View Full Version : STT's C20XE Tb'd Nova Rally Car
I thought it was about time that i started a progress thread on my nova.
I've owned the nova since 1997 when i bought it from an insurance auction as a stolen recovered gsi.
I converted it to c20xe with twin 45 dellortos and used it for navigational scatters and 12 car road rallies,
At the time i did the conversion there wasnt widespread knowledge on bit to use etc so i had custom shafts made etc.
In 2000 i parked it up in one of the barns on the farm and mothballed it.
Until earlier this year......
I decided to strip it back to a bare shell, and build it up again from there with a bit of a spec change!
Im not great at taking pics so the progress thread might be a bit disjointed but i'll try and take pics of some interesting bits as it comes back together.
Rough Spec.
Shell:
Fully Stripped out seamwelded shell with 6 point Safety Designs rollcage which is tagged into A and B pillars, with extra CDS tubing running forward to the front turrets, door bars, turreted rear end. homemade strengthening plates.
Internal gear shifter
Sill stand supports
Doors have been fully stripped out to a bare shell, as has tailgate (i did get a CF one from chip but it didnt fit great tbh)
bonnet fully lightened - pinned at front, hinged at rear
Sunroof plated, 5 piece polycarb windows
Sumpguard
Suspension
Coilovers all round - still undecided between GAZ GHA and GAZ Gold.
Front wishbones strengthened and homemade rose jointed tie bars
standard nova Gsi front ARB
Rear beam modified to fit VW rear disc stub axles so i can lose the inboard drums for the handbrake, beam fitted with standard GSi ARB and an extra Saab 900 turbo ARB fitted.
Stud conversion all round
Brakes
Corsa pedal (bracket shortened not pedal)
Corsa bias pedal box (6.25/7) - remotely adjustable
Vectra 284/288 (cant remember which) front calipers and discs -Now bought wilwoods
Golf 16v rear calipers and discs
Wilwood hydraulic handbrake
Goodridge Braided lines
Engine
C20XE
Emerald management
Jenvey 45mm TB's
90mm trumpets
Pipercross 6004 filter
Neil Roper worked coscast head
+1mm inlet and exhaust valves
solid lifters
double valve springs
billet Piped cams (aprox 290degree)
Early crank
Steel rods
Accralite pistons - aprox 12:1 CR - tbc on assembly
Lightened flywheel
Dry sumped
possible electric waterpump (undecided yet)
arp fasteners throughout
Fuel system - facet red top - swirl pot - 044 - fuel reg (yet to buy)
Oversized exhaust manifold (cant remember make)
homemade system 2.5" running right up in tunnel
Gearbox
early F16 rebuilt with new bearing and seals with added oil cooler setup
lsd (yet to buy)
Interior
Not much!
Fully stripped
Pair of Cobra Evolution or Corbeau Revolutions (yet to buy)
6 point harnesses aero catch style (yet to buy)
Suede steering wheel on quick release boss
Intercom
brantz trip meter
co- driver has aluminium footrest with horn and screenwash controls
Exterior
Standard Gsi Bodykit
Mudflaps all round
2 Cibie Torinis on brackets with 130w bulbs
4 Cibie Torinis in light pod with 130w bulbs
headlights with HID units (yet to buy)
extra reversing lights
Wheels
lots:
2 sets of MO's
3 sets or cesaros
http://img3.imageshack.us/img3/3272/novaside.jpg
http://img718.imageshack.us/img718/1884/novaweld.jpg
http://img13.imageshack.us/img13/8361/penetrationt.jpg
http://img69.imageshack.us/img69/7615/turret.jpg
http://img192.imageshack.us/img192/1551/img0020ho.jpg
http://img97.imageshack.us/img97/3820/img0021bh.jpg
http://img683.imageshack.us/img683/6003/img0022pv.jpg
http://img706.imageshack.us/img706/1296/img0023zv.jpg
http://img153.imageshack.us/img153/6883/wishbone2.jpg
http://img17.imageshack.us/img17/2263/wishbonel.jpg
http://img38.imageshack.us/img38/1345/sillstandinuse.jpg
http://img683.imageshack.us/img683/2800/sillstandhole.jpg
http://img291.imageshack.us/img291/157/sillstand.jpg
http://img522.imageshack.us/img522/6713/wishbone3.jpg
im building it to blue book specs but i doubt i'll bother to get it log booked as it's being built for navigational scatters and 12 cars which dont require logs, and it should be more than competitive for it.
For ASWMC road rallies i'll be using my 205 1.9 gti which still has a full interior (as reqd by road rallie regs)
If i was to stage it i wouldn't be remotely competitive in my class imo,
but who knows one drunken night i might change my mind and end up putting it into a few stages!
No doubt it will see combe a few times too
but the best bit..........
I will be fitting blue lights to it!!
The biggest problem I have with my lights is that my spots are 10" cibie torinos and they take H2 fitment bulbs which you can't get in an HID.
I'm currently looking into grafting an H1 bulb holder onto the back of my lights.
I know the reflectors aren't great but the issue I have is that on some events you aren't allowed auxillary lamps so I need as good a headlights as possible.
I've thought about bonding a couple of lights behind a nova glass so it would look like standard lights from a distance but actually be 2 small projector HID units behind.
been doing a little bit more today.......
I am adding some extra tubing into my rollcage,
I did make a tube notcher jig for my pillar drill but unfortunately when i tried to use it the lateral force on the hole saw caused the morse taper to drop down all the time.
So plan B
a quick google and i came across THIS WEBSITE (http://metalgeek.com/static/cope.pcgi) which you simply enter your parameters and it produces an image which you print off!
http://img39.imageshack.us/img39/8810/notchdiagram.jpg
then cut it out and wrap it around the pipe,
mark the line with a permanent marker,
http://img91.imageshack.us/img91/7641/tubenotch.jpg
then grind it all back with an angle grinder,
the fit is superb, really happy with it!
Had a productive couple of days on the nova,
thanks to Gary (GP on here) for his help - although i wont be letting him near the welder again!
Made some more blanking plates to cover all the unused holes in the bulkhead - nearly had a moment of stupidity and almost plated over the steering column hole!
http://img227.imageshack.us/img227/3888/blankingplates.jpg
http://img231.imageshack.us/img231/4436/weldedblankingplate.jpg
The we finished notchin out the rear diagonal and welded that in,
http://img594.imageshack.us/img594/4012/tubenotched2.jpg
http://img718.imageshack.us/img718/4097/notchedtube.jpg
Then welded in the extra bars that go forward to the strut tops.
http://img709.imageshack.us/img709/436/extratube.jpg
Im debating adding an extra dash bar to the cage, but not sure it will be too much benefit.
Ive ordered a set a Gaz Golds coilovers all round,
Also been looking into exhaust manifolds, i currently have an aftermarket janspeed manifold which does flow better than a standard one but given my increase in spec im not sure its up to the job.
So ive been looking at SBD's BTB type C manifold, but then found T45 STE's simpson race exhaust manifold.
http://img297.imageshack.us/img297/3201/manifoldq.jpg
the benefits of going for a complete custom is that i can cet it tucked in really tight to the sump to give me more ground clearance - it may only be a few mm, but that might make the difference i need!
oh and ive also bought an ali sumpguard
had a bit of a mixed day today,
Managed to weld in the blanking plate for the sunroof - i cut the panel from an old roof i had kept for the purpose,
i measured the appeture and cut it out so i had (hopefully) the same curvature
Really happy with how it went, just needs grinding down with a flap wheel and then a skim of filler
http://img180.imageshack.us/img180/2791/sunroofpanel.jpg
then got on with making my front tiebar mounts ready for the rose jointed tie bars
http://img179.imageshack.us/img179/572/tiebarmount1.jpg
http://img3.imageshack.us/img3/8173/tiebarmount2.jpg
so they are ready to go off for rotabrating and powdercoating
I then set about mocking up an engine to check all the clearances
I used a bare block and a stripped out f18 gearbox casing - although its still a blody lump to lift and bolt in on your own - moreso when youve lent out your engine crane!
the recess for the alternator is spot on
http://img195.imageshack.us/img195/8489/alternatorclearance.jpg
however when i was adding the plates to the shell i hadnt planned on dry sumping it, but now im going down the drysump route........
i have a slight problem
http://img25.imageshack.us/img25/7189/drysumpclearance.jpg
its more of a ballache than a real problem, its easy enough to notch out the bit and reinforce it with some 3mm plate, but its a job i didnt really want to have to do, so the next day i get on it i'll drop the lump out and do that!
and then whilst drilling the holes for the rear sill stands i managed to break the 30mm holesaw - both the 30mm cutter and the centre arbor - so i'll have to get a new one before i can crack on
went on a bit of a road trip last night to pick up some more bits for the nova.
Had to go to near Gatwick for my manifold,
a simpson race exhausts manifold specifically for a dry sumped XE
The quality of the welds is phenomonal, its already wrapped although there is a slight bit of damage to the wrap on the bottom but i'll just wrap over the top
http://img708.imageshack.us/img708/9683/manifold6.jpg
http://img80.imageshack.us/img80/2905/manifold1.jpg
http://img404.imageshack.us/img404/2158/manifold5.jpg
http://img241.imageshack.us/img241/9931/manifold4.jpg
http://img22.imageshack.us/img22/5546/manifold3.jpg
http://img139.imageshack.us/img139/4374/manifold2.jpg
And then it was down towards brighton for my calipers, complete with 2 sets of new ferodo ds3000 pads!
http://img64.imageshack.us/img64/6936/wilwoodcaliper.jpg
I think my best bargain so far has been the dry sump kit for 400!
Rear brakes : I'm running vw rear stub axles on a modified nova beam - with extra antiroll bar added.
the reasoning behind this is I get to bin the horrible shoe handbrake arrangement and hence some unsprung weight, the vw calipers are better too IMO
I need to get the centre of the discs turned down a bit from 57.1 to 56.6mm so I can use vx wheels
I'm currently trying to source some early vw mk2 golf gti discs as they are 8mm thick rather than the 10mm.
If I can't find any 8mm I'll just get a pair of 10's turned down to 7mm
Wow, awesome project. Knew you'd been building something..
Really impressive that you've owned it all that time too. Very nice welding there
Love the rear beam arb.
t45_ste
31-05-10, 10:14 PM
Great build, i can vouch for the quality of welding on simpons exhaust's. Looking forward to more updates.
t45_ste
31-05-10, 10:15 PM
I think rally design sell the slimmer discs, thats whats on the rear of mine. Are you using alloy mk4 calipers?
I think rally design sell the slimmer discs, thats whats on the rear of mine. Are you using alloy mk4 calipers?
At the moment (purely because i already have them) i'll be using mk2 (heavy cast iron) calipers, but when funds allow i'll either go mk4/A3 alloy ones or go for some hispec 2 pots
t45_ste
31-05-10, 10:27 PM
Wouldnt bother with the hi spec jobbies. Golf calipers are fine.
Did you buy the manifold off Giles?
Also found this pic for you:
http://www.cruisewestcumbria.info/cossiematt/pepe/17.jpg
16v Nova Kev
31-05-10, 10:31 PM
good welding skills i will be watching this one.
yeah i got the manifold from giles,
unbelieveable quality imo!
only downside (well not really a downside just extra cost) is that im now going to have to run equal length driveshaft to make sure the shaft doesnt clip the manifold!
done a little bit more today,
Added a dash bar to the cage, made it so that the steering column just clears it
http://img594.imageshack.us/img594/8631/dashbar.jpg
I'll weld the underside of the joint when i roll the shell over
http://img217.imageshack.us/img217/3457/dashbarweld.jpg
I also added a bit of bar to the sill stands,
http://img69.imageshack.us/img69/8435/sillstandwithbar.jpg
the bar is to store the wheel nuts on when i take the wheels off
I also finished adding in the rear sill stand points
Gary (GP on vauxsport) came round and i set him onto making my rollover jig - I figured it was safe to let him learn to weld on something off of the car!
Up until now i've always just rolled the shell over carefully onto some tyres - its not damaged it yet - but im sure if i keep doing it i'll eventually dent it so i figured its time to build a rollover jig, plus it will come in handy to help prepare my spare shell and my mk1 golf
hopefully i'll have the shell in paint by the weekend
Exterior is going to remain black,
Interior will go gunmetal
Cage will go satin black
Under the bonnet will be white or silver
Wow, awesome project. Knew you'd been building something..
Really impressive that you've owned it all that time too. Very nice welding there
Love the rear beam arb.
Thanks! - i can guarantee its the other end of the scale to yours when it comes to shinyness!
I've been keeping it quiet until i was ready to chuck a fair bit of time (And money) at it to keep the momentum up!
lol nothing wrong with that. Having seen hints of yours i could see a build comming. I do fancy copying your beam arb set up.
lol nothing wrong with that. Having seen hints of yours i could see a build comming. I do fancy copying your beam arb set up.
if you do - dont forget to grind the coating off of the nuts before you weld them - or you'll end up with **** looking welds (like me!) lol lol
i was hoping to have it done for PV, but thats not going to happen now,
It will definitely be at TV live though - unless i've wrapped it up by then!
About time!
it'll be done quicker if you drag your **** up to somerset and give me a hand!
Looks a very nice project.
Rear beam set up looks interesting, something I will look into in the future after seeing yours.
MattBrown
01-06-10, 10:04 AM
Looks a very nice project.
Rear beam set up looks interesting, something I will look into in the future after seeing yours.
Same here, whats the ARB off?
As ive been told you can mod a cav one to fit like this?
the extra ARB is from a saab 900 turbo, but some astra Gsi's had a similar setup iirc
On the rear i'll be running the standard gsi and the saab ARB with fairly (in the scheme of things) soft springs
and similarly on the from i'll be using a thick front ARB and soft springs
if i take it on track then i'll put stiffer springs in it
vaughanmc
01-06-10, 10:21 AM
Nice project fella - Get more pictures :)
novarally
01-06-10, 11:36 AM
the extra ARB is from a saab 900 turbo, but some astra Gsi's had a similar setup iirc
On the rear i'll be running the standard gsi and the saab ARB with fairly (in the scheme of things) soft springs
and similarly on the from i'll be using a thick front ARB and soft springs
if i take it on track then i'll put stiffer springs in it
Astra GSi ARB's are exactly the same as that.
I haven't gone through this thread in detail, but it sounds like you are going to use the car for road rallying?
I'm a bit out of touch with the regulations, but I thought you weren't allowed to use multiple throttle bodies?
Pistol Pete
01-06-10, 11:42 AM
Looking good so far. Would like to have a go at a similar rear ARB setup myself.
I'm a bit out of touch with the regulations, but I thought you weren't allowed to use multiple throttle bodies?
the cars being built for navigational scatters and 12 cars,
you are correct about the regs for road rallies, i use my 205 gti for them!
novaxe235
01-06-10, 11:58 AM
awesome!
Nice project, and top work so far
Will be watching this one :thumb:
little bit more of an update from today,
gary came round again today so managed to get a bit done
Started off making some blanks to weld into the grommet holes in the floor
http://img257.imageshack.us/img257/5739/holeblanks.jpg
then started to do a bit more to my rollover jig, made some brackets which will bolt to the shell where the bumper normally would
http://img31.imageshack.us/img31/3541/rolloverbrackets.jpg
then finished up welding in the rear sill stand points to the car
http://img156.imageshack.us/img156/1903/sillstands.jpg
started to cut out the notch required for the dry sump pump
http://img695.imageshack.us/img695/7189/drysumpclearance.jpg
then noticed a small problem, the outlet on the pump will foul the engine mount so it looks like i'll have to make a mount out of steel
http://img9.imageshack.us/img9/6238/pumppipeclearance.jpg
and heres a pic of the rollover stand ready to add the rear hub onto to, im going to weld a plate to the top of the stand and bolt the stub axle to it, then bolt the car side to the drum arrangement, the hub will provide a good pivot and if i use a handbrake cable i'll be able to lock it in any position i want!
http://img101.imageshack.us/img101/4310/rolloverstand.jpg
started to weld in the floor blanks but wasnt 100% happy at how the welder is going so stopped after the first one
http://img580.imageshack.us/img580/2723/floorblank.jpg
hopefully a new shroud should sort it out! i'll find out tomorrow morning!
And ive been spending bloody money again!
bought some seats
http://i26.photobucket.com/albums/c139/gsijoe/XTP660V/DSC02279-1.jpg
and have arranged to buy a set of equal length shafts,
so i stripped down a set of astra gsi shafts i had so that i can build them up as soon as i get them - this time with plenty of copper grease on the lay shaft!
mk1nova_rich
04-06-10, 12:02 AM
looks a good project mate, nice spec too :) will watch for updates on this one
16v Nova Kev
05-06-10, 09:44 AM
what gas do you use with the welder mate.
cracking build going to be good once finished :thumb:
what gas do you use with the welder mate.
CO2 - i dont seem to get any better results with a mix so i just use c02 as its cheaper (about 14 to refill!)
Your welding should be in an art gallery mate lol
This is one of the best projects ive seen.
Would you of had that problem with the pump if you'd of used a conversion mount?
djbrowney
05-06-10, 09:12 PM
Would you of had that problem with the pump if you'd of used a conversion mount?
i havent had the problem with mine :confused:
cracking project mate :thumb:
you spit looks very much the same as mine lol
i havent had the problem with mine :confused:
cracking project mate :thumb:
you spit looks very much the same as mine lol
looking at your pics, your pump has been assembled differently to mine
on yours - its:
pulley
first chamber: top blanked, bottom scavenge
second chamber: top return to tank, bottom scavenge
third chamber : top feed to engine, bottom from tank
whereas mine is currently:
first chamber - top feed to engine, bottom from tank
etc
im hoping its possible to rearrange the order of my chambers so that i have clearance, if not i'll just make a new engine mount bracket!
16v Nova Kev
06-06-10, 02:34 PM
CO2 - i dont seem to get any better results with a mix so i just use c02 as its cheaper (about 14 to refill!)
aye thats what i use too i seem to get better results. keep up the god work:d
only a small update for today as i've been feeling like crap with a chest infection!
Yesterday i set up my electrolysis tank for rust removal
http://img28.imageshack.us/img28/7130/electrolysistank.jpg
i then pressed out the bearings out of a pair of rusty old nova hubs i had lying around, and pressed the flanges out of a pair of big block legs.
http://img715.imageshack.us/img715/4033/bigandsmallblockflanges.jpg
the rusty hubs were then wired together and put in the tank for 24 hours - i forgot to take a pic before i put them in, but there were about as rusty as this caliper
http://img249.imageshack.us/img249/6117/rustycaliper.jpg
so today after a 24hr treatment i pulled them out, rinsed them off under a tap and gave them a very light wire brush which left them like this
http://img441.imageshack.us/img441/4688/hubafterelectrolysis.jpg
a quick dust in red oxide and they are ready for top coat when i get round to it.
http://img694.imageshack.us/img694/1532/paintedhub.jpg
Im still undecided yet as which route to go down regarding big block hubs, either get the flange turned down to fit a nova bearing or get the hub enlarged to accomodate a big block bearing
The last thing i did was finish making the plate to box off the cut away chassis leg for the drysump pulley clearance,
after hearing about Lee's drysump problem i decided to engineer a guard into the plate - with an access hole so i can still get to the bottom pulley bolts.
Its now tacked in and i'll weld it properly once its on its side so i can get into weld it a bit better
http://img541.imageshack.us/img541/8905/drysumpclearanceplate.jpg
djbrowney
06-06-10, 06:07 PM
CRACKING WORK BUDDY
how did you make the electro cleaner i want one lol
its really simple, you need:
A big plastic container
a battery charger
some sacraficial steel
something non conductive to support the items (bit of wood lol)
soda crystals
i used some thin sheet steel that i bent to shape to go around the perimeter of the tank,
fill the tank with water with soda crystals disolved in it (i used a bag (1kg) to about 50 litres of water)
suspend the items in the water - i just use cable ties to get them at the right height
wire the items you want cleaned together - i used mig wire
connect the sacraficial plates to the +ve terminal on the battery charger
connect the items you want cleaned to the -ve
swtich on , wait 24 hours (or 2 weeks if you forget like i did once) and come back to rust free items.
Works magic on all steel and doesnt damage seals etc
Once you take them out just rinse well and dry!
Easy
im currently trying to make a big tank that i can fit rear beams etc into - tempted to make one to lift a shell into lol
16v Nova Kev
06-06-10, 08:31 PM
hubs look great. I'm off to steal a wheely bin now and make one lol.
craig green
08-06-10, 10:12 PM
Nice to finally catch up with you again tonight Si. Car will be an absolute beast when you've finished her. Tight schedule too.
LOL @ the beam in the soda tank!!
Nice to finally catch up with you again tonight Si. Car will be an absolute beast when you've finished her. Tight schedule too.
LOL @ the beam in the soda tank!!
Yeah, good to see you again mate,
Hopefully it will be a bit of a handful, I dont think it will take that long to come together, its more finances that might slow it up!
as for the beam - just a shame the tank isnt another foot taller!
stupot89
09-06-10, 12:10 AM
Yeah, good to see you again mate,
Hopefully it will be a bit of a handful, I dont think it will take that long to come together, its more finances that might slow it up!
as for the beam - just a shame the tank isnt another foot taller!
could you not do one side at a time or does it need to be fully submerged????
could you not do one side at a time or does it need to be fully submerged????
thats exactly what i'm doing,
stupot89
09-06-10, 02:40 PM
thats exactly what i'm doing,
arhhh good good might have to try this when i start mine :)
slight update for today!
As usual nothing ever goes to plan....
went to my local scrappy to get some mk4 golf rear calipers for myself, also had a list of bit to get for other people.
After 1.5hrs in the scrappy rumaging about, climbing up stacks of cars and taking off bits i needed i came away with
Saab 9000 NA 3 piece manifold for one mate
Golf Mk3 Gti centre console for a different mate
A couple odds and sods for a vectra for another mate
and that was it
I completely forgot about the bit i wanted - typical
Back in the workshop i cracked on with finishing the rollover jig,
The car is now all mounted on it and it spins over really easily, jsut need to mount the handbrake lever so i can lock it in any given position.
http://img689.imageshack.us/img689/5813/rolloverjog2.jpg
http://img208.imageshack.us/img208/3002/rolloverjig1.jpg
Now all i need is my gaz golds to arrive so i can check my rear turrets are big enough before i weld them in!
How's the rear beam looking?
craig green
10-06-10, 03:00 PM
Yeah hows the rear beam looking.
Forgot to say I love those old Carlton alloys you have on the floor. Still got the centre caps?
Wow, how cool... welding is great..
Love the electrolysis tank ,.. think I need one :)
today i mounted the handbrake lever and cable to the frame,
it works really well, just rotate the car to the angle you want and then pull up the handbrake to lock it into position
http://img210.imageshack.us/img210/5381/rolloverhandbrake.jpg
i finished box sectioning the chassis leg that i had to cut away to allow for drysump pump clearance - but i didnt get any photos
Tomorrow i'll be dropping my block off to be rebored, then i can get on with the first dry build of the lump.
I pick up my seats on sunday so on monday i should be able to get the seat bars welded into the shell, then as soon as the gaz golds turn up i can weld in my turrets - i already made a set that clear standard gaz's but then i found out the golds were bigger OD - bugger!
Then once the turrets are done the car can be painted, its going to stay black outside, white(or possibly silver) for the inside and under bonnet and then the cage and dash section will be painted satin black.
Good read mate keep it up :thumb:
Yesterday i pulled the rear beam out of the electrolysis tank, and im fairly happy with the results.
So far i've just given the easy to reach bits a quick dust off with the wire brush - but i got broed after about 5 mins!
I'll hopefully get a bit more time on it later today.
http://img815.imageshack.us/img815/510/rearbeam1.jpg
http://img815.imageshack.us/img815/7828/rearbeam3.jpg
http://img823.imageshack.us/img823/9133/rearbeam2.jpg
my bits that i sent off to be powdercoated are now done so i shall hopefully pick them up later,
I've also decided to sell my old turrets - as they are no longer needed due to my spiraling spec syndrome!
I built them to accomodate gaz 1.9" coilovers, then i decided to buy a set of Gaz Golds only to find out they are a bigger OD than the normal coilovers!
16v Nova Kev
12-06-10, 12:29 PM
the beam looks pretty good I'm going to try and make a tank today,
picked up some bits fresh from being powdercoated!
Really happy with the finish - only problem is i have to remove a bit of the powdercoat from the clutch pedal that i forgot to mask off!
http://img99.imageshack.us/img99/7936/powdercoatedbits.jpg
16v Nova Kev
12-06-10, 08:11 PM
cool I wasn't sure about powder coat tbh but they look good.
I've gone for a light colour (yellow) on the wishbones so any cracks etc that might appear will be immediately evident!
What a nice project! Good luck with it.
gary_126
06-12-10, 10:03 PM
Great project, shell looks nice :d Any updates?
LEWI007
06-12-10, 10:53 PM
im currently trying to make a big tank that i can fit rear beams etc into - tempted to make one to lift a shell into lol
Now that would be something worth doing.
Id pay to have my shell done at some point :cool:
nearly a year since the last update!
i have been doing the odd bit here and there on it, and have been buying up all manner of stuff too.
I'll host up some pics and let them do the talking mainly
using my rotaspit i got the car on its side and got the underside to bare metal and then treated it to many coats or bodyschultz
rear beam has been modified to fit vw stub axles and calipers and i have had the vw discs turned down to 7mm to save some weight,
The rear beam is now fitted along with the 2 anti roll bars (standard + extra astra gsi one) and is sitting nicely with my gaz golds
The fuel system is now mounted on a tray arrangement where the back seat would of been, this will be boxed over to provide a firewall and one extinguisher output will be within the box,
The fuel lines run along inside the car,
Corsa brake pedal assembly has been modified - so pedal pivot is the same plane as clutch (not just shortened pedal) and i have my corsa bias box fitted - although i need to relocate the reservoirs as the wiper assembly fouls them and i am not going to single wiper.
The front brakes i mocked up initially using vw 280mm 4 stud discs - but due to the caliper/wheel choice it would of meant running a spacer which i dont like the idea of, so i then looked at honda integra type r discs - these have a greater offset - so only need a 3mm spacer, but im still not overwhelmed with that so i have resided myself to the extra cost of 2 piece discs which will be offset inboard enough to mean i wont need a spacer, i will also go from 25mm to 20mm thick so losing some unsprung weight at the same time
My quick rack is now fitted and im using a corsa bracket to help strengthen the already strengthened bulkhead
My block is now all painted up and im just waiting on some bits for the drysump assembly before its all assembled and sent off to be rotating mass balanced
My recent(ish) outlays have included my gaz golds, corbreau revolutions, new harnesses, a radical sr3 dash, and i have had all my wheels shot blasted and powdercoated
Looking forward to getting some time on it in the next few weeks and seeing it start to come together!
pics in no particular order
http://img846.imageshack.us/img846/6142/picture153u.jpg
interior was rubbed down and given a couple generous coats of red oxide before top coat
http://img156.imageshack.us/img156/7923/picture159g.jpg
my 50mm trumpets
http://img7.imageshack.us/img7/812/picture160cq.jpg
but think im going to change them for 90mm
http://img8.imageshack.us/img8/9038/picture178b.jpg
on the spit half way through its undersealing
http://img580.imageshack.us/img580/2461/picture179z.jpg
large rear turrets welded in
http://img14.imageshack.us/img14/92/picture180af.jpg
http://img843.imageshack.us/img843/3255/picture182o.jpg
the rear beam after being modified - a tapped 10mm plate has been welded on to fit the vw stub axles, i have also modified the shock mount as im running coilovers so they need to be weight bearing now, i have also moved the mounting point slightly forward and inboard to make the coilover work in a vertical plane and give more clearance to the wheel
http://img705.imageshack.us/img705/5426/picture572d.jpg
pic of the rear beam fitted up, complete with vw rear stub axles and gaz golds - still have to fit rear pads
http://img836.imageshack.us/img836/3157/picture183i.jpg
the 10mm plate tapped to accomodate the vw stub axle
http://img855.imageshack.us/img855/2019/picture184h.jpg
rear beam after having a few generous coats of hammerite
http://img851.imageshack.us/img851/4213/picture185.jpg
http://img834.imageshack.us/img834/8106/picture187y.jpg
http://img851.imageshack.us/img851/9017/picture188s.jpg
the equal length shafts being painted up
http://img845.imageshack.us/img845/8843/picture189s.jpg
vw rear discs ready to be turned down,
I had the centre spigot reduced to enable me to fit vaux wheels and had the disc turned down to be 7mm thick
http://img14.imageshack.us/img14/6618/picture190r.jpg
the disc is now 7mm thick instead of the original 10mm, i figure i dont have mcuh weight to stop on the back end and you used to be able to get 8mm thick discs (NLS) so 7 should be fine - and it reduces unsprung weight
http://img804.imageshack.us/img804/9971/picture193p.jpg
initial mock up of my wilwoods with vw 280mm discs
http://img220.imageshack.us/img220/4298/picture194s.jpg
my mdf mock up bracket
http://img803.imageshack.us/img803/8720/picture195.jpg
http://img863.imageshack.us/img863/4899/picture242.jpg
my Radical SR3 dash - does everything i need i to - with nice bright warning lights, i'll need a pulse convertor for the rev counter as its set up for a bike engine and i'll be wanting my shift light at about 8k
http://img716.imageshack.us/img716/8525/picture247x.jpg
interior after its coating of silver!
http://img163.imageshack.us/img163/5527/picture250.jpg
corsa brake pedal assembly fitted - note the bracket is modified rather than the pedal so that the pivot point is very similar to the clutch - to make left foot braking easier
http://img840.imageshack.us/img840/1517/picture251a.jpg
http://img855.imageshack.us/img855/7896/picture263wt.jpgaccralites being warmed in hot water to enable the gudgeon pins to move
http://img831.imageshack.us/img831/4548/picture264j.jpg
all fitted up on my steel rods
http://img847.imageshack.us/img847/2613/picture273.jpg
i think i need to tidy my workshop
http://img96.imageshack.us/img96/4829/picture274m.jpg
i think i need to tidy my workshop
http://img687.imageshack.us/img687/8771/picture275r.jpg
i think i need to tidy my workshop
http://img534.imageshack.us/img534/8504/picture276h.jpg
i think i need to tidy my workshop
http://img842.imageshack.us/img842/3093/picture277x.jpg
http://img855.imageshack.us/img855/6972/picture278s.jpg
http://img808.imageshack.us/img808/1130/picture279d.jpg
http://img42.imageshack.us/img42/7477/picture280l.jpg
http://img825.imageshack.us/img825/9423/picture281.jpg
http://img828.imageshack.us/img828/3927/picture282e.jpg
http://img600.imageshack.us/img600/1096/picture546k.jpg
front hub fitted into a machined knuckle using a vw bearing
http://img146.imageshack.us/img146/50/picture552s.jpg
nasty little bugger
http://img98.imageshack.us/img98/6610/picture558w.jpg
rear caliper fitted up complete with home assembled flexi
http://img690.imageshack.us/img690/3290/picture559v.jpg
http://img593.imageshack.us/img593/3963/picture560k.jpg
gear shifter and hydraulic handbrake fitted - the handbrake is at an angle as the seats limit the ability to move my elbow back so thats the natural position for the turning aid
http://img859.imageshack.us/img859/7474/picture562y.jpg
fuel pipes on the passenger sill
http://img828.imageshack.us/img828/416/picture564d.jpg
my fuel system 'tray' - facet red top to swirl pot then c20xe pump to engine - there is a box that will fit over all this to provide a separation from the cabin - one of the extinguisher outputs will be in this box if the worst happens
http://img543.imageshack.us/img543/7463/picture565i.jpg
corsa rack bracket holding on my 2.5 rack
http://img21.imageshack.us/img21/8369/picture566h.jpg
corsa bias box fitted - but need to use remote reservoirs as they foul the wiper linkage
http://img101.imageshack.us/img101/9098/picture567.jpg
fuel hoses coming up into engine bay
http://img852.imageshack.us/img852/1495/picture568x.jpg
the block after a liberal coat of hammerite
http://img863.imageshack.us/img863/1285/picture570.jpg
my gaz golds
http://img696.imageshack.us/img696/1693/picture571.jpg
Good to see some pics Si, I was only asking Craig weather he had seen you the day
Any idea when you'll have it finished ?
We must come and move the nova flair we left with you :d has it rusted away yet ? lol
just a little update,
not had time to do anything to the car but i have received another package from QED Motorsport (http://qedmotorsport.co.uk/)
http://img24.imageshack.us/img24/2320/inletmanifold.jpg
my new manifold which will sit the throttle bodies at the same angle that the manifold bolts to the head - meaning my airfilter will sit above the bulkhead allowing me to run big trumpets!
http://img190.imageshack.us/img190/5899/drysumppulley.jpg
and a new pulley and boss to bolt to my crank to run the dry sump pump!
NOV4_SPORT
10-06-11, 08:01 PM
I dont know how i missed this thread !
Epic welding/ fabrication skills buddy, i will keep an eye on this thread.
Keep up the good work.
iain
craig green
11-06-11, 01:01 PM
I was wondering only a couple weeks ago how you were getting on with this Si.
top progress Si, had forgotten about this thread
Small update!
I've been slowly plugging away at it,
currently have a mock up engine and box in it, with bodies, dry sump pump, starter,alternator etc fitted
now its a case of making up the loom for everything, just finalising what lights im going to be running, and whether or not im going to have thermocouples on the primaries,
Im also trying to find out more infomation about my radical dashboard to see if its suitable or not,
Im going to keep the loom as simple as possible with fusebox accessible from passenger seat, hoping to use circuit breakers rather than fuses if budget allows!
Pics to follow soon!
Great thread/work,whats with the wasp? did it sting you or summat?! lol
mk1nova_rich
25-03-12, 07:15 PM
Bloody awesome mate, been a while since I've had a nosey. Looks fantastic :cool:
stuartp
20-01-13, 09:16 PM
this still going?
Si's comment to me when I last spoke was "its coming on" lol
Sure he said that to me a year ago lol
It's still coming on slowly, I find Im either in the position of having spare money and no time or spare time and no money!
At the moment I have time........
As it sits at the moment it has a mock up engine and box in place with exhaust manifold on and inlet and bodies etc bolted up so I can make the loom etc for the emerald
I'll try to do a proper update on here soon!
Calamity Josh
23-01-13, 09:33 PM
went on a bit of a road trip last night to pick up some more bits for the nova.
Had to go to near Gatwick for my manifold,
a simpson race exhausts manifold specifically for a dry sumped XE
The quality of the welds is phenomonal, its already wrapped although there is a slight bit of damage to the wrap on the bottom but i'll just wrap over the top
http://img708.imageshack.us/img708/9683/manifold6.jpg
http://img80.imageshack.us/img80/2905/manifold1.jpg
http://img404.imageshack.us/img404/2158/manifold5.jpg
http://img241.imageshack.us/img241/9931/manifold4.jpg
http://img22.imageshack.us/img22/5546/manifold3.jpg
love the Simpson exhaust, it's what i run on my race car, have to agree the quality is amazing and matts a top bloke
time for a well overdue update!
The project has been slowly continuing as time has allowed, although sometimes its felt like 3 steps backwards before i could move forwards!
I have mounted the drivers seat on adjusters so that it gives me easier access to get in, and allows people shorter than me to drive it, but now i need to move the gear stick and handbrake too,
I intend to use a cable shift system from a vectra C 1.8, i will mount the gear stick up a fair bit higher and closer to the steering wheel.
http://imageshack.us/a/img153/249/9fpx.jpg
Next problem i encountered was my corsa bias pedal box, when i planned it i forgot all about the wiper mechanism, so i need to move the reservoirs
http://imageshack.us/a/img11/4551/25ac.jpg
http://imageshack.us/a/img580/623/0svc.jpg
http://imageshack.us/a/img856/6804/qyhh.jpg
the plan is to remote mount the reservoirs to the bit of the roll cage that comes thru to the turrets
next thing was to replace the copper fuel lines which i never liked
so i ordered some pipe spacers from torques.co.uk
they needed drilling out as they arent designed as mounts,
then i rivnuted the car and fixed them using a m3 allen bolt
http://imageshack.us/a/img546/944/6zg7.jpg
http://imageshack.us/a/img443/4216/uj3j.jpg
http://imageshack.us/a/img543/5908/c04k.jpg
http://imageshack.us/a/img12/3838/e0qz.jpg
http://imageshack.us/a/img33/7207/v7vf.JPG
all terminating at the firewall
http://imageshack.us/a/img21/5694/gs6c.jpg
then protect the sharp edges of the lightened doors
http://imageshack.us/a/img585/4691/x2hz.jpg
mounted the brake adjuster
http://imageshack.us/a/img820/8710/nmtm.jpg
I mounted my davies craig water pump
http://imageshack.us/a/img59/9435/9g65.jpg
then trial fitted an oil cooler to help with gearbox cooling
http://imageshack.us/a/img43/5901/7x6w.jpg
ready to be pumped by my new gear oil pump - which will be thermostatically controlled
http://imageshack.us/a/img703/7315/iwqs.jpg
more updates to come soon!!!!
8valve-craig
17-10-13, 09:28 PM
Why the tinypic's? Nice to see some progress.... but I'm sure I saw more pic's than that on your phone
oh **** ive buggered up the links!
i'll sort it shortly
yes theres more pics to come!
Glad to see your still doing this, brake lines look good.
kenny_afh
18-10-13, 10:49 AM
i wouldn't be running those lines between the cage and pillars like that, they'll be crushed in an impact. don't be surprised if a scrutineer pulls you up for that if you go rallying, however the little seperators are a neat touch!
ive seen corsa pedal boxes turned round 90degrees, so the cylinders point towards the front wing, could you try that? a bit easier than remote mounting, so long as the mounting bolts are in a square pattern it would be easy.
8valve-craig
18-10-13, 11:21 AM
Nice touch on those seperators, i bought the same ones and have been planning exactly the same, drilling them and using as mounts. Would definately, as stated above re-route the fuel though.
There are a few pics in my build thread of how i relocated the handbrake which might may be of use.
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