107.jpg

Only 3 weeks to go before my first rally so I need to get a move on.

[phunkynova]

Some more progress with the car.
I got the seat's in and was able to put the door bars in.

http://i995.photobucket.com/albums/af71/phunkferret/Making%20of%20the%20yellow%20rally%20car/NewShell117.jpg

http://i995.photobucket.com/albums/af71/phunkferret/Making%20of%20the%20yellow%20rally%20car/NewShell116.jpg


Then I started on the adjustable tie bars
First I set the adjusters to the middle of there adjustment, did some measuring then some cutting

http://i995.photobucket.com/albums/af71/phunkferret/Making%20of%20the%20yellow%20rally%20car/NewShell112.jpg

http://i995.photobucket.com/albums/af71/phunkferret/Making%20of%20the%20yellow%20rally%20car/NewShell111.jpg

Then some welding

http://i995.photobucket.com/albums/af71/phunkferret/Making%20of%20the%20yellow%20rally%20car/NewShell114.jpg

http://i995.photobucket.com/albums/af71/phunkferret/Making%20of%20the%20yellow%20rally%20car/NewShell115.jpg

Then loosely fitted them to the car just see how they look.

http://i995.photobucket.com/albums/af71/phunkferret/Making%20of%20the%20yellow%20rally%20car/NewShell118.jpg

http://i995.photobucket.com/albums/af71/phunkferret/Making%20of%20the%20yellow%20rally%20car/NewShell119.jpg

[mowgli]

It might not look too cool, but i think you should get something like bike inner tube & some cable ties to cover the adjusters up so they don't seize up with rust & crap

[phunkynova]

Good point mowgli. I was going to give them a good coat with copper slip.

[thedjse]

excellent motor mate looks really smart and some very nice mods gone into it

[phunkynova]

Thanks thedjse

[novasrikev]

just gone from page1 awesome thread keep up the good work fella

[Royston]

Phunkynova, I am really concerned over your adjustable tie bars, I fear for your safety!!!!:eek:

It has instant failure written all over it..........:eek:

How good are the welds???? The welds are in tension under braking, and from pothole strikes, (which you may come across whilst rallying ) which is bad practice, so there are 2 failure locations on each tiebar, if one lets go you are in serious trouble:eek:

Please, Please, Please............take them off, I beg you, they are a bad idea

(I did spend many years durability/strength testing automotive suspension for an OEM supplier)

[mowgli]

royston, in your opinion, what would be a good way of doing this? are we talking external lh & rh threads on the tie bars, re hardening & then tap a lh & rh thread into a piece of tube for the turnbuckle??

[phunkynova]

Then how else should I do it Royston ?. I do understand your concerns.

[Royston]

I am still thinking about a solution, I just know when I have seen a bad idea

Why do you want adjustability? (I assume to set up the suspension of course) do you anticipate changing the set up between rallies?

Once to have your suspension set up, or know where it need to be I think I would probably use standard tie bars and modify the tiebar bracket to suit or a set of shims/washers

I would ask if you really need them

[Royston]

royston, in your opinion, what would be a good way of doing this? are we talking external lh & rh threads on the tie bars, re hardening & then tap a lh & rh thread into a piece of tube for the turnbuckle??

That sounds like a reasonable solution, i.e. no welds in tension, depending on the forging/heat treatment process used in manufacture (not sure what the O/dia on the tie bar is)

Might be worth seeing if you can cut a thread direct onto the tiebar (may need to turn down the o/dia first) if it cuts well, might be worth inverstgating further, would recommend a standard course metric thread.

I am a slow burner I'm afraid, like to think about things, especially safety criticallol

I still think the best solution is to use standard tie bars

[phunkynova]

Slowly it's starting to look like a car again, got a bit more done over the weekend.
Got the block and gear box back together and in the car

http://i995.photobucket.com/albums/af71/phunkferret/Making%20of%20the%20yellow%20rally%20car/NewShell122.jpg


http://i995.photobucket.com/albums/af71/phunkferret/Making%20of%20the%20yellow%20rally%20car/NewShell123.jpg

Then I did the doors, put the polycarbonate in plus a bit of tint on them.
Did the door cards complete with carbon fiber look.

http://i995.photobucket.com/albums/af71/phunkferret/Making%20of%20the%20yellow%20rally%20car/NewShell120.jpg

http://i995.photobucket.com/albums/af71/phunkferret/Making%20of%20the%20yellow%20rally%20car/NewShell121.jpg

http://i995.photobucket.com/albums/af71/phunkferret/Making%20of%20the%20yellow%20rally%20car/NewShell124.jpg

Also covered the rear strut brace with the carbon wrap.

http://i995.photobucket.com/albums/af71/phunkferret/Making%20of%20the%20yellow%20rally%20car/NewShell125.jpg


it's getting there slowly :thumb:

[Andy]

Glad someone else noticed the tie bars,the design is horrendous im sorry to say.1 good whack and you would be in an ambulance.

[phunkynova]

Some more work done over the weekend, it really is starting to look like a rally car again.

http://i995.photobucket.com/albums/af71/phunkferret/Making%20of%20the%20yellow%20rally%20car/NewShell126.jpg

Got the spare wheel holder straps in place a old Subaru Justy rear seat belt.

http://i995.photobucket.com/albums/af71/phunkferret/Making%20of%20the%20yellow%20rally%20car/NewShell129.jpg

Hand held fire extinguisher in and the Navigators foot rest done.

http://i995.photobucket.com/albums/af71/phunkferret/Making%20of%20the%20yellow%20rally%20car/NewShell128.jpg


Back in the car dew to popular demand Standard Tie bars !. :):thumb:

http://i995.photobucket.com/albums/af71/phunkferret/Making%20of%20the%20yellow%20rally%20car/NewShell127.jpg

And last of all for now the rim painted in black.

http://i995.photobucket.com/albums/af71/phunkferret/Making%20of%20the%20yellow%20rally%20car/NewShell132.jpg

http://i995.photobucket.com/albums/af71/phunkferret/Making%20of%20the%20yellow%20rally%20car/NewShell130.jpg

[novasrikev]

starting to come together now fella keep up the good work

[phunkynova]

A bit of a sad update took the old shell to the scraper's today :(


http://i995.photobucket.com/albums/af71/phunkferret/Making%20of%20the%20yellow%20rally%20car/NewShell133.jpg


http://i995.photobucket.com/albums/af71/phunkferret/Making%20of%20the%20yellow%20rally%20car/NewShell134.jpg


And it's final resting place :cry:

http://i995.photobucket.com/albums/af71/phunkferret/Making%20of%20the%20yellow%20rally%20car/NewShell135.jpg


But the good news is that I got a Grand for it lol

http://i995.photobucket.com/albums/af71/phunkferret/Making%20of%20the%20yellow%20rally%20car/NewShell136-1.jpg

[pikey1986]

how much in GBP?

[phunkynova]

how much in GBP?

Just over £35. Not much but the price of scrap metal is not much over here.

[mowgli]

280kg works out at over £100 a ton for mixed steel... not too bad really..

when you look at all the ally that modern cars have in them it starts to get pretty close to uk price

[calibra-keith]

loving the yellow/black and red, yours is basically how i want mine to look but with wide arches

[Connor]

Haven't checked this in a while, but some top work going into the new build. Keep it up :thumb:

[Spudly]

Just re-read through this from the start, and re the tie bars, if you really NEED adjustment, the only way i could think of doing it and retaining as much strength as possible i think, would be to remove them again, and machine down the front end (cross member end) so that it can slide into the mounting point and move further forward than normal, then space it out with suitable washers depending on where you need it to be, then bung the nut back on, granted this will only give you a little adjustment on them and will only be to move the wheel forwards, but i cant think why you would need to move the angle of the wheel rearwards, so this may be an effective solution?


Oh and it looks far too nice now to throw around a rally stage lol

[phunkynova]

Not done much on the car for the last few weeks as I've been awaiting some part from the UK.
And they are here so time to get cracking again.
Decided to clean the inside of the sump pan before refitting it and found this in there at first I thought it was metal I would have to pull the engine apart to find where it came from but after cleaning it, it's glass :wtf:

http://i995.photobucket.com/albums/af71/phunkferret/Making%20of%20the%20yellow%20rally%20car/NewShell140.jpg

http://i995.photobucket.com/albums/af71/phunkferret/Making%20of%20the%20yellow%20rally%20car/NewShell142.jpg

Don't ask I have no idea how it got there.
Here are the goodies to help put the motor back together.

http://i995.photobucket.com/albums/af71/phunkferret/Making%20of%20the%20yellow%20rally%20car/NewShell138.jpg

So sump back on now start at the top.

http://i995.photobucket.com/albums/af71/phunkferret/Making%20of%20the%20yellow%20rally%20car/NewShell144.jpg

Got some of the GM sealant

http://i995.photobucket.com/albums/af71/phunkferret/Making%20of%20the%20yellow%20rally%20car/NewShell145.jpg

http://i995.photobucket.com/albums/af71/phunkferret/Making%20of%20the%20yellow%20rally%20car/NewShell149.jpg

New head bolts and instructions on fitting.

http://i995.photobucket.com/albums/af71/phunkferret/Making%20of%20the%20yellow%20rally%20car/NewShell146.jpg

http://i995.photobucket.com/albums/af71/phunkferret/Making%20of%20the%20yellow%20rally%20car/NewShell147.jpg

Knocked up a angel card.

http://i995.photobucket.com/albums/af71/phunkferret/Making%20of%20the%20yellow%20rally%20car/NewShell150.jpg

And it's all back together and running some work to be done tomorrow.

http://i995.photobucket.com/albums/af71/phunkferret/Making%20of%20the%20yellow%20rally%20car/NewShell151.jpg


:):thumb:

[phunkynova]

Did a bit more today put the braided brake line's in

http://i995.photobucket.com/albums/af71/phunkferret/Making%20of%20the%20yellow%20rally%20car/NewShell152.jpg


http://i995.photobucket.com/albums/af71/phunkferret/Making%20of%20the%20yellow%20rally%20car/NewShell153.jpg


I wanted to fit a different steering wheel but I know they are complete B's to get off , but I have a puller just the wrong one for the steering wheel :(

http://i995.photobucket.com/albums/af71/phunkferret/Making%20of%20the%20yellow%20rally%20car/NewShell154.jpg

So I made some new leg's for it out of some scrap metal and two Allan keys :thumb:
and it worked.

http://i995.photobucket.com/albums/af71/phunkferret/Making%20of%20the%20yellow%20rally%20car/NewShell156.jpg

http://i995.photobucket.com/albums/af71/phunkferret/Making%20of%20the%20yellow%20rally%20car/NewShell157.jpg

All so knocked up a pedal stop as the bike carbs have a very short pedal travel.

http://i995.photobucket.com/albums/af71/phunkferret/Making%20of%20the%20yellow%20rally%20car/NewShell159.jpg

I've got just over a week to have it fully ready for the next rally.

[phunkynova]

Fitted the sump guard today I all so added some side guard to limit the amount of water/stones and so on getting into the engine bay.

http://i995.photobucket.com/albums/af71/phunkferret/Making%20of%20the%20yellow%20rally%20car/NewShell163.jpg

http://i995.photobucket.com/albums/af71/phunkferret/Making%20of%20the%20yellow%20rally%20car/NewShell161.jpg


http://i995.photobucket.com/albums/af71/phunkferret/Making%20of%20the%20yellow%20rally%20car/NewShell160.jpg


http://i995.photobucket.com/albums/af71/phunkferret/Making%20of%20the%20yellow%20rally%20car/NewShell164.jpg


http://i995.photobucket.com/albums/af71/phunkferret/Making%20of%20the%20yellow%20rally%20car/NewShell162.jpg

http://i995.photobucket.com/albums/af71/phunkferret/Making%20of%20the%20yellow%20rally%20car/NewShell165.jpg

Well it's all most finished, soon will be the photos of the complete car :d:thumb:

[kenny_afh]

looking good! like the attention to detail that youve been putting in. especially the sump guard sides!

im curious, with a name like graham sheil, how do you find yourself living in CZ?

[thedjse]

loving the work again pal colours are awesome but as mentioned it is far to nice to throw into a rally lol

[phunkynova]

looking good! like the attention to detail that youve been putting in. especially the sump guard sides!

im curious, with a name like Graham Shiel, how do you find yourself living in CZ?

Thanks for the comments, as for attention to detail it has nothing on some of the build threads on here.
Why am I in Czech it's a no brainer that one, cheap bloody good beer £1 a pint in town and 50p local, cheap motor sport, fine women, good weather, good job, I left the Uk in 1991 and not been back to live there since, I lived 16 years in Germany and now here it's where my work took me.:thumb:

[phunkynova]

loving the work again pal colours are awesome but as mentioned it is far to nice to throw into a rally lol

I should have it finished by Saturday and I will put up some photos of the full car then and as for rallying it, that's what it's built for I just hope I don't throw it off the road too soon, But I will at one point :d as my brother all ways said if you don't have one big off a year your not trying hard enough :thumb:.

[kenny_afh]

cant argue with that! sure theres plently of folk who dream of doing that but dont have the bottle, so fair play to you! keep up the good work with the car!

[phunkynova]

It's Done yerrrrrrrrrr :):thumb:

http://i995.photobucket.com/albums/af71/phunkferret/Making%20of%20the%20yellow%20rally%20car/NewShell166.jpg

http://i995.photobucket.com/albums/af71/phunkferret/Making%20of%20the%20yellow%20rally%20car/NewShell167.jpg

http://i995.photobucket.com/albums/af71/phunkferret/Making%20of%20the%20yellow%20rally%20car/NewShell168.jpg


http://i995.photobucket.com/albums/af71/phunkferret/Making%20of%20the%20yellow%20rally%20car/NewShell169.jpg


http://i995.photobucket.com/albums/af71/phunkferret/Making%20of%20the%20yellow%20rally%20car/NewShell170.jpg

http://i995.photobucket.com/albums/af71/phunkferret/Making%20of%20the%20yellow%20rally%20car/NewShell171.jpg

But I'm not too happy with the back screen tint it was the first one I did so when I get some time I'll redo it.

http://i995.photobucket.com/albums/af71/phunkferret/Making%20of%20the%20yellow%20rally%20car/NewShell172.jpg

http://i995.photobucket.com/albums/af71/phunkferret/Making%20of%20the%20yellow%20rally%20car/NewShell173.jpg

http://i995.photobucket.com/albums/af71/phunkferret/Making%20of%20the%20yellow%20rally%20car/NewShell174.jpg

http://i995.photobucket.com/albums/af71/phunkferret/Making%20of%20the%20yellow%20rally%20car/NewShell175.jpg

[phunkynova]

http://i995.photobucket.com/albums/af71/phunkferret/Making%20of%20the%20yellow%20rally%20car/NewShell176.jpg


http://i995.photobucket.com/albums/af71/phunkferret/Making%20of%20the%20yellow%20rally%20car/NewShell177.jpg


What do you think to this works or dose not work ?

http://i995.photobucket.com/albums/af71/phunkferret/Making%20of%20the%20yellow%20rally%20car/NewShell178.jpg


http://i995.photobucket.com/albums/af71/phunkferret/Making%20of%20the%20yellow%20rally%20car/NewShell179.jpg


http://i995.photobucket.com/albums/af71/phunkferret/Making%20of%20the%20yellow%20rally%20car/NewShell180.jpg

And the name of the car is

http://i995.photobucket.com/albums/af71/phunkferret/Making%20of%20the%20yellow%20rally%20car/NewShell181.jpg


http://i995.photobucket.com/albums/af71/phunkferret/Making%20of%20the%20yellow%20rally%20car/NewShell182.jpg


http://i995.photobucket.com/albums/af71/phunkferret/Making%20of%20the%20yellow%20rally%20car/NewShell183.jpg


http://i995.photobucket.com/albums/af71/phunkferret/Making%20of%20the%20yellow%20rally%20car/NewShell184.jpg


http://i995.photobucket.com/albums/af71/phunkferret/Making%20of%20the%20yellow%20rally%20car/NewShell185.jpg

http://i995.photobucket.com/albums/af71/phunkferret/Making%20of%20the%20yellow%20rally%20car/NewShell186.jpg


I hope you all like it now to go out there and race it :d:thumb:

[pie]

looking good buddy :)

[phunkynova]

Thanks pie :thumb:

[Royston]

Looks great, look after this one:d

[phunkynova]

Looks great, look after this one:d

I will try too Royston ...first rally on Tuesday :thumb: a small event but will be good for testing.

[kent14sr]

What wheels are they? Minator? They look awesome on the car - and the car looks great too!

[dc1984]

Hahaha that's quality mate, love the fuel tank:thumb:

David.

[tom reid]

Very nice mate, it's a credit to you.

[phunkynova]

What wheels are they? Minator? They look awesome on the car - and the car looks great too!

Sorry I'm not sure what make they are I got them with the car but they have had the centers machined out to fit over the GM hubs.

[phunkynova]

Hahaha that's quality mate, love the fuel tank:thumb:

David.

Are taking about the Jerry can one, if so that was only in for the short time I used it for Rally-cross.

[phunkynova]

Thanks Tom :thumb:

[phunkynova]

Thanks Royston I will try too.
just be testing the car some small problems which are :

1 As I gone up a wheel size and tyer size they are rubbing on the front wings so I will have to use a small spacer on the front hub.
2 There is a small problem with the cooling system the temp is fine around 85 but after a run its hissing lightly and burbling lightly if I undo the res tank cap there is some pressure but no more than I would expect, with engine off I can put the cap back on and 5 mins later its hissing again.
I'm hoping its not the head gasket.

[thedjse]

loveeeeeeeeeeeeeeeee it what is the silver thing on the grill and what did you use for door cards?????

[phunkynova]

loveeeeeeeeeeeeeeeee it what is the silver thing on the grill and what did you use for door cards?????

The door cards are thin alloy with carbon fiber look vinyl wrap on them and as for the silver thing its a side latch that stops the center of the fiberglass bonnet from lifting as high speeds.

[mowgli]

Thanks Royston I will try too.
just be testing the car some small problems which are :

1 As I gone up a wheel size and tyer size they are rubbing on the front wings so I will have to use a small spacer on the front hub.
2 There is a small problem with the cooling system the temp is fine around 85 but after a run its hissing lightly and burbling lightly if I undo the res tank cap there is some pressure but no more than I would expect, with engine off I can put the cap back on and 5 mins later its hissing again.
I'm hoping its not the head gasket.

are you sure its not just the coolant bottle cap that needs renewing?

[phunkynova]

Hi all done a bit more work on the car.
To start of with, the tie bars I need to get 4 degrees of castor and my first attempt to make adjustable arms was not liked by many they were deemed unsafe.
So here the Evo 2 type, I had the front insert milled down a 10mm more so I could push them through the front tie bar mount more moving the bottom of the strut forwards to give me the castor and by using washers I could set how much I moved them.
Standard one in red milled in black.

http://i995.photobucket.com/albums/af71/phunkferret/Big%20V%20head/Newbigvhead018.jpg


The washers.

http://i995.photobucket.com/albums/af71/phunkferret/Big%20V%20head/Newbigvhead019.jpg


And in place

http://i995.photobucket.com/albums/af71/phunkferret/Big%20V%20head/Newbigvhead020.jpg

Any comments !.

[Nova-nation]

Oooh finally found your project thread, nice colour! Mines seat cupra yellow, what's yours?

[phunkynova]

Not 100% sure I just picked it out from a set of colour cards but I think it is all so seat yellow.

[Nova-nation]

Looks sweet what ever it is!

[phunkynova]

Thanks Nova-nation sorry for the slow reply's I watching DTM live

[Iain]

Nice work. I remember looking into doing that to the tiebar and I think I was told the difficulty would be mounting it in the machines to do the work, how did you do it?

[phunkynova]

Nice work. I remember looking into doing that to the tiebar and I think I was told the difficulty would be mounting it in the machines to do the work, how did you do it?
I could not tell you I found after a long time looking a small Czech work shop that could do it but in a normal turning machine it was not possible.

[mowgli]

i'm impressed. seriously impressed, the machine to do that must be pretty rare & intricate.

and you get rock solid tie bars too..

well done.

[phunkynova]

Thanks mowgli :thumb:

[Lewis.]

How have I only just seen this thread? the car looks fantastic mate, looking forwards to seeing some pictures of it in action :)

[phunkynova]

Got my BIG VALVE HEAD the other day so it time to fit it.
The old and new heads together

http://i995.photobucket.com/albums/af71/phunkferret/Big%20V%20head/Newbigvhead011.jpg

some spot the difference photos now

http://i995.photobucket.com/albums/af71/phunkferret/Big%20V%20head/Newbigvhead016.jpg


http://i995.photobucket.com/albums/af71/phunkferret/Big%20V%20head/Newbigvhead017.jpg


The operating table is per-paired let surgery begin.

http://i995.photobucket.com/albums/af71/phunkferret/Big%20V%20head/Newbigvhead022.jpg

Out with the old

http://i995.photobucket.com/albums/af71/phunkferret/Big%20V%20head/Newbigvhead021.jpg

In with the new

http://i995.photobucket.com/albums/af71/phunkferret/Big%20V%20head/Newbigvhead023.jpg

[phunkynova]

How have I only just seen this thread? the car looks fantastic mate, looking forwards to seeing some pictures of it in action :)

What like this !

http://i995.photobucket.com/albums/af71/phunkferret/Sosnova/Sosnova2012.jpg

[gteben]

that looks bloody awsome mate............. have you got any clips of it running ???? would love to hear an see it go on them carbs

[phunkynova]

that looks bloody awsome mate............. have you got any clips of it running ???? would love to hear an see it go on them carbs

It's not so good but here you go


http://youtu.be/clWGsPbvJx0

[phunkynova]

I've been have some fuel feed problem over the last two rally's, at first I believed it to be electrical but after changing every thing the problem was still there :mad:.
I had a the start of this year fitted a second fuel pump as back up but it seams that these motorbike pumps don't like back pressure causing them to shut down.

The old two pump set up

http://i995.photobucket.com/albums/af71/phunkferret/Making%20of%20the%20yellow%20rally%20car/NewShell109.jpg

So I when out and got a new Facet Pump and planed to put it here.

http://i995.photobucket.com/albums/af71/phunkferret/Fuel%20Pump/Fuel%20Pump%20002_zps917b1898.jpg


http://i995.photobucket.com/albums/af71/phunkferret/Fuel%20Pump/Fuel%20Pump%20005_zps3fee320a.jpg

But there was no room to make a good fitting safety box around it and get the Co-Driver seat back in its original place.
So it was then to Plan B (all good villains have a Plan B lol)
Put it under the car near the fuel tank

http://i995.photobucket.com/albums/af71/phunkferret/Fuel%20Pump/Fuel%20Pump%20006_zpsb4071114.jpg

http://i995.photobucket.com/albums/af71/phunkferret/Fuel%20Pump/Fuel%20Pump%20009_zps749e763c.jpg

Hope that this solves the problem :thumb:.

[kenny_afh]

in terms of the pump thats the perfect place for it, apparently they prefer to "push" the fuel towards the engine rather than being in the bay and having to "pull" towards the engine. and they work best sitting vertical with the outlet to the top. however, be very careful that it doesnt come off, those rubber bobbins arent great! might be better drilling a bit of rubber to act as a shock absorber and stick a bolt through the lot. thats how mine are done. mine are in the engine bay tho, and work absolutely fine with a thirsty 1400 16v on 45s! so thats another option available to you.

[phunkynova]

OK thanks for the info Kenny_afh the rubbers came with the pump as part of a kit.

[kenny_afh]

yeah i know, i fitted mine with them initially but they gave alot of movement and the pumps were hitting off the shell with their own vibrations so i changed to bolts and a small bit of rubber, mudflap material or similar would be enough. id recommend nyloc nuts too, i was surpised at the vibrations from them. its looking good tho, and i certainly wasnt trying to take anything away from the car, just sharing my experiences :)

[phunkynova]

I did not think for one moment you was dissing my car Kenny_aft, I keep it in mind what you said and if I have any problems I'll know the cure.

[turbojolt]

amazing thread mate, i was going to run full braided lines for my brakes but if the old style metal pipes are good enough for this then there going to be fine on my fast road/track day car, epic work fella i will keep a better eye out for this thread from now on :thumb:

[phunkynova]

TJ you only need to replace the flexible brake lines with braided it is easier and cheaper to do, you can buy kit set to do it.

[phunkynova]

OK so I haven't done much with the car for a bit so I decided to make myself some work to do


http://i995.photobucket.com/albums/af71/phunkferret/OFF.jpg


So today I started to take some parts off to see how bad it is.

http://i995.photobucket.com/albums/af71/phunkferret/2ndcrashYellow001.jpg


http://i995.photobucket.com/albums/af71/phunkferret/2ndcrashYellow002.jpg


Seams to be some buckling here at the front of the leg

http://i995.photobucket.com/albums/af71/phunkferret/2ndcrashYellow003.jpg


http://i995.photobucket.com/albums/af71/phunkferret/2ndcrashYellow005.jpg

Hopefully it will pull out

http://i995.photobucket.com/albums/af71/phunkferret/2ndcrashYellow008.jpg


This side looks good

http://i995.photobucket.com/albums/af71/phunkferret/2ndcrashYellow011.jpg


From up-top both legs look OK

http://i995.photobucket.com/albums/af71/phunkferret/2ndcrashYellow012.jpg


http://i995.photobucket.com/albums/af71/phunkferret/2ndcrashYellow013.jpg


It will need a new crossmember plus the rad/bumper and grill.

[Mazz]

Bugger :( But it could have been a lot worse!

[Danny mul]

Just read from page one.
A super job on the second build.
That shell you found was immaculate and you made good work of building it.
Your too legs look straight enough from the top so happy days.
Enjoy tiding it up and getting it back out for stretch!!!!
Some rep your way for enjoying your machine:thumb:

[kent14sr]

Measure the gaps in the inner wing/leg where the trackrod ends pass through as they often close up after an impact and is difficult to spot till you panel it back up.

[16v Nova Kev]

Bsturd!!!!! wish i lived a bit closer i would love to fix that

[phunkynova]

Just read from page one.
A super job on the second build.
That shell you found was immaculate and you made good work of building it.
Your too legs look straight enough from the top so happy days.
Enjoy tiding it up and getting it back out for stretch!!!!
Some rep your way for enjoying your machine:thumb:

Thank's Danny not sure when I will get around to working on it but hopefully not too long.

[phunkynova]

Thank's for the tip kent14sr I'll keep a eye on that. :thumb:

16v Nova Kev, from Dumbarton to Plzen is not so far lol

[kent14sr]

Here is a link to the thread I started on it;

http://www.pngclub.com/forum/showthread.php?186706-Help-needed-please-Inner-Wing-Chassis-measurements&highlight=

Stunning car by the way, and it bring back memories of my old rally car! The clubman rallying scene looks so much better where you are!

Are shells and parts easy to come by in Czech Republic?

[phunkynova]

No they are not that's the big problem out here I can get some stuff out of Germany but most bit's come from UK if i was running Skoda then it would be easy.

[phunkynova]

Thank's Kent14sr I'll check these out next week :thumb:

http://www.pngclub.com/forum/showthr...ents&highlight (http://www.pngclub.com/forum/showthread.php?186706-Help-needed-please-Inner-Wing-Chassis-measurements&highlight)=

[16v Nova Kev]

This not fixed yet???? Does your carbs run a return line to the tank?

[phunkynova]

This not fixed yet???? Does your carbs run a return line to the tank?

No it's not lol no big rush to do it as there are no normal rally's here in winter time.
No Kev they don't need a return line they use low psi just 3psi :thumb:

[phunkynova]

Ok I've made a start on the rally car this weekend :):thumb:
Chopped out the bent front panel and replaced it had the inner wing pulled straight,
luckily it had only very minor damage just to the front part of the left inner wing.


http://i995.photobucket.com/albums/af71/phunkferret/Front%20end%20Yellow/Xmaspluscar015.jpg


http://i995.photobucket.com/albums/af71/phunkferret/Front%20end%20Yellow/Xmaspluscar014.jpg


http://i995.photobucket.com/albums/af71/phunkferret/Front%20end%20Yellow/Xmaspluscar020.jpg

http://i995.photobucket.com/albums/af71/phunkferret/Front%20end%20Yellow/Xmaspluscar016.jpg


http://i995.photobucket.com/albums/af71/phunkferret/Front%20end%20Yellow/Xmaspluscar017.jpg


http://i995.photobucket.com/albums/af71/phunkferret/Front%20end%20Yellow/Xmaspluscar022.jpg

http://i995.photobucket.com/albums/af71/phunkferret/Front%20end%20Yellow/Xmaspluscar024.jpg


All so got a new rad and front grill as there is not much left of the old one :cry:


http://i995.photobucket.com/albums/af71/phunkferret/Front%20end%20Yellow/Xmaspluscar025.jpg


That's all for now will do some more on it over the next few day's or so.

[16v Nova Kev]

You make that look easy!!!!!

[phunkynova]

You make that look easy!!!!!

It's not so hard to do if you have the right tools for the job.
The first part I did with help of a Czech mechanic as I had no jig to pull the inner wing and being Czech the cost is low ;) :thumb:

[faker]

awesome work mate. Here's a wee pic of mine.
http://i44.photobucket.com/albums/f14/tyreface/DSC00156.jpg

[phunkynova]

NO the number 23 every time I've been given that start number the rally's gone tits up for me :cry:.
Your car looks good I do like the MK1 :thumb:

[phunkynova]

Did a small bit more on the car today worked on the front bumper with a heat gun and big hammer


http://i995.photobucket.com/albums/af71/phunkferret/Front%20end%20Yellow/Xmaspluscar027.jpg


http://i995.photobucket.com/albums/af71/phunkferret/Front%20end%20Yellow/Xmaspluscar029.jpg


http://i995.photobucket.com/albums/af71/phunkferret/Front%20end%20Yellow/Xmaspluscar033.jpg


And then started to repair the damaged fiberglass bonnet

http://i995.photobucket.com/albums/af71/phunkferret/Front%20end%20Yellow/Xmaspluscar031.jpg


http://i995.photobucket.com/albums/af71/phunkferret/Front%20end%20Yellow/Xmaspluscar026.jpg

[Danny mul]

Think you Photoshoped that lump hammer into that pic.
Its way to clean looking!!!!!

[phunkynova]

No just a new one the lads at work killed the old one. :thumb:

[turbojolt]

love how this thread has only 17 pages, but has more work done to a nova then most other project threads (including mine) lol

[phunkynova]

Got some more done today
Did a bit of spray painting and bumper work.

Before

http://i995.photobucket.com/albums/af71/phunkferret/Front%20end%20Yellow/Xmaspluscar030.jpg

After not perfect but not bad it was well mangled in the crash

http://i995.photobucket.com/albums/af71/phunkferret/Front%20end%20Yellow/Xmaspluscar037.jpg


Then but some primer on the panels

http://i995.photobucket.com/albums/af71/phunkferret/Front%20end%20Yellow/Xmaspluscar036.jpg

And now the Yellow bit

http://i995.photobucket.com/albums/af71/phunkferret/Front%20end%20Yellow/Xmaspluscar038.jpg

http://i995.photobucket.com/albums/af71/phunkferret/Front%20end%20Yellow/Xmaspluscar039.jpg

http://i995.photobucket.com/albums/af71/phunkferret/Front%20end%20Yellow/Xmaspluscar040.jpg


Next will be putting it back together when the paint has hardened :thumb:

[turbojolt]

amazing stuff well done fella

[black death]

Nice car mate did you do the carbs your self.also could you give a rough guide on what i would need to do this to a small block spi 8v cheers

stu

[phunkynova]

Nice car mate did you do the carbs your self.also could you give a rough guide on what i would need to do this to a small block spi 8v cheers

stu


The carbs I bought as a complete set from SRJack on here they are on a Bogg Brothers manifold. One of the best people to speak to is Tom Reid, all so on here he has done a far bit with bike carbs on car engines.

[phunkynova]

amazing stuff well done fella

Thanks TJ :thumb:

[phunkynova]

Did some more work on the car today
Fitted the Rad, wings and front bumper
Stated with the Rad and fan housing.

I had to use the heat gun on the plastic fan housing to get it back in shape
Before

http://i995.photobucket.com/albums/af71/phunkferret/Front%20end%20Yellow/Xmaspluscar042_zps109ad73b.jpg

After

http://i995.photobucket.com/albums/af71/phunkferret/Front%20end%20Yellow/Xmaspluscar046_zpse936f101.jpg

Decided not to use the old Rad

http://i995.photobucket.com/albums/af71/phunkferret/Front%20end%20Yellow/Xmaspluscar043_zpscdc6e8c7.jpg


http://i995.photobucket.com/albums/af71/phunkferret/Front%20end%20Yellow/Xmaspluscar044_zpscd7e50aa.jpg

But use this one instead

http://i995.photobucket.com/albums/af71/phunkferret/Front%20end%20Yellow/Xmaspluscar045_zps5566f7d2.jpg

Rad in place

http://i995.photobucket.com/albums/af71/phunkferret/Front%20end%20Yellow/Xmaspluscar047_zpsc4a14248.jpg

Then the wings and headlights

http://i995.photobucket.com/albums/af71/phunkferret/Front%20end%20Yellow/Xmaspluscar048_zps3d8a369d.jpg

And last but not lease A EPIC fight with the front bumper dew to all the metal work behind the plastic being misshaped from the crash. It was on and off the car many times for tweeking.

http://i995.photobucket.com/albums/af71/phunkferret/Front%20end%20Yellow/Xmaspluscar049_zps278db6b6.jpg

I had to use bolts at the side of the bumper dew to the plastic tabs behind being ripped off in the crash. I will paint the bolts black later.

http://i995.photobucket.com/albums/af71/phunkferret/Front%20end%20Yellow/Xmaspluscar050_zps13bd8f3d.jpg

That's all for now folk's .

[Iain]

Liking how you're reusing rather than replacing almost everything! Great work on the new front panel

[phunkynova]

Liking how you're reusing rather than replacing almost everything! Great work on the new front panel

Manly because there is a good chance that I'll crash it again :d

[Danny mul]

Great work mate.

[phunkynova]

It's about 95% finished now just the sump guard / cut off pull and a few small finishing touches to do now.
Today I did the Front Grill / Door and door mirror.

Started with the front grill which would not sit in the original holes dew to the crash damage
I had to make new holes.

http://i995.photobucket.com/albums/af71/phunkferret/Front%20end%20Yellow/Xmaspluscar052.jpg

Then on to the door
Before

http://i995.photobucket.com/albums/af71/phunkferret/Front%20end%20Yellow/Xmaspluscar053.jpg

After

http://i995.photobucket.com/albums/af71/phunkferret/Front%20end%20Yellow/Xmaspluscar054.jpg

So how it's looking now

http://i995.photobucket.com/albums/af71/phunkferret/Front%20end%20Yellow/Xmaspluscar055.jpg


http://i995.photobucket.com/albums/af71/phunkferret/Front%20end%20Yellow/Xmaspluscar057.jpg


http://i995.photobucket.com/albums/af71/phunkferret/Front%20end%20Yellow/Xmaspluscar058.jpg

Just needs the finishing touches doing now and a good cleaning and it's ready for crashing again

[16v Nova Kev]

I would have thought you removed the metal bumper bars to save weight

[phunkynova]

I would have thought you removed the metal bumper bars to save weight

Not a good idea with my history :thumb:
I have in other race Nova's I've had.

[phunkynova]

Did a oil and filter change today
Then heat wrapped the exhaust manifold. I did it dry I know it can be do wet to, I'll see how it is if I have problem with it I'll redo it wet.

To start with

http://i995.photobucket.com/albums/af71/phunkferret/Front%20end%20Yellow/Xmaspluscar059.jpg

http://i995.photobucket.com/albums/af71/phunkferret/Front%20end%20Yellow/Xmaspluscar062.jpg

First down pipe done
Then all 4 pipes

http://i995.photobucket.com/albums/af71/phunkferret/Front%20end%20Yellow/Xmaspluscar063.jpg

Then the main pipe

http://i995.photobucket.com/albums/af71/phunkferret/Front%20end%20Yellow/Xmaspluscar065.jpg


http://i995.photobucket.com/albums/af71/phunkferret/Front%20end%20Yellow/Xmaspluscar066.jpg

Back in the car

http://i995.photobucket.com/albums/af71/phunkferret/Front%20end%20Yellow/Xmaspluscar067.jpg

http://i995.photobucket.com/albums/af71/phunkferret/Front%20end%20Yellow/Xmaspluscar068.jpg


I started work on the sump guard as well
After straightening out and before mounting brackets

http://i995.photobucket.com/albums/af71/phunkferret/Front%20end%20Yellow/Xmaspluscar070.jpg

A bit of a clean up and brackets back on

http://i995.photobucket.com/albums/af71/phunkferret/Front%20end%20Yellow/Xmaspluscar071.jpg

Tomorrow I will put it back in the car but I know I will have to work on the fixing points on the car which have moved in the crash that will be fun, NOT.

[16v Nova Kev]

Looks sweet

[kent14sr]

Brilliant work - I love this thread!

[faker]

Good skills there fella

[phunkynova]

Thanks for the comments lads :thumb:

[M Sutton]

Nice ;)

[phunkynova]

Went in to do some more on the car today but hit a problem and could not do so much.
The day started ok, Put the sump guard on the front pick up points no problem but I knew the problem would be with back points from crash damage.
I was right.:wtf:

http://i995.photobucket.com/albums/af71/phunkferret/Front%20end%20Yellow/Xmaspluscar072.jpg

The yellow bracket fixed to the car has been pulled down at the front, it should sit level with the sump guard not tilted down to the front as it is now.

http://i995.photobucket.com/albums/af71/phunkferret/Front%20end%20Yellow/Xmaspluscar075.jpg

Put then I saw a other problem as well,:eek: I had to have the guard pressed back to shape after the crash but they put too much angel into one off the bends making it hang too low in the middle and all so be to short for the hole to line up for the bolts.
So back to the firm that pressed it for me to take out some of the bend which should lengthen it by the 10mm I need.
It will be next weekend before I can get back to it now.:(

[Jamie.bowen]

Hi mate awsome car, i noticed that I have the same fuel pump as you and I had it In the engine bay was told to move it and your spot looks ideal to me. Where did you run the fuel lines? Mine will be in use all the time (weather permitted) so don't want to be stinking of fuel inside the car haha.

[phunkynova]

Hi Jamie I replaced the old one with this type and moved it outside the car as I only do tarmac rally's and the risk of damage is a lot lower. These pumps work better near to the fuel tank. The fuel line runs inside the car beside the center tunnel maybe you can see it some of the photos.
Hope this helps you.

[phunkynova]

I've just knocked up a spec on the car here it is:



Opel Corsa A 1.4 Rally Car


Body Shell
Year 1991
Safety Devices roll cage with x door bars, rear brace bar, mid brace and tunnel bars, plus front triangulation to strut tops added.
Body shell strengthening kit welded in, some seam welding done.
Front and rear strut braces.
Fuel and brake lines inside the car.
Kevlar fuel tank guard.
10mm Alloy engine sump guard.
Seat rails welded in.
Fiberglass bonnet and rear hackback
Polycarbonate window kit


Engine and Gearbox
130 hp @ 7231 rpm 150Nm @ 4530 rpm
1398cc NV block standard
1.4SE head with big valves fitted, polished and ported by Tsport (Tom Reid).
Motorbike Carburetors on a Bogg Brothers inlet manifold. Pipercross air filter. Filterking fuel pressure regulator, Facet fuel pump.
Autosprint 290 camshaft, Autosprint Lightweight competition specification cam followers.
Vernier cam pulley.
4 into 1 exhaust manifold 2inch system.
F13 Gearbox with 5 speed Quaife straight cut, close ratio kit.
Tran-x LSD with 4.53 crownwheel & pinion.


Suspension
AVO competition specification coil overs front and back, height and damper rate adjustable.
Bottom arms plated and adjustable rose jointed inner mounts.
Rose jointed front Tie Bar mounts
Eccentric ball joint top mounts.
Quaife quick steering rack 2.5 lock to lock


Brakes
256 mm vented disk front brakes with Mintex 1155 pads
Standard rear drum brake
Steel braided brake lines front & rear.
Dot 5.1 brake fluid.


Interior
Motordrive competition seats, Alloy seat mounts.
RRS 3inch 6 point harnesses.
RRS steering wheel.
Alloy Co-Drive footrest.
Rev limit warning light.
Quick release spare wheel holder.
Alloy door cards.
Map light.
Fire extinguisher.


Wheel & Tiers
6 x Hankook 170x560x14 Z209 4 medium 2 soft compounds
6 x Hankook 170x560x14 Z210 wet weather tiers
2 x Hankook 160x530x13 Z209 soft compound
4 x Yokohama Advan A048 195x50x15 medium compound.


Spares
1x full 1.4 engine and gearbox, standard in working order.
1x F13 CR gear cluster plus 4.18 & 3.94 CWP
Full set of Bilsten Suspension
4 drive shafts
Plus some body panels and parts and all most a full car of spare parts.

[phunkynova]

Got around to looking at the Sump guard problem today.
I had the guard repressed to take out some of the angel so that it would match up to the mounting hole on the car and yerrrr it fits now
So a test fit and then tack the mounting brackets in place. Then some manipulation was needed to aline the metal.


http://i995.photobucket.com/albums/af71/phunkferret/Front%20end%20Yellow/2ndcrashYellow019_zps68e40f8e.jpg

http://i995.photobucket.com/albums/af71/phunkferret/Front%20end%20Yellow/2ndcrashYellow021_zpsb073a258.jpg

The rose jointed arm where removed to save them from the heat. Now let the welding beguine.

http://i995.photobucket.com/albums/af71/phunkferret/Front%20end%20Yellow/2ndcrashYellow022_zps4bbfa45c.jpg

http://i995.photobucket.com/albums/af71/phunkferret/Front%20end%20Yellow/2ndcrashYellow026_zps4780895d.jpg

After some cleaning up

http://i995.photobucket.com/albums/af71/phunkferret/Front%20end%20Yellow/2ndcrashYellow023_zps4824ec71.jpg


http://i995.photobucket.com/albums/af71/phunkferret/Front%20end%20Yellow/2ndcrashYellow024_zps8679aad7.jpg

And a lick of paint

http://i995.photobucket.com/albums/af71/phunkferret/Front%20end%20Yellow/2ndcrashYellow027_zps1d6252f7.jpg

http://i995.photobucket.com/albums/af71/phunkferret/Front%20end%20Yellow/2ndcrashYellow030_zps7dd773d6.jpg


http://i995.photobucket.com/albums/af71/phunkferret/Front%20end%20Yellow/2ndcrashYellow029_zps2ad56ad7.jpg

http://i995.photobucket.com/albums/af71/phunkferret/Front%20end%20Yellow/2ndcrashYellow028_zpsab702ff9.jpg

Let it dry now and finish it off tomorrow.

[phunkynova]

Carried on where I left off yesterday.
first job was to put the bottom arms back in but they were dead hard to get out yesterday so I knew they were going to be tough to get back in.
So I made a wooden block wedge to open up the gap a bit to make life easier.

http://i995.photobucket.com/albums/af71/phunkferret/Front%20end%20Yellow/2ndcrashYellow032_zps8ee220fe.jpg


http://i995.photobucket.com/albums/af71/phunkferret/Front%20end%20Yellow/2ndcrashYellow031_zps9cdae83f.jpg

This work well and bottom arms went in nice and snug with ease.
Then I put the side guards onto the sump guard.

http://i995.photobucket.com/albums/af71/phunkferret/Front%20end%20Yellow/2ndcrashYellow033_zps4ea46da8.jpg

http://i995.photobucket.com/albums/af71/phunkferret/Front%20end%20Yellow/2ndcrashYellow034_zps51b61eec.jpg

Bolted the guard in place.

http://i995.photobucket.com/albums/af71/phunkferret/Front%20end%20Yellow/2ndcrashYellow035_zpsb6814f77.jpg


http://i995.photobucket.com/albums/af71/phunkferret/Front%20end%20Yellow/2ndcrashYellow040_zps4c7b4979.jpg


Then the side guards up and Bobs your Uncle finished.

http://i995.photobucket.com/albums/af71/phunkferret/Front%20end%20Yellow/2ndcrashYellow041_zps1b9fd19b.jpg


http://i995.photobucket.com/albums/af71/phunkferret/Front%20end%20Yellow/2ndcrashYellow042_zpsc192de69.jpg


http://i995.photobucket.com/albums/af71/phunkferret/Front%20end%20Yellow/2ndcrashYellow043_zpsbfb961a2.jpg

Just need to go out and crash it again so I can do some more work on it :):thumb:

[mowgli]

have you fitted lock stops on your rack?? i see you get tyre rubbig on the side plate

[phunkynova]

No it's more a problem that the side guard stick out a bit too much so on full lock the tiers rub a bit not a big problem.

[mowgli]

ok

[phunkynova]

Its dew to the Tie bar I need some slack in the side guard for when the suspension is on full drop that the guard did not fowl it.

[mowgli]

i assume there is no point to cutting the guard down so it fits inside the tie bars? i guess it will allow too much debris/damage up inside

[phunkynova]

Yes your right I did look at it but this was the best way that I could see.

[phunkynova]

Did some work on the car over the weekend.
First up was to change the crown wheel and pinion as the 4.53 which is the car is to low for the high speed of the Czech rally roads, I was revving out in 5th at about 105 mph
so I have a 4.18 which I have now put in should give me about 10 mph more.
Gearbox and diff out
time to take the 4.53 crown wheel off

http://i995.photobucket.com/albums/af71/phunkferret/diffandEPAS001_zpsa118a403.jpg

The Quaife sccr box and 4.18 crown wheel & pinion

http://i995.photobucket.com/albums/af71/phunkferret/diffandEPAS002_zpsb06258cd.jpg


Crown wheel off the Tran-x LSD diff

http://i995.photobucket.com/albums/af71/phunkferret/diffandEPAS004_zps34643e5b.jpg

PS not my old under wear.

Pulling the pinion off (yes my gearbox dose have blue blood in it)

http://i995.photobucket.com/albums/af71/phunkferret/diffandEPAS005_zpscd170fc3.jpg

All back in place

http://i995.photobucket.com/albums/af71/phunkferret/diffandEPAS008_zpsc828cb52.jpg

Then I moved on to the Corsa B EPAS I got.
First problem is that it's for a rhd car and I have a lhd car it would not go in dew to the heater matrix.
So I had to turn it 180 degrees to fit swinging the electric motor to the fuse box side on my car.
I had to tap out the center of the column and then turn it and knock it back in.

http://i995.photobucket.com/albums/af71/phunkferret/diffandEPAS009_zps2a5eeca8.jpg


http://i995.photobucket.com/albums/af71/phunkferret/diffandEPAS011_zps121e3e95.jpg


Then put in to the car for a test fit.

http://i995.photobucket.com/albums/af71/phunkferret/diffandEPAS012_zpsdc3b0c7b.jpg


http://i995.photobucket.com/albums/af71/phunkferret/diffandEPAS013_zpsf0b31522.jpg


http://i995.photobucket.com/albums/af71/phunkferret/diffandEPAS014_zps52f22468.jpg

At this point I had to go back the the original setup as time was running out on me and I did not have a way of connecting the EPAS to my rack as this part did not come with it and the Nova one is way to long to fit in there.
But I will come back to this to finish it.

[tom reid]

Great update as always, do you really need power steering?

[phunkynova]

On the slow hairpins and chicanes it is a bit hard needing both hands on the wheel the rest of the time it's ok.(getting old)
I just what to try it out see if it's any better.
All I need is the connector bit from the bottom of the EPAS unit to where the rack comes through the floor pan.
Do you have one Tom ?.

[tom reid]

I don't mate sorry, ya old bugger,lol.

[faker]

http://i995.photobucket.com/albums/af71/phunkferret/diffandEPAS001_zpsa118a403.jpg


What did use, or how did you fix the speedo drive to the tran-x?

[phunkynova]

Look here faker


HOW TO fit a speedo drive to a F10/13/15 Tran-x L.S.D. (http://www.pngclub.com/forum/showthread.php?160270-HOW-TO-fit-a-speedo-drive-to-a-F10-13-15-Tran-x-L.S.D.)

[faker]

Good work there sir. I will have to try that for myself. Thanks.

[phunkynova]

OK after fitting the EPAS it worked fine on the first 2 rally's and then on the 3rd rally it worked it's way loose leaving me with a steering wheel moving from side to side in the corners.
I had to temporary fix it with a ratchet strap for the rest of the rally.
So now to fix the problem permanently, as I had fitted a RHD column in a LHD car it was not going to be easy.
Main Problem is that the EPAS is only secured with two bolts at the front which is just not up to the job dew to the weight of the EPAS column.

So some where back here I had to fix the EPAS to the shell
http://i995.photobucket.com/albums/af71/phunkferret/Epasfix001_zpsac494e22.jpg

http://i995.photobucket.com/albums/af71/phunkferret/Epasfix002_zpsc5697242.jpg

So I looked at using this

http://i995.photobucket.com/albums/af71/phunkferret/Epasfix003_zps2d7e27bf.jpg

The original bracket had to be cut as it could not be turned around or repositioned dew to it being asymmetrical

http://i995.photobucket.com/albums/af71/phunkferret/Epasfix004_zps20b111c9.jpg

Then re-welded and strengthened

http://i995.photobucket.com/albums/af71/phunkferret/Epasfix005_zps5e066832.jpg

http://i995.photobucket.com/albums/af71/phunkferret/Epasfix006_zps978716be.jpg

Now in place

http://i995.photobucket.com/albums/af71/phunkferret/Epasfix007_zps48b73a3c.jpg

http://i995.photobucket.com/albums/af71/phunkferret/Epasfix008_zps2ef31074.jpg

Then offered up to the car
http://i995.photobucket.com/albums/af71/phunkferret/Epasfix010_zps45ebb202.jpg

I then marked up where I needed to drill holes for the bolts took the EPAS back out and drilled the holes and crap it's double skin which made a new problem to get around !
But I did

http://i995.photobucket.com/albums/af71/phunkferret/Epasfix012_zpseb8278b6.jpg

It's now seam's to be will fixed in place time will tell.

[phunkynova]

As some of you know on the last rally I all so had a problem with my fuel mix being to rich and making the car run rough in the hot weather.
So I took the Bike Carbs off to get some new smaller main jets for them only to find out that they are only 36mm carbs off a 600cc bike and not the 40mm I thought they were.

http://i995.photobucket.com/albums/af71/phunkferret/Epasfix030_zpsc4a31642.jpg

So any I went to to a local bike shop to see if they had any main jets for these carbs.
But no they had none in stock.
But they did have these.
ZX9 Kawasaki 40mm carb's for £66.

http://i995.photobucket.com/albums/af71/phunkferret/Epasfix027_zpsb165796d.jpg

But then came the next problem.
The old inlet manifold did not fit the new car's

old carb's and manifold
http://i995.photobucket.com/albums/af71/phunkferret/Epasfix035_zps6af020ed.jpg

New Carb's and old manifold.
http://i995.photobucket.com/albums/af71/phunkferret/Epasfix036_zps3f031d3d.jpg

Close but no cigar !.

[phunkynova]

So do I modify the old manifold to fit or get a new one ?.
After talking to a few people I decided to order a new one from the Bogg brothers.
In only a short time Steve Bogg had bogged this up for me.

http://i995.photobucket.com/albums/af71/phunkferret/Epasfix016_zps8f34d17d.jpg

http://i995.photobucket.com/albums/af71/phunkferret/Epasfix014_zpsea55504a.jpg

http://i995.photobucket.com/albums/af71/phunkferret/Epasfix013_zps9e064bc8.jpg

Nice bit of work by Mr S Bogg.

[phunkynova]

Just side by side view of the new and old set

http://i995.photobucket.com/albums/af71/phunkferret/Epasfix031_zps16a69d9b.jpg

The new carb's and manifold on the engine

http://i995.photobucket.com/albums/af71/phunkferret/Epasfix019_zps149a63b0.jpg

http://i995.photobucket.com/albums/af71/phunkferret/Epasfix020_zpse919de0a.jpg

http://i995.photobucket.com/albums/af71/phunkferret/Epasfix021_zps67d94ca6.jpg

Now with the air filter back plate on.

http://i995.photobucket.com/albums/af71/phunkferret/Epasfix022_zps4b08018d.jpg

And with filter.

http://i995.photobucket.com/albums/af71/phunkferret/Epasfix025_zps00e5d000.jpg

All so fitted some new plugs

http://i995.photobucket.com/albums/af71/phunkferret/Epasfix023_zpsc3c2181c.jpg

I'll have to see how it runs on the first 2 rally's as I can't get on the rolling road untill after these 2 events as the guy who has the rolling road is on holiday.

[phunkynova]

A update on the Bike Carbs they ran crap once the motor was warm they just would not work. :wtf:
So off they came and back on went the old ones but with the smaller jets for the newer carbs in them.
They run a bit funny at low speed and under 1/2 throttle BUT on full throttle it fly's now :thumb:

[phunkynova]

Had a problem with the gearbox on the last rally it would not select 2nd.
So time for a box strip down.
I pulled 2 gearboxes apart one to repair the other.

http://i995.photobucket.com/albums/af71/phunkferret/Boxrebuild001_zpse3cbbfc4.jpg

http://i995.photobucket.com/albums/af71/phunkferret/Boxrebuild002_zps136b5f3b.jpg

The problem turned out to be worn selector fork and broken syncro ring.
I decided to build up a selector fork with weld and grind it back to shape. Above is the rebuild and below a standard one without nylon tips

http://i995.photobucket.com/albums/af71/phunkferret/Boxrebuild007_zps72ca2516.jpg

The fork in place.

http://i995.photobucket.com/albums/af71/phunkferret/Boxrebuild008_zps8a2d8198.jpg

The rebuild.

http://i995.photobucket.com/albums/af71/phunkferret/Boxrebuild005_zpscdac6fc2.jpg

http://i995.photobucket.com/albums/af71/phunkferret/Boxrebuild003_zpsdf1e9410.jpg

http://i995.photobucket.com/albums/af71/phunkferret/Boxrebuild006_zpsf2ba2f5c.jpg

The build up finished It went back in the car and is working well for now.

[lee303]

those tips being made of metal will just wear against the baulk ring, damaging it or the tips themselves, and also depositing the metal filings into the gearbox, not a great idea imo

[phunkynova]

It's just a temporary fix until I get a selector fork with good nylon tips.

[lee303]

It's just a temporary fix until I get a selector fork with good nylon tips.

:thumb:

[phunkynova]

Hi All it's been a quite year for me on the car front as I've been so busy changing jobs and Country, but the car has not run well this year and I some times do historic rallies with the and some of the guys are not happy with Bike carbs on a historic rally car so I'm going Old School........Weber 40 DCOE.
I got a set from German Ebay.
They are old but the spec is very close to what I what to run. I must just change the pump jets and the main chokes from 34mm to 32mm and of course a good clean and rebuild.

Here are the Weber's with one of the chokes and ventures taken out

http://i995.photobucket.com/albums/af71/phunkferret/20141108_114537_zps6854a443.jpg

http://i995.photobucket.com/albums/af71/phunkferret/20141108_114451_zpsd812f19c.jpg

http://i995.photobucket.com/albums/af71/phunkferret/20141108_114424_zps237394a6.jpg

http://i995.photobucket.com/albums/af71/phunkferret/20141108_114314_zps8ab35833.jpg

I'll post more as I progress with this change to the engine spec. :thumb:

[mowgli]

are you going for historic group a?? didn't the opel ones ran injection?

[phunkynova]

Czech rallies run their own rules I do a mix of normal modern club rallies and some old timer's rallies so Weber's are good for both and the injection system is rare and expensive

[turbojolt]

Will be intresting to see the diffrence between the two diffrent types if carbs...will they be set up on a rolling road?

[phunkynova]

Will be intresting to see the diffrence between the two diffrent types if carbs...will they be set up on a rolling road?

I hope so TJ but it will be a rolling road in Germany as in Czech the only good one is now no longer in operation.
I'm not expecting a performance difference but a easier setting of the carbs as there is no Bogg Brothers or like out here.

[turbojolt]

Do you have a graph for the bike carbs? Would still be cool to see the diffrences across the range even if there is no top end gain :)

[BRoadGhost]

Carbs look clean given the age; couple of new jet covers & a set of radius trumpets FTW

[phunkynova]

Yes TJ some where I do have a rolling road graph for the rally car, and it's some where it's on here as well BUT I will not be using the same rolling road so they can not really be compared with one an other, shame.

[phunkynova]

Carbs look clean given the age; couple of new jet covers & a set of radius trumpets FTW

Yes they are in good condition for their age and they came with a Ford X flow inlet manifold to boot which a good friend of mine will have .

[phunkynova]

Anyone know which size ie length trumpets work best with 1.4 tuned Nova engines ? .

[phunkynova]

I did a bit more work on the Weber's over the weekend.
I gave them a cleaning in a Ultra Sonic bath, my aim was not to have show standard ultra polished Weber's but that all the gallery's and small openings are clean and free from any derby and buildup.

http://i995.photobucket.com/albums/af71/phunkferret/20141129_120501_zps571027ff.jpg

http://i995.photobucket.com/albums/af71/phunkferret/20141129_124151_zps5803b845.jpg

http://i995.photobucket.com/albums/af71/phunkferret/20141129_142234_zps59276ef5.jpg


http://i995.photobucket.com/albums/af71/phunkferret/20141129_124207_zps206e16dd.jpg

http://i995.photobucket.com/albums/af71/phunkferret/20141130_092222_zps12ebac2e.jpg

more to come later.

[phunkynova]

So Weber all done and ready to go on the engine BUT I've not been happy with the way it has been running so we did a compression test and number 1 pot was very low on compression,so I have a spare engine and decided to change the bottom end.
We took the the head off the rally engine and could not find any fault or problem which is a bit annoying as I now have no idea why the compression was low, Tested the head all good there, head gasket good, no sign of water in the oil or oil in the water :confused: :wtf:
Ho yer.

But we did find this problem.

http://i995.photobucket.com/albums/af71/phunkferret/20141204_155234_zpsc57b0a2c.jpg

http://i995.photobucket.com/albums/af71/phunkferret/20141204_155336_zps174f4f53.jpg

http://i995.photobucket.com/albums/af71/phunkferret/20141204_155348_zpsa311824c.jpg

http://i995.photobucket.com/albums/af71/phunkferret/20141204_155359_zps173d7e25.jpg

http://i995.photobucket.com/albums/af71/phunkferret/20141204_155422_zpsb0d84abc.jpg

I think I need a new one lol

But for the time being I will use my old SR manifold and down pipes. :thumb:

[phunkynova]

So now it's on to the engine swap which is being done in a real farm barn not the best place but at lease it's dry.
Take the old rally used engine out.

http://i995.photobucket.com/albums/af71/phunkferret/20141203_133532_zps2d40ba50.jpg

with the help of a pulley hanging from one of the old wood beams.

Bit's and pieces in boxes everywhere.

http://i995.photobucket.com/albums/af71/phunkferret/20141203_133507_zpsc95f712f.jpg

http://i995.photobucket.com/albums/af71/phunkferret/20141203_133445_zps1c5ce9fc.jpg

The block I will put in.

http://i995.photobucket.com/albums/af71/phunkferret/20141203_133358_zps7722af8a.jpg

Not in bad condition.

http://i995.photobucket.com/albums/af71/phunkferret/20141203_133418_zps7d1e4b1f.jpg

http://i995.photobucket.com/albums/af71/phunkferret/20141203_133426_zps067a7f8d.jpg

We put the Block and gearbox back in the car with a new clutch plate and then built up the rest complete with the Weber 40 DCOE's.
Then came the time to start it, the first couple of tries it fired but did not run and then brumm brumm IT'S A LIFE :thumb: ..........
....For 2 minutes and it just dies and will not restart not even a hint of firing :(
After a quick look around I found this had happened.

http://i995.photobucket.com/albums/af71/phunkferret/20141206_104556_zps32f816ec.jpg

The end of the camshaft had broken off :eek:
and take the Dizzy drive pin with it :cry:
http://i995.photobucket.com/albums/af71/phunkferret/20141206_104614_zps26f461c3.jpg

What I'm not happy with is that this cam is only about 1500 Km old, will not be buying any more products from that company again..

[phunkynova]

Okay after some problem with the supply of my new camshaft from Piper I was ready to do some work on the car last weekend.
I now had a new motorsports spec distributor, new camshaft followers and camshaft from Piper Cam's.
Also wanted to fit the solid engine mounts, I like the way nobody tells you that you must do some modifications to the mount points in the car to fit these things !!! :mad:
like you need new bolts for the back gearbox mount to body, you make all the holes where the bolt goes through from the middle of the mount into the chassis bigger as the new solid mount has bigger bolts in it than standard ones :(.

http://i995.photobucket.com/albums/af71/phunkferret/20150221_100158_zpsfe0a4fea.jpg

http://i995.photobucket.com/albums/af71/phunkferret/20150122_144030_zps5f9f84ed.jpg

http://i995.photobucket.com/albums/af71/phunkferret/20150221_100330_zps396df71f.jpg

http://i995.photobucket.com/albums/af71/phunkferret/20150221_100357_zpsc8f940dd.jpg

The rally car is now up and running I'm just sorting out a rolling road setup session to do the Weber's , cam and dizzy timing.
I could be going to Poland to have it done !:thumb:.

[phunkynova]

Okay loads to update one this one and it will be over the next few days before I get to the end.
So I did a 600Km trip up to Risse motorsport in Germany to have the Weber's set up

http://i995.photobucket.com/albums/af71/phunkferret/Engine%20Blow%20out%202015/20150420_131831_zpsmxsgvmod.jpg

Got there at 9 in the evening and slept in the van over night so we could start on the car first thing in the morning !
Got the car on the rolling road and it was running but not good they messed with it for a bit set the camshaft timing but was still rough :confused:
A bit more looking a round then came the bad news one of the twin Webers has a hair line crack in it on the inside which let extra petrol into just one side causing all the running problems :cry:

[phunkynova]

So I had no choice but to put the bike carbs back on the car for the first rally of the year :wtf:
Start number 16 was given to us ( I like the number 16 :thumb:) I made a fast start to the rally and had a big moment on one corner which caught out a good few cars (in car video is in the video thread: http://www.pngclub.com/forum/showthread.php?210969-Latest-in-car-with-big-moment )
The 2nd stage was driven a bit slower but I need to get back on it for the 3rd stage which was a repeat of the 1st test but the engine felt and sounded off song and just yards before the finish line the engine let go :(

http://i995.photobucket.com/albums/af71/phunkferret/Engine%20Blow%20out%202015/20150510_111725_zpsx1gf2wcp.jpg

http://i995.photobucket.com/albums/af71/phunkferret/Engine%20Blow%20out%202015/20150509_130519_zpsny1cnphc.jpg

Which caused a small fire.

http://i995.photobucket.com/albums/af71/phunkferret/Engine%20Blow%20out%202015/fire_zpszglr5pnm.jpg

http://i995.photobucket.com/albums/af71/phunkferret/Engine%20Blow%20out%202015/20150510_111759_zpsntngixqm.jpg

http://i995.photobucket.com/albums/af71/phunkferret/Engine%20Blow%20out%202015/20150510_111817_zpswewpnpp9.jpg

Found this when I took the sump guard off :eek:

http://i995.photobucket.com/albums/af71/phunkferret/Engine%20Blow%20out%202015/20150705_093805_zpsncymps1x.jpg

[1396rally]

Is that a ARP big end bolt? If so, you did chamfer the big end caps prior to fitting the ARP bolts?

[phunkynova]

Is that a ARP big end bolt? If so, you did chamfer the big end caps prior to fitting the ARP bolts?

No it had standard big end bolts and that's why it failed

[phunkynova]

And so it goes on!
I removed the bust engine and stripped it down and there was more bad news in the same pot in which the con rod broke lose I now have 2 bent valves in the cylinder head and of course they are none standard ones

http://i995.photobucket.com/albums/af71/phunkferret/Engine%20Blow%20out%202015/20150718_100309_zpspxxvxtfr.jpg

So after a some time trying to get a replacement over sized valves I found some but I must buy 2 full sets, one set inlet one set exhaust and they where not cheap.

[phunkynova]

As you can imagine I'm not to keen that this will happen again so I shelled out £70 and bought these :thumb:


http://i995.photobucket.com/albums/af71/phunkferret/Engine%20Blow%20out%202015/20150830_102158_zpsrhszslwk.jpg

and now to put them in my old (well old and used) but reliable NV (SR) block :)

With out
http://i995.photobucket.com/albums/af71/phunkferret/Engine%20Blow%20out%202015/20150830_102229_zpsc8v1yfry.jpg

Half way there

http://i995.photobucket.com/albums/af71/phunkferret/Engine%20Blow%20out%202015/20150830_104713_zpsowc39g5x.jpg

I could show you a photo of them all in but you know what that would look like anyway lol

[phunkynova]

Started to prep the engine for a bit of paint

http://i995.photobucket.com/albums/af71/phunkferret/Engine%20Blow%20out%202015/20150830_112420_zpsxcibhmpe.jpg


http://i995.photobucket.com/albums/af71/phunkferret/Engine%20Blow%20out%202015/20150830_112433_zpsfq9t7b1x.jpg

Now with a touch of colour :thumb:

http://i995.photobucket.com/albums/af71/phunkferret/Engine%20Blow%20out%202015/20150830_143819_zpsq1woemdn.jpg

http://i995.photobucket.com/albums/af71/phunkferret/Engine%20Blow%20out%202015/20150830_143834_zps3eoc6bd0.jpg

Did the gearbox while I was at it ;)

http://i995.photobucket.com/albums/af71/phunkferret/Engine%20Blow%20out%202015/20150830_152246_zpsxfcz6vtp.jpg


Then started to put the motor back together again

http://i995.photobucket.com/albums/af71/phunkferret/Engine%20Blow%20out%202015/20150905_112717_zpswqga6r2y.jpg


http://i995.photobucket.com/albums/af71/phunkferret/Engine%20Blow%20out%202015/20150905_112730_zpssc3e892k.jpg


http://i995.photobucket.com/albums/af71/phunkferret/Engine%20Blow%20out%202015/20150905_142659_zpsw1ovp9dr.jpg

http://i995.photobucket.com/albums/af71/phunkferret/Engine%20Blow%20out%202015/20150905_142725_zpszgrjb8eq.jpg

:thumb:

[phunkynova]

Before I put the motor back in the car there was a few things I wanted to do, one of them is to repair the right side of the wiring loom going to the headlight and cooler fan switch which was fire damaged

http://i995.photobucket.com/albums/af71/phunkferret/Engine%20Blow%20out%202015/20150905_142813_zpsdnt6sqvx.jpg


http://i995.photobucket.com/albums/af71/phunkferret/Engine%20Blow%20out%202015/20150905_143011_zpslpvb4myy.jpg

I found a Corsa A in a local scrapyard and cut out the part of the loom I needed and then spliced it into my car

http://i995.photobucket.com/albums/af71/phunkferret/Engine%20Blow%20out%202015/20150905_142738_zpsrn7ea6d7.jpg

[phunkynova]

I was not to happy with the fire damage to the radiator it looked like it was going to be brittle


http://i995.photobucket.com/albums/af71/phunkferret/Engine%20Blow%20out%202015/20150906_100036_zpsefkoqmle.jpg


So I felt it better to get a new one


http://i995.photobucket.com/albums/af71/phunkferret/Engine%20Blow%20out%202015/20150906_100013_zps2iaaucb6.jpg

[phunkynova]

Next I put the Block and Gearbox together, ready to go in the car.


http://i995.photobucket.com/albums/af71/phunkferret/Engine%20Blow%20out%202015/20150906_103044_zpshaeyogv2.jpg



And then into the car with the help of a fork lift truck !


http://i995.photobucket.com/albums/af71/phunkferret/Engine%20Blow%20out%202015/20150906_121046_zpsnoqui5oy.jpg

[phunkynova]

Next up is to put the new valves into the head

http://i995.photobucket.com/albums/af71/phunkferret/Engine%20Blow%20out%202015/20150919_101959_zpsovcn5vtl.jpg


So after some hours of lapping in the new valves into the head (long and boring work) I'm nearly there.


http://i995.photobucket.com/albums/af71/phunkferret/Engine%20Blow%20out%202015/20150919_105928_zpsba9eo7hg.jpg


next strip down and cleaning of the hydraulic lifters


http://i995.photobucket.com/albums/af71/phunkferret/Engine%20Blow%20out%202015/20150919_164115_zpsbgeag1il.jpg


Then started to put it all back together again

http://i995.photobucket.com/albums/af71/phunkferret/Engine%20Blow%20out%202015/20150920_132235_zpspao9rv9a.jpg


http://i995.photobucket.com/albums/af71/phunkferret/Engine%20Blow%20out%202015/20150920_165132_zpsqiaae3xs.jpg


Getting there soon be starting it :thumb:.

[BRoadGhost]

Whoa those pistons are dished; can you not find some flat tops at least for the normally aspirated 8V?

[phunkynova]

Whoa those pistons are dished; can you not find some flat tops at least for the normally aspirated 8V?

They came with the engine, standard GM one's
No money for flash after market one's sorry.

[phunkynova]

So I finally got to the point of starting the engine :)

It started and ran for some 20 minutes with out problems, I turned it off to control a few things and about 1 hour later restated the engine to let it run up to full temperature to see if the fan kicks in, but after 5 minutes running at around 2000 rpm it went BANG :cry:

http://i995.photobucket.com/albums/af71/phunkferret/20150926_160331_zpsprgkyift.jpg

The camshaft snapped in 3.

This was most likely a result of the 1st engine failure where the con-rod went through the block, that the cam had become some hair line cracks in it.

[phunkynova]

Damage to the head is pretty bad many valves are bent and the seat are damaged

http://i995.photobucket.com/albums/af71/phunkferret/20150927_111454_zpsrf8ijrqj.jpg

http://i995.photobucket.com/albums/af71/phunkferret/20150927_111527_zpsojcofbdq.jpg

The camshaft in 3 pieces

http://i995.photobucket.com/albums/af71/phunkferret/20150927_114437_zps5ehco0ct.jpg

Damage to the pistons as well

http://i995.photobucket.com/albums/af71/phunkferret/20150928_143935_zps0alhn8yo.jpg


http://i995.photobucket.com/albums/af71/phunkferret/20150928_144050_zpstvu9nzfk.jpg


http://i995.photobucket.com/albums/af71/phunkferret/20150928_144146_zps7cs01qaa.jpg

:( so I some more work ahead of me.

[_Tomiboy]

That is bad. :(

[AndrewC]

That's quite a bang...I think
I'd be ready to drown my sorrows after that

[turbojolt]

At less it didn't let go mid way through some stages mate :)

[phunkynova]

At less it didn't let go mid way through some stages mate :)

TJ at less it still runs on petrol and not had the famous TJ coolant conversion :d .

[turbojolt]

I thought I solved the oil crisis ffs original thinkers never get the credit in their life time lol

[phunkynova]

Okay time for a update on this one,
So the head had to be sent away to be worked on, it needed work on some of the valve seat and valve guides, even with the spare valves I had I must buy 2 more new valves to finish off the head (more money spent :().
Having looked at the pistons after the camshaft failure, I set about looking for some new pistons and rings.
Found some on ebay a full set of new GM pistons and rings :thumb:


http://i995.photobucket.com/albums/af71/phunkferret/N%20P%20x%204_zpsfhkdb5ru.jpg


http://i995.photobucket.com/albums/af71/phunkferret/New%20Pistons%20x%204_zpsyc3efd7d.jpg

As these pistons use a press fit gudgeon pin and I don't have the kit to do this properly, so off to some one who can.

http://i995.photobucket.com/albums/af71/phunkferret/Old%20pistons_zpslu4dfjuj.jpg

one of the finished ones

http://i995.photobucket.com/albums/af71/phunkferret/New%20piston_zps9ypv5aos.jpg

As you can see from the photo I needed to replace the bearings shell,
So I order a set and then got them only to find out that I needed a set of 0.25 and not standard ones ....... Doooooh :(

http://i995.photobucket.com/albums/af71/phunkferret/Shells_zpspj4bmljp.jpg

More money spent and the right size ordered this time (above are the old ones).

[phunkynova]

Got my new camshaft a few days ago.
A Newman 288/507 PH3.

http://i995.photobucket.com/albums/af71/phunkferret/Newman%20box_zps1i989ckj.jpg


http://i995.photobucket.com/albums/af71/phunkferret/Newman%20camshaft_zpsg3i87gou.jpg


As you can see the profile of the Newman 288 is quite different from that of a Piper 300


http://i995.photobucket.com/albums/af71/phunkferret/Piper%20amp%20Newman%20camshafts_zpsfjsmuiex.jpg


http://i995.photobucket.com/albums/af71/phunkferret/Piper%20amp%20Newman%20profile_zpswl1ypcbp.jpg

[phunkynova]

Hi all as some of you know since my engine let go at the start of 2015 and then rebuilt it I've not had it running properly.
It would run but had no power and would not rev over 4500 rpm or just not start at all.
Over the past year I've tried every thing I could to get it to run good, complete carb rebuild, dizzy settings, different dizzy, spark plugs, leads, different module, cam timing, and other things too, none worked.
Question to myself WHY was it running before using the same parts and now not ?!!.
Only answer I have is the cam shaft is new !!. Could that be the problem ?.
So I will change the cam shaft. I set about this undoing the head bolts to remove the head and cam carrier. Once the head was removed I checked the motor over and I was not happy with the new pistons I had fitted, only to find out there are the wrong size the block had been bored out and I put standard size pistons in.
Yer good now what, not too sure just to what size it was bored out to I decided to have it re-bored and buy new pistons to fit.

[phunkynova]

Below are photos of the new gaskets, seals and bolts and other parts I have bought to rebuild the engine again plus the block and new pistons.


http://i995.photobucket.com/albums/af71/phunkferret/20161119_114225_zpsjrdjgzl5.jpg


http://i995.photobucket.com/albums/af71/phunkferret/20161119_114316_zpsq6vtiywn.jpg


http://i995.photobucket.com/albums/af71/phunkferret/20161119_114448_zpsj3i2o9cu.jpg


http://i995.photobucket.com/albums/af71/phunkferret/20161119_114604_zpszcw4aknu.jpg


http://i995.photobucket.com/albums/af71/phunkferret/20161119_114904_zpsgr6qf3ny.jpg


http://i995.photobucket.com/albums/af71/phunkferret/20161119_121943_zpssxko2bai.jpg


http://i995.photobucket.com/albums/af71/phunkferret/20161119_122111_zps9oeng5wz.jpg


http://i995.photobucket.com/albums/af71/phunkferret/20161119_122158_zpsj5rnyvdr.jpg


http://i995.photobucket.com/albums/af71/phunkferret/20161119_122319_zpsq1s5ctig.jpg

[phunkynova]

I don't know how to but I'm sure that there is someone on here who can, with a 1mm oversize re-bore what will be the cc of the engine now ?. It is a 1.4NV block.

[turbojolt]

Thourght you sold it

[phunkynova]

What to sell but no one is buying