1.4 SR project

[stewart_2004]

Hi all,

my names stew ive been a member for abit so I though id put up a project thread for my 1.4 SR. The shell was pruchased from a member off here it all looked good when I went to look at it but when I got it to the garage it needed some welding. I didnt have a trailer so had to use a merc sprinter to collect the shell.

http://i118.photobucket.com/albums/o98/stewart29992000/P1010147.jpg
new shell been delivered
http://i118.photobucket.com/albums/o98/stewart29992000/P1010009-1.jpg
http://i118.photobucket.com/albums/o98/stewart29992000/P1010006.jpg
http://i118.photobucket.com/albums/o98/stewart29992000/P1010005-1.jpg
The floor, crossmember, inner wings suspension turrets needed welding but the car got untouched due to time and lack of motivation but after going to PV I got the motivation back and ive been doing lots of work to the shell.

[stewart_2004]

Hers some pics of the problem areas

http://i118.photobucket.com/albums/o98/stewart29992000/P1010022.jpg
http://i118.photobucket.com/albums/o98/stewart29992000/P1010020-1.jpg
http://i118.photobucket.com/albums/o98/stewart29992000/P1010019-1.jpg

http://i118.photobucket.com/albums/o98/stewart29992000/P1010044.jpg
http://i118.photobucket.com/albums/o98/stewart29992000/P1010047.jpg
passanger side turret

So yesterday I fired up the welder and to to work fixing the holes. all the rust got cut out and replaced. I started with the inner wings and then the battery tray.once It was all welded I put a skim of filler on it to make it look neater.

I also de greased the engine block and gave it a coat of gloss black paint. I did the same with the top of the manifold and then added heat wrap.

http://i118.photobucket.com/albums/o98/stewart29992000/P1010018-2.jpg
http://i118.photobucket.com/albums/o98/stewart29992000/P1010017.jpg
http://i118.photobucket.com/albums/o98/stewart29992000/P1010019-2.jpg
http://i118.photobucket.com/albums/o98/stewart29992000/P1010028-2.jpg
http://i118.photobucket.com/albums/o98/stewart29992000/P1010029-2.jpg
http://i118.photobucket.com/albums/o98/stewart29992000/P1010022-1.jpg
http://i118.photobucket.com/albums/o98/stewart29992000/P1010033-2.jpg

[stewart_2004]

I need to order a front crossmember to replace this
http://i118.photobucket.com/albums/o98/stewart29992000/P1010026.jpghttp://i118.photobucket.com/albums/o98/stewart29992000/P1010025.jpg
and also get 2 new sills once this is done I can get some paint on it and start putting it back togeter. I will put more updates on soon.

[mk1nova_rich]

sprinter ftw lol hope it all goes well mate. What are your plans for it??

[waynes sri]

sprinter ftw lol hope it all goes well mate. What are your plans for it??
yea i like the van bit

[stewart_2004]

plans are to leave it stripped out keep the 1.4 engine for now maybe fit redtop at a later date. will be keeping it the original colour.

[mk1nova_rich]

thinking about it im sure iv seen this car before and in the back of the sprinter. Are you on migweb?

[stewart_2004]

yeah mate i put the pic on migweb

[stewart_2004]

Todays update Ive been removing the driver side sill as it was rotten. It looks like its been replaced before it was full of filler but who ever did it left all the old rusty metal inside so its just rotten even worse again there was old bolts and all sorts in there so now I need to order 2 new sills and get them fitted.

http://i118.photobucket.com/albums/o98/stewart29992000/P1010035-2.jpg

[G-nova]

looking good mate keep up the good progress

[stewart_2004]

Cheers mate

[mikec123]

good luck with this the rot aint that bad at the front, makes sur you check everywhere like the rear chasis legs especially by the spring seats, i found out to my cost:thumb:

[stewart_2004]

Cheers mike yeah that was the first place I looked as my previous car the chassis legs were no where to be seen lol just afew strips of rust. heres some pics once I removed the underseal the second pic was after a coat of zinc primer.

http://i118.photobucket.com/albums/o98/stewart29992000/P1010070.jpg
http://i118.photobucket.com/albums/o98/stewart29992000/P1010073-1.jpg
http://i118.photobucket.com/albums/o98/stewart29992000/P1010071-1.jpg

[stewart_2004]

Bit of an update got sills ordered today, also some new gaskets from vaux so I can rebuild the engine. I also have the sump a lick of gloss black paint to tidy it up abit. should hopefully get the sills tomorrow and start to fit them.

[stewart_2004]

Well I havent toutched the nova for weeks so got back on it today. This time it was working on the engine. so jobs today were fit new core plugs, oil pump and new gasket, sump gasket and also the crankshaft ventilation. So I ordered the new bits from vaux.

http://i118.photobucket.com/albums/o98/stewart29992000/P1010046-1.jpg
http://i118.photobucket.com/albums/o98/stewart29992000/P1010049-1.jpg

http://i118.photobucket.com/albums/o98/stewart29992000/P1010053-1.jpg
http://i118.photobucket.com/albums/o98/stewart29992000/P1010050-1.jpg

[stewart_2004]

http://i118.photobucket.com/albums/o98/stewart29992000/P1010057.jpg

I also managed to pick up some genuine strut bearings for £1 each so will be replacing them soon. I need to continue to build the rest of the engine tomorrow. i need 2 get hold of the oil pump round gasket will try vaux tomorrow.

http://i118.photobucket.com/albums/o98/stewart29992000/P1010056-1.jpg
there shouldnt be anything in these two holes should there its been a while since i stripped the engine.

[stewart_2004]

just started to clean the cylinder head ready to paint it and removed the thermostat pipe to reveal that there wasnt one fitted bit strange ? will need to order a new one.

[stewart_2004]

Not been on here for a while which means no work done to the poor nova, but tonight I got bored and cracked on with rebuilding the engine. so cleaned cylinder head and camshaft gave it a quick rub down then afew coats of high temp engine paint. then started to put it all back togeter. fitted new headgasket and head bolts torqued it up 55nm 60 + 60 + 30 then gave the rocker cover a quick paint of red high temp just need to fit covers then belt pulley and get a new water pump.

some pics

http://i118.photobucket.com/albums/o98/stewart29992000/P1010074.jpg
http://i118.photobucket.com/albums/o98/stewart29992000/P1010075-1.jpg
http://i118.photobucket.com/albums/o98/stewart29992000/P1010077.jpg

I made sure everything was covered in oil when it went back together then I turned it over by hand but the end rocker and lifter got stuck I think it wasnt pushed in enough so gave it a little tap with rubber mallet and it turns free now.

[dj_wudgey]

nice project mate!! loving it in the van lol

[stewart_2004]

Had afew hours spare so decided to tackle the crossmember got some metal did abit of cutting and bending and the end result is below. i will do the other side tomorrow.

http://i118.photobucket.com/albums/o98/stewart29992000/P1010139.jpg

[stewart_2004]

Today I set about finishing the crossmember repair got the other side cut out ready for new metal then welded in, a good coat of zinc primer and some seam sealer for protection should see it right for a number of years fingers crossed.
http://i118.photobucket.com/albums/o98/stewart29992000/P1010143.jpg
http://i118.photobucket.com/albums/o98/stewart29992000/P1010141.jpg

[dj_wudgey]

god progress matey!! keep it up!

[stewart_2004]

cheers mate Ive got some headlight panels on order so should get them fitted soon.

[dj_wudgey]

nice mate get some pictures up when youve got it done!!!

[stewart_2004]

More updates on the shell repair. Yesteray me & my dad replaced the sills. Worst part of it was getting the old sills off due to a previous bad repair.

Some pics of the progress.

Old sill cut off ready for new metal

http://i118.photobucket.com/albums/o98/stewart29992000/P1010144.jpg

Trial fit of new sill had to do some work to make it fit as the replacement panel wasnt a great fit.

http://i118.photobucket.com/albums/o98/stewart29992000/P1010147-1.jpg

Sill tacked in place then trial fitted door with door seal once it all line up and clamped we drilled the holes ready for welding.

Start of filler

http://i118.photobucket.com/albums/o98/stewart29992000/P1010153-1.jpg

And finally starting to look like a car again just need to so do more filler work.

http://i118.photobucket.com/albums/o98/stewart29992000/P1010152-1.jpg

The other sill is cut and clamped on just need to drill and weld but its getting there slowly.:)

[dj_wudgey]

good work!! its coming on pretty quick matey will look like a mint sr again soon!!

[stewart_2004]

Its just the floor that I need to sort out now really thats the main welding work almost complete. Im not sure how to tackle the floor will get sills finished first.

[dj_wudgey]

best way mate!! looks like you have the skills to easily tackle the floor though lol

[stewart_2004]

small update my dad was free today so we had a good full day on the nova which included welding on the driver side sill and repairing the driver side floor. It took time but we got there in the end also made some ribs in the floor to make it look original. its strong thats the main thing just need to do some welding underneath then do same to the other side. some pics.

http://i118.photobucket.com/albums/o98/stewart29992000/P1010002-3.jpg

[stewart_2004]

Small update today I mamaged to cut off old rusty mudguard and create a new one to weld on not the best but looks alot better.

http://i118.photobucket.com/albums/o98/stewart29992000/P1010004-2.jpg

then abit of etch primer will cover welds in seam sealer soon.

http://i118.photobucket.com/albums/o98/stewart29992000/P1010005-2.jpg

[stewart_2004]

Hey all,

well I havent been on here for a while and the nova got put on hold due to lack of motivation, but I got it back and then spent many a cold night (-7) in the garage working on it. I am now at a point where the body work is ok all rust holes welded up.
new floor welded in

http://i118.photobucket.com/albums/o98/stewart29992000/P1010017-1.jpg
http://i118.photobucket.com/albums/o98/stewart29992000/P1010016-1.jpg
once the floor was done I removed all the old underseal off and re primed it ready for a fresh coat of underseal.

http://i118.photobucket.com/albums/o98/stewart29992000/P1010012-2.jpg
http://i118.photobucket.com/albums/o98/stewart29992000/P1010001-4.jpg
http://i118.photobucket.com/albums/o98/stewart29992000/P1010010-2.jpg
My next job over xmas is to get the fuel tank rubbed down then painted & fitted back on then re fit exhaust. then Prep engine bay ready for the engine to be fitted. Thats all for now. Hope you all have a good christmas!!!!.

[dj_wudgey]

good work matey nice to see this coming allong!! its allways good to see a sr getting saved!!

[merv beckett]

keep it up m8 looking good so far

[stewart_2004]

Hey all,

well I new year brings new updates. last week I had four days off work so I could crack on with the nova. my first job was to rub down the engine bay and floor so I could prime it.

http://i118.photobucket.com/albums/o98/stewart29992000/P1010059-2.jpg

http://i118.photobucket.com/albums/o98/stewart29992000/P1010060-2.jpg

Once this was all done a quick rub down and then it was time for colour. The paint was done using rattle cans so its not perfect but I just wanted to get engine In and running. I think it looks ok as most of the engine bay is covered with components.

http://i118.photobucket.com/albums/o98/stewart29992000/P1010089-1.jpg

http://i118.photobucket.com/albums/o98/stewart29992000/P1010083-1.jpg

[stewart_2004]

I also decided to give the steering rack a lick of paint while it was off the car nice & shiney now.

http://i118.photobucket.com/albums/o98/stewart29992000/P1010097-1.jpg

Next major job was to fit the engine so out came the engine crane to lift up the car ready to get it on stands so I could slide the engine in.

http://i118.photobucket.com/albums/o98/stewart29992000/P1010105-1.jpg

Going under

http://i118.photobucket.com/albums/o98/stewart29992000/P1010106-1.jpg

getting ready to be lifted up

http://i118.photobucket.com/albums/o98/stewart29992000/P1010107-1.jpg

All done lol (Not as easy as that )

http://i118.photobucket.com/albums/o98/stewart29992000/P1010002-5.jpg

next job was to fill all fluids and to find out that the radiator has loads of leaks but thats nothing major. So now the engine is all fitted and sorted it was time to sort this lot out

http://i118.photobucket.com/albums/o98/stewart29992000/P1010001-5.jpg

I forgot where most of it went but it started coming back to me after time.

It went from a bundle on the floor to this

http://i118.photobucket.com/albums/o98/stewart29992000/P1010012-3.jpg

http://i118.photobucket.com/albums/o98/stewart29992000/P1010006-3.jpg

Me & my dad were working for 4 days solid to get it to this stage early starts and some nights knocking off at midnight. But Im pleased with the progress.

My aim was to get the engine running but we ran out of time. I was filled with petrol and the battery was charged but I couldnt get the starter motor to turn The dash was doing weird things. I have started I thread in the electrical section asking for help if anyone can.

http://www.pngclub.com/forum/showthread.php?p=1780897#post1780897

I am still currently working on the wiring loom so I can start putting the interior back in. Will post more updates soon.

[AdamK]

Gettin on well mate stay motivated and keep up the good work

[stewart_2004]

Cheers mate just having problems with the wiring now its bugging me

[AdamK]

Afraid i cant help you there mate wirings not my strong point lol im sure someone on here will be able to help you no probs

[7ova]

nice work mate
have some rep :thumb:

[cuatrolatas]

good job in this engine bay

[Nobby]

looking good mate im in the same situation lol

[stewart_2004]

I havent updated on here for a while but I have still been doing the odd bits to the nova.

Firstly I needed to fit a new rad as the old one was leaking I also got hold of another carb as the auto choke on mine had been damaged and the pipes blanked off so now thats all working properly. The car was missfiring so I fitted new plugs, cap & rotor arm to see if this solved the problem but it didnt it was me been stupid and the leads were on the wrong way round. The engine now runs sweet I just need to set the fueling up.

My next job is to fit a new rear beam and some front bilstein shocks. Then I need to crack on with the brake lines. I am hoping to get it all finished for PV so fingers crossed. I will post some more progress pics soon.

[mk1nova_rich]

Glad to hear its coming on mate, hope them bits were some use to you then?! :thumb:

[stewart_2004]

yeah mate the bits worked a treat cheers. when do you want to come and get the manifold mate ?

[mk1nova_rich]

bit busy for next couple of weeks mate.. you need rid asap??

[stewart_2004]

no mate im in no rush will keep it as long as you want

[stewart_2004]

bit of an update today I have wired up my calibra volt gaugues and they work spot on. I have fitted them where the cd player goes. Also I have fitted my new front seats.

I now have a new rear beam which needs painting and fitting will get it done next week.

[shed-on-wheels]

sounds good dude get some updated photos though :) :D

[stewart_2004]

cheers mate will get some pics up asap I left the camera in garage lol

[stewart_2004]

Heres some progress pics.

seats trial fitted

http://i118.photobucket.com/albums/o98/stewart29992000/P1010063-2.jpg
Calibra volt gaugues fitted
http://i118.photobucket.com/albums/o98/stewart29992000/P1010064-2.jpg
suspension
http://i118.photobucket.com/albums/o98/stewart29992000/P1010059-3.jpg

[7ova]

nice work mate
gauges look great

[stewart_2004]

Some small updates on the nova as Im really trying to get it ready for pv. Firstly I painted my new rear beam ready for fitting as my old one was starting to rot. once it was all fitted up my next job was to get all the brake lines sorted. I wasnt looking forward to doing it but one I got started it was ok. Only problem I has was one of the unions were leaking due to a badly flaired bit of pipe. So I cut it off and re done it and the brakes feel spot on.

http://i118.photobucket.com/albums/o98/stewart29992000/P1010073-2.jpg

http://i118.photobucket.com/albums/o98/stewart29992000/P1010069-1.jpg

Now I just need to get my handbrake set up. will post more updates soon.

[yellowsrnova]

brill work man ! loving the red ! great work :)

[stewart_2004]

Got abit more done to the nova over the past couple of days. I am starting to fit the interior back in now. The dash is all fitted and bolted up and I have fitted various trim.
Today I also fitted and set up the handbrake so thats the last of the major work that needs doing to the car. All I need now is to get some wings and bumpers and It should be ready for MOT. Then I will look at doing the body work. Its slowly taking shape now. Will post some pics later.

[stewart_2004]

Afew more updates

Last night I removed the remains of an old alarm system which was bodged in.
I now have wings & bumpers which I have trial fitted. The rear bumper fits fine but the front is a diffrent story.

driver side fittment

http://i118.photobucket.com/albums/o98/stewart29992000/P1010119-2.jpg
passanger side
http://i118.photobucket.com/albums/o98/stewart29992000/P1010120-1.jpg
http://i118.photobucket.com/albums/o98/stewart29992000/P1010123-1.jpg
on the wings is there only one bracket for the bumper as I have two holes ?
Another thing is how do I secure the bumper bar to the bumper the pics might help

http://i118.photobucket.com/albums/o98/stewart29992000/P1010118-3.jpg

[LDAWSON]

Any updates mate? Still coming to mine on the 30th?...

[stewart_2004]

Hey mate yeah still on for dropping the wing of for you on 30th. Afew small updates firstly Ive got some new wheels GTE teardrops but they need a refurb. Today I have fitted the windscreen, now I am struggling to get the bonnet release to work the cable seems to be very slack. I will be sorting the wings and bumper tomorrow and hopefully getting it ready for MOT at end of the month I will get some pics up of how it stands now.
More updates tomorrow.

[stewart_2004]

Today I had a full day messing around with the nova got quite abit done, Firstly I got all the doors lined up and fitted correctly rather than fitting the door pins I used M8 nuts and bolts which worked well. Once they were on I fitted and aligned up the wings & bonnet. IM still having problems with the bumper not sitting peoperly as you can see in the pics. The the front end is now almost finished I just need to get the head lights aligned and fit the grill. I also got round to fitting the seats and now I just need afew things to do before the MOT including the bonnet cable and sorting out the horn. There is a problem with the earth lead on the horn and it wont work when its pressed. Heres some pics of how it stands now.

http://i118.photobucket.com/albums/o98/stewart29992000/P1010122-2.jpg

http://i118.photobucket.com/albums/o98/stewart29992000/P1010124-1.jpg

http://i118.photobucket.com/albums/o98/stewart29992000/P1010125-1.jpg

http://i118.photobucket.com/albums/o98/stewart29992000/P1010126-2.jpg

more updates to come tomorrow

[stewart_2004]

Not updated my project thread for ages theres been afew changes since last time its now got full mk 1 interior and dash and ive fitted astra gsi fanblades, rose jointed gear linkage its had a new clutch as it lost drive on the way back from MOT It still needs a respray but its now road legal it passed its mot with only 2 advisorys slight play in rear wheel bearings. I had it out last weekend and did over 70 miles in it. its got afew small problems that need looking at one is fuel guage dosent work, the front brakes need replacing as the discs are warped and also i struggle to get 5th gear need to set up linkage again but apart from that it drives well. Heres some recent pics.

http://i118.photobucket.com/albums/o98/stewart29992000/FE09F6C6-BDB2-4409-95E4-6FE00E24DBAF_zpsnuzmrt58.jpg (http://s118.photobucket.com/user/stewart29992000/media/FE09F6C6-BDB2-4409-95E4-6FE00E24DBAF_zpsnuzmrt58.jpg.html)

http://i118.photobucket.com/albums/o98/stewart29992000/image_zps7183f826.jpg (http://s118.photobucket.com/user/stewart29992000/media/image_zps7183f826.jpg.html)

http://i118.photobucket.com/albums/o98/stewart29992000/image_zps20e49672.jpg (http://s118.photobucket.com/user/stewart29992000/media/image_zps20e49672.jpg.html)

clutch had seen better days

http://i118.photobucket.com/albums/o98/stewart29992000/image_zpsfc35c3bf.jpg (http://s118.photobucket.com/user/stewart29992000/media/image_zpsfc35c3bf.jpg.html)

http://i118.photobucket.com/albums/o98/stewart29992000/image_zps39895f04.jpg (http://s118.photobucket.com/user/stewart29992000/media/image_zps39895f04.jpg.html)

all road legal now
http://i118.photobucket.com/albums/o98/stewart29992000/image_zps66c97757.jpg (http://s118.photobucket.com/user/stewart29992000/media/image_zps66c97757.jpg.html)

need to get it painted before pvs will keep you updated.

[LDAWSON]

congrats on getting her road legal....any updates???