Meriva Z20LET project.

[joff-turbo-nova]

Well having trundled around in the wife's Meriva this year, I'm quite impressed with the comfort,
handling and load lugging capacity, so have decided that in 2011 I will be replacing the Vectra with another Meriva.

I have already sourced a suitable vehicle and again it needs a little work to get it roadworthy.

This one's a CAT D write off , first registered Feb 2010 (on a 59 plate) and has done 2500 miles .....

http://i2.photobucket.com/albums/y15/joff-turbo-nova/DSC03239.jpg

http://i2.photobucket.com/albums/y15/joff-turbo-nova/DSC03238.jpg

The front part of the nearside chassis leg is a bit pushed in and it needs 2 wings, bonnet, front
bumper & bar plus a rad pack.

I'm not starting this till I have sorted the nova trailer out and as the vectra is still going strong I
'm in no major rush. It will give me time to source the necessary parts , I may try to find a VXR front
bumper but know that these are rocking horse do do rare :(

I'm off to Gloucester on Saturday with a trailer to pick it up and it can sit in a friends barn till I'm ready
for it sometime in 2011 . :thumb:

Joff

[joff-turbo-nova]

Also just noticed that even though its only a 1.4 16v (Z14XEP) it has 5 stud alloys.

I thought only the 1.7 Cdti's came with 5 stud?

Joff

[Spudly]

Ahhh theres pics of it, was waiting for them to come up lol


Cheers for this afternoon youre a star, still a spline out though but i can live with it for now haha:thumb:



Ummm id be willing to bet theyre the new style steelies with clip over trims to look like alloys?

[Graeme]

Starting to like these more and more, must be due to starting a family and seeing the Russian c20let one on mig lol, good look Joff

[Bubba]

Ummm id be willing to bet theyre the new style steelies with clip over trims to look like alloys?

i doint think so

[joff-turbo-nova]

I think they are alloys as it looks as though they have typre valves and you can see the brake caliper though the aperture ....

http://i2.photobucket.com/albums/y15/joff-turbo-nova/DSC03231.jpg

[John]

I'll have a tenner spud is correct.

Nice one joff! You really do love the meriva don't you! (not thought about the vxr?)

[tb16v]

Yes they are the steels that are made to look like alloys with full cover wheel trims!

[Stuart]

I've seen (and want) 5 spoke steel rims that have 'real alloy' appearance trims... very very convincing

[AlanH]

I've seen (and want) 5 spoke steel rims that have 'real alloy' appearance trims... very very convincing

had a 10 plate astra as a courtesy car a few months ago, that had said wheeltrims never seen a set that convincing, only noticed because i spotted a wheel weight clip behind them

[joff-turbo-nova]

I'll have a tenner spud is correct.

Nice one joff! You really do love the meriva don't you! (not thought about the vxr?)

I did really want the VXR version, but they seem to command silly money 2nd hand (like the Zafira GSI's and VXR's) and never turn up as salvage, so I thought I would get a nice solid reliable runaround.

If all else fails in a few years time I can start looking at a transplant :thumb:

Joff

[davidfox280585]

100 percent steelies

[joff-turbo-nova]

Morning all,

Well after a 400 mile round trip I now have my 2011 project sitting on the drive.

Having inspected the damage most of the problem bits are bolt on / off so its really just the chassis leg that needs sorting (the bodyshop attached to my diddy Vauxhall dealer in Mappleton have said they can pull it straight for a reasonable price!)

http://i2.photobucket.com/albums/y15/joff-turbo-nova/DSC03239.jpg

http://i2.photobucket.com/albums/y15/joff-turbo-nova/DSC03238.jpg

http://i2.photobucket.com/albums/y15/joff-turbo-nova/DSC03231.jpg

http://i2.photobucket.com/albums/y15/joff-turbo-nova/PICT0292.jpg

http://i2.photobucket.com/albums/y15/joff-turbo-nova/PICT0297.jpg

http://i2.photobucket.com/albums/y15/joff-turbo-nova/PICT0295-1.jpg

http://i2.photobucket.com/albums/y15/joff-turbo-nova/PICT0294-1.jpg

http://i2.photobucket.com/albums/y15/joff-turbo-nova/DSC03268.jpg

And Spudly you were right - the wheels are steelies with plastic trims.

Joff

[Sloth]

not to piss on this but if its had a smack on the leg end ill bet the legs gone out at teh bulkhead. they are very very fragile, and it usually bends the subframe too. heads up really mate.

[Spudly]

And Spudly you were right - the wheels are steelies with plastic trims.

Joff




Thought they would be, Rob was saying to me before that they folled a lad in his bodyshop at stonacre in scunny, into prepping for rubbing them down for refurb, till someone pulled it off after a breif argument over whether they were trims or alloys or not lol

[16v Nova Kev]

that chassis leg will needs lots of work but looks fixable.

[John]

chassis legs looks pretty straight further back though, Iirc the ends on these are designed to collapse anyway.

[Mike]

chassis legs looks pretty straight further back though, Iirc the ends on these are designed to collapse anyway.

There the same as the crash cans on a Corsa C. I.e, collapsable.

[Spudly]

And besides which this is Joff, it will be sorted 100% by the book as we all know his standard and attention to detail:thumb:

[joff-turbo-nova]

Hi all,

I've had a change of plan due to the vectra starting to become a little bit unreliable.

It threw a cambelt last month which mashed all 16 valves in the head and yesterday a
brake pipe leak developed which I sorted this morning with a new length of copper pipe ,
some use of the flaring tool and a couple of unions.

So with this in mind I have swapped priorities and have decided that I need the new Meriva
fixed and onto the road sooner rather than later.

Therefore after fixing the Vectra this morning I have started stripping the front end in
preparation for it being put on a local jig and pulling straight.

Unbelievably the aircon system was still pressurised and there were no leaks on the aircon rad.
Once removed it was a bit twisted but its straightened up without problems.

The water rad is fubar'ed as the two top brackets have ripped holes in the endcaps on each side.

The offside headlamp seems to be fine and although the ABS unit is fine, the cradle that it
sits in is a bit bent - nothing that a trip in the vice won't fix!

Now that its stripped back it seems the impact on the chassic leg has rotated around the
point where it bolts to the engine bed, so going back to the bulkhead seems prettry straight
with none of the sealer cracked.

The fronts of both chassis legs need some work as the captive nuts in 3 places have ripped
out of the metal. I'll let the jig guys sort this when they are trial fitting the panels once the
leg is straight.

So it's gone from this at lunchtime ....

http://i2.photobucket.com/albums/y15/joff-turbo-nova/PICT0297.jpg


to this when I finished today.....

http://i2.photobucket.com/albums/y15/joff-turbo-nova/PICT0507.jpg


http://i2.photobucket.com/albums/y15/joff-turbo-nova/PICT0509.jpg
With this pile of scrap awaiting a trip to the tip .....

http://i2.photobucket.com/albums/y15/joff-turbo-nova/PICT0510.jpg

Next jobs are removing the arch liners and wings, then the scuttle panel so I can attach the
new bonnet hinges (as the existing ones were twisted in the impact).

Cheers

Joff

[MK1_Ben]

Looks good :)

Any photos of the Steels without the trims, Intrigued as to what they look like underneath

[Spudly]

Lol so the poor vectra is heading to the breakers eh Joff, btw did you get my text this morning?

[16v Nova Kev]

can you get/buy new chassis leg ends. i have fixed a few ford focus's that way basicly pull it as much as you can then cut the ends off and replace.

[joff-turbo-nova]

can you get/buy new chassis leg ends. i have fixed a few ford focus's that way basicly pull it as much as you can then cut the ends off and replace.

Just had a scout round ebay and YES GM do replacement chassis leg ends - will get a pair shortly ....

http://i.ebayimg.com/17/!BWuj0EgBGk~$(KGrHgoH-D8EjlLlzKDlBKY1YM5wVw~~_12.JPG

http://i605.photobucket.com/albums/tt140/munichparts/125-1.jpg

Joff

[16v Nova Kev]

cool i would deffo get them and dont throw anything out till your done. i.e the plastic part on the cross member that looks re useable.

[Danny s-p]

looking good joff

[stupot89]

look a easy fix tbh joff should make a nice car when done

[joff-turbo-nova]

Finished off the stripping today ready for the jig .


Looks good :)

Any photos of the Steels without the trims, Intrigued as to what they look like underneath

Ben as requested here is a couple of pics of the steels behind the wheel trims - they
look quite cool just bare ! Noticed that they are ET43 as well !

http://i2.photobucket.com/albums/y15/joff-turbo-nova/PICT0511.jpg

http://i2.photobucket.com/albums/y15/joff-turbo-nova/PICT0512.jpg


Anyway, got busy with the spot weld drill and removed the headlamp surrounds
and got the wings off as well . Just in case anyone else is doing a wing change /
removal on a meriva there is a really tricky bolt behind the quarter light. That's
right the bolt is actually behind the fixed glass - great bit of design :confused:

Fortunately the nice people at Haynes had told me (even though it wasn;t in the
manual - I had to email them direct to get it) how to get the wings off - the last
bolt behind the glass is reached from underneath using a 13mm spanner - all you
need to do it back it off by half a turn and the wing tag pulls out !

So wings and headlamp surrounds sorted - I pulled some more loom out of the way
and removed the chassis leg end plate ready to weld in a new one.

You can now see by the pics where the n/s chassis leg has been smacked. It's
rotated around the engine bed bracket, however looking at the o/s chassis leg
and the angle of the front of the upper wing I suspect this side has also been
knocked out of alignment.

I think everything shound pull back straight - I may need to put a plate on the
inside of the n/s chassis leg just to put a bit of strength back into the panel,
but apart from that things are as I suspected....

http://i2.photobucket.com/albums/y15/joff-turbo-nova/PICT0513.jpg

http://i2.photobucket.com/albums/y15/joff-turbo-nova/PICT0514.jpg

http://i2.photobucket.com/albums/y15/joff-turbo-nova/PICT0515.jpg

http://i2.photobucket.com/albums/y15/joff-turbo-nova/PICT0516.jpg

http://i2.photobucket.com/albums/y15/joff-turbo-nova/PICT0517.jpg

http://i2.photobucket.com/albums/y15/joff-turbo-nova/PICT0521.jpg

http://i2.photobucket.com/albums/y15/joff-turbo-nova/PICT0523.jpg

Cheers

Joff

[16v Nova Kev]

i would be tempted to cut the pasenger side chassis leg. along the top down the engine side and bottom then knock f out it

[joff-turbo-nova]

Very short update.

Went to see a nice bloke last night called Chris Peart :- Peart Motorsport (http://www.pasmotorsport.co.uk/gallery.html)

Based in the middle of nowhere he seems to know his stuff and has been recommended by a trusted friend who has had a couple of write offs pulled straight by him.

The Meriva is being collected on Wednesday evening and should be ready the following week.

I'm off to see the bodyshop I use in Brid this morning to get it booked in there for the spraywork the following weekend.

Cheers

Joff

[joff-turbo-nova]

More of an update today ...

I now have a straight meriva - yay ! The n/s leg needed a fair bit of fettling to get straight, however the offside leg was out by 12mm as well, which I suspected.

All the new panels have been welded and bolted back on and I collected it for transportation this morning .....

http://i2.photobucket.com/albums/y15/joff-turbo-nova/08042011020.jpg

http://i2.photobucket.com/albums/y15/joff-turbo-nova/08042011021.jpg

So took it on a road trip down some rather narrow lanes from the middle of nowhere up to Bridlington to the spray shop I use and started to unload accordingly ...

http://i2.photobucket.com/albums/y15/joff-turbo-nova/08042011022.jpg

http://i2.photobucket.com/albums/y15/joff-turbo-nova/08042011025.jpg

You can see here the now straight leg - they had to take the outer panel off to get it heated up as the chassis leg is double skinned - just needs a bit of filler and seam sealer and jobs a good 'un !

http://i2.photobucket.com/albums/y15/joff-turbo-nova/08042011023.jpg

http://i2.photobucket.com/albums/y15/joff-turbo-nova/08042011024.jpg

Should be ready to collect next saturday which will give me time to rebuild it and do a bit of tweaking before it gets taxed on the 1st May !

Joff

[Spudly]

Looking miles better there Joff, good work.


One question though, why on earth didnt we have that trailer when we moved the twelve door/trailer project across your village lol

[joff-turbo-nova]

One question though, why on earth didnt we have that trailer when we moved the twelve door/trailer project across your village lol

The trailer isn't mine- it belongs to the guys doing the jig work - they let me transport the meriva around which saved them a job and kept the costs down - which is good by me !

Would be handy to have a trailer like that - just don't have anywhere to store it !

Joff

[Spudly]

You need to build a thunderbirds style entrance in your drive and build a garage under your garage, then build a trailer to fit into it lol

[Ben]

Good work as ever, didnt seem a hard knock, must have only just been written off as hardly any structural damage and the age mileage makes it worthwhile.

Did you get that off CMS?

[joff-turbo-nova]

Did you get that off CMS?

The meriva was purchased privately from a chap who lives in Gloucester. The car was insured through Allianz and the brother of the Gloucester chap works there.

He sources written off cars directly from Allianz and sells them on privately.

Did all the usual HPI checks before purchase and all that came up was the cat D marker. The meriva was originally purchased through the motability scheme and is currently registered as a disabled tax class, so I will need to visit my local DVLA office to get it taxed.

Joff

[Ben]

I think i know the guy you mean lol

[16v Nova Kev]

looks good joff.

[joff-turbo-nova]

Update :-

Whilst the Meriva is being sprayed this week I have been prepping the new alloys for spraying .

The alloys are originally from a Zafira and were rather rough when I picked them up - I only paid £40
for them so I wasn't that bothered ! They are 16" x 6" in size on a 49mm offset.
I have some 195/45 16" Continental tyres to go on which have only done 200 miles so are like new.

I had them shot blasted which although has cleaned them up a treat has left the surface somewhat pitted
(I will get the next wheels I do acid dipped) ....

http://i2.photobucket.com/albums/y15/joff-turbo-nova/PICT0563.jpg

http://i2.photobucket.com/albums/y15/joff-turbo-nova/PICT0564.jpg

But after a rub down with some 120 wet and dry and some liberal coats of primer filler, they have come
up OK - 3 done one to go...

http://i2.photobucket.com/albums/y15/joff-turbo-nova/PICT0566.jpg

Will take these up to Bridlington on Saturday when I pick up the Meriva, alloys being sprayed the
usual anthricite colour.

Joff

[Vlietje]

Looking good Joff...

[joff-turbo-nova]

Update from todays work ....

With the kind help of Spud we went on a mini road trip today around the East Riding. First stop was Oustwick to collect the trailer,
next stop Nafferton near Driffield to collect the keys to the sprayshop and then we landed in Brid to collect the fixed meriva ....

http://i2.photobucket.com/albums/y15/joff-turbo-nova/16042011026.jpg

Got it loaded up on the trailer ....

http://i2.photobucket.com/albums/y15/joff-turbo-nova/16042011027.jpg

And then 17 miles down the road to my house to drop off the meriva and push it up onto the drive .....

http://i2.photobucket.com/albums/y15/joff-turbo-nova/16042011028.jpg

http://i2.photobucket.com/albums/y15/joff-turbo-nova/PICT0571.jpg

Seem to have done a great job on the chassis leg , however the paint has reacted on the wings so it will need to go back
to get this sorted at some point. It needs an aircon regas so I will get it all sorted at the same time once its rebuilt and
on the road .


http://i2.photobucket.com/albums/y15/joff-turbo-nova/PICT0569.jpg

http://i2.photobucket.com/albums/y15/joff-turbo-nova/PICT0570.jpg

Now awaiting all the bits to go back on, first job up is to get the hammerite on and then the waxoyl - I have 10l of Waxoyl
and 5 litres of the black underseal coming on Monday . I already have two 1 litre tins of hammerite so have plenty of stuff
to be getting on with !

A BIG thanks to Spud for helping out and keeping me entertained !

Enjoy

Joff

[Spudly]

Not a problem Joff, happy to help out as always and was a good jolly out into our own part of the countryside:d



Note to Jack, that is not your cavalier in pic #5, merely an identical replica of a TD-GSi and seemed to be badged as a 'GSi 2000' whatever one of those may be lol

[16v Nova Kev]

is it just me or do the wings not look as shiney as the doors?

[Spudly]

is it just me or do the wings not look as shiney as the doors?



Yes we know about that, they had some reaction so rather than try to polish it out and pull the wool over joff's eyes, they told him about it and are taking the car back once finished and repainting them:thumb:

[16v Nova Kev]

ahhh ok cool.

[joff-turbo-nova]

More work today....

I have given the engine bed and inner wings two coats of hammerite just to seal everything up that may have been disturbed when the shell was mashed and pulled straight ......

http://i2.photobucket.com/albums/y15/joff-turbo-nova/PICT0573.jpg

http://i2.photobucket.com/albums/y15/joff-turbo-nova/PICT0575.jpg


http://i2.photobucket.com/albums/y15/joff-turbo-nova/PICT0576.jpg

Also fitted the Irmscher grille I got off ebay in January.

http://i2.photobucket.com/albums/y15/joff-turbo-nova/PICT0572.jpg

Next job is get the kettle out and heat up the waxoyl for a good coating in all the nooks and crannies and box section, then on with the arch liners.

Joff

[Dervy]

thats looking really nice now joff, are you selling it when its done?

[L14MNP]

Looking good mate! Seems like a decent bodyshop too, although I'm sure you wouldn' rate them were they not!

I was down Driffield just the other week collecting a car I got on eBay. Some nice villages along the way, and funny names! lol

[joff-turbo-nova]

Looking good mate! Seems like a decent bodyshop too, although I'm sure you wouldn' rate them were they not!

I was down Driffield just the other week collecting a car I got on eBay. Some nice villages along the way, and funny names! lol


Yeah, we have Wetwang and Gembling up near Driffield !


thats looking really nice now joff, are you selling it when its done?

No , I wouldn't be doing all this hammeriting and waxoyling if I was going to flog it on !

Joff

[L14MNP]

Wetwang! That was it. lol. Stamford Bridge and Sunderlandwick were also of interest lol.

[blue_peg_16v]

The meat van in the garden of the village before malton but after wetwang makes me chuckle every time I pass

[Spudly]

Wetwang! That was it. lol. Stamford Bridge and Sunderlandwick were also of interest lol.




Which is not very far from either me or Joff, how rude you didnt come say hai:cry:

[L14MNP]

Which is not very far from either me or Joff, how rude you didnt come say hai:cry:

:eek: Wish I had known dude! :cry: I really can't remember where we went, I hope I wasn't in your village! lol

[joff-turbo-nova]

:eek: Wish I had known dude! :cry: I really can't remember where we went, I hope I wasn't in your village! lol

I'm about 15 miles south east of Driffield, I'm more nearer Hornsea and Beverley!

Did a bit of waxoyling today on the near side - lots of gunge in the box sections (a bit came out at the bottom as well :confused: ) - need to crack on and get the otherside done tomorrow - got waylaid with birthday parties and Asda shopping today !

No pics as I was busy - will take some tomorrow !

Joff

[Spudly]

And waylaid with Patrick shooting you with his nerf guns aswell im sure Joff lol



Liamp, as said Joff is about 15 miles from there as he is out one side of Hull and im about 15 miles away the other side, spitting distance really, but i think you didnt make an attempt to come see us as you do not really exist and you are in fact just a bot with no real entity:p

[joff-turbo-nova]

And waylaid with Patrick shooting you with his nerf guns aswell im sure Joff lol



I banned him from firing the nerf near the car as there was waxoyl everywhere today!

Had quite a successful day all round really !

Got the waxoyl gun set up and off we went at 9:30am this morning - my neighbours had gone to church so I wasn't disturbing anyone .....

http://i2.photobucket.com/albums/y15/joff-turbo-nova/PICT0581.jpg

http://i2.photobucket.com/albums/y15/joff-turbo-nova/PICT0579.jpg

http://i2.photobucket.com/albums/y15/joff-turbo-nova/PICT0580.jpg

I then cracked on with getting the ABS back in situ, the battery box and the wiring loom sorted - nearside headlamp was next then the rad pack, pipes and expansion tank.

http://i2.photobucket.com/albums/y15/joff-turbo-nova/PICT0582.jpg

The aircon rad is a little twisted so the mounts needed tweaking here and there to get it to attach to the new GM radiator.

http://i2.photobucket.com/albums/y15/joff-turbo-nova/PICT0583.jpg

Bumper bar was next, then the rest of the loom. The rear panel, scuttle panel and wipers were next and then the other headlamp.

http://i2.photobucket.com/albums/y15/joff-turbo-nova/PICT0584.jpg

http://i2.photobucket.com/albums/y15/joff-turbo-nova/PICT0585.jpg

Everything seems to be working fine (touching lots of wood !) - need to get some coolant so I can get the cooling system
filled and run it up to temperatue to make sure the engine wasn't cooked and left running with no coolant. I have had
the engine running before and it was nice and quite with no noises.

Finished off by building up the front bumper , it already has the irmscher lower spoiler fitted and is ready for fitting in the morning!

http://i2.photobucket.com/albums/y15/joff-turbo-nova/PICT0587-1.jpg

Next jobs are hammerite the floor pan and rear, waxoyl and underseal . I need to take the rear bumper off to waxoyl
behind it and I need to fit the Irmscher rear valance as well.

Side skirts and Lester top spoiler are next up then waxoyling the doors and tailgate . A good valet inside and out and it will be ready for the road !

Joff

[Spudly]

Looking good mr, really good to see it looking like a car again and fingers crossed for first startup/run-up to temp:thumb:

[joff-turbo-nova]

More work today inbetween gardening jobs and cutting down a 30ft tree (I like my chainsaw!) .....


Archliners and front bumper all fitted and wired up .......

http://i2.photobucket.com/albums/y15/joff-turbo-nova/PICT0588b.jpg

http://i2.photobucket.com/albums/y15/joff-turbo-nova/PICT0589b.jpg

Clean and painted the brake calipers as well whilst I was tidying things up !


Need to do some more hammeriting on the floor pan next - forecast rain tomorrow so may have to wait until wednesday .


Joff

[Spudly]

Your camera seems to be doing that odd swirly effect a lot just of late lol


Lol @ the edit showing your puddy cat hiding in the grass too:d

[joff-turbo-nova]

Whilst I have the door cards off for waxoyling I thought it would be an opportune time to upgrade the speakers so I sourced some nice Focal Access 165's which arrived on Thursday....


http://i2.photobucket.com/albums/y15/joff-turbo-nova/PICT0593.jpg

One set for the front and the other for the rears (Patrick will love them :thumb: )

Joff

[joff-turbo-nova]

I sourced some Vauxhall long life coolant this morning and filled up the cooling system.

Ran the engine up to temperature and the fan kicked in on a 3 stage fan, slow , medium and high speed fan speeds.

Sat for ten minutes at 95 degrees with the fan kicking in and out without any problems !

I then dropped the oil and changed the cartridge filter (strange affair if you ask me!) and refilled using Vauxhall's fully synthetic oil.

I then did a bit of loft insulation, had lunch, did a bit more in the loft, then started with the hammerite on the floor pan....

http://i2.photobucket.com/albums/y15/joff-turbo-nova/PICT0597.jpg

Got half done and then got a bit cold.

Will finish the other half in the morning.

Joff

[Spudly]

Spot on Joff, whens it in for VIC and MOT then?

[joff-turbo-nova]

Spot on Joff, whens it in for VIC and MOT then?

Not required as it was only classified as a Cat D . I already have the logbook and it is in my name, and MOT isn't due until February 2013 !

Just need to go to the DVLA place in Beverley to get the logbook change from Disabled to PLG so I can get a tax disc.

Joff

[Spudly]

Jammy git lol

[Southie]

Well hats off Joff you've done a cracking job getting this back together, has it been an expensive fix then?

Will the insurance be dearer due to being Cat D?

Good work though it looks very well :)

[joff-turbo-nova]

Well hats off Joff you've done a cracking job getting this back together, has it been an expensive fix then?



Chassis work and spray came in at £700 with parts another £300 or so , so all in about a grand. I splashed out on some irmscher bits (£160) and some nice speakers (£180) and have got some original vauxhall mats at £35 but thats it really.

I needed to get some hammerite and waxoyl which was extra, but that's just me being a n a l really lol lol

I plan to use the money I get for the Vectra to go towards an LPG conversion (as the nearest garage for LPG is 100 yrds away!) as I plan on keeping this Meriva for at least 10 years .

Joff

[joff-turbo-nova]

Got some time on the drive today....

Got the Meriva reversed around under its own power :thumb: Stripped the back bumper and rear arch liners......

http://i2.photobucket.com/albums/y15/joff-turbo-nova/PICT0608.jpg

http://i2.photobucket.com/albums/y15/joff-turbo-nova/PICT0609.jpg

http://i2.photobucket.com/albums/y15/joff-turbo-nova/PICT0610.jpg



Its amazing how little protection there is behind the liners and bumpers. Handly GM has given me little grommets to pull out so I can get my waxoyl nozzle in !!!

Also got the Irmscher rear apron attached to the rear bumper whilst it was off ....

http://i2.photobucket.com/albums/y15/joff-turbo-nova/PICT0607.jpg

A brace of Meriva's on the drive!

http://i2.photobucket.com/albums/y15/joff-turbo-nova/PICT0612a.jpg

Joff

[joff-turbo-nova]

Bit more work done today....

Cracked on with the Hammeriting on both wheel arches and the rear floor pan. Didn't quite get it all finished
as I have now run out of Hammerite - I've used just over 2 1/4 litres so far and will need another half a litre to finish off !

http://i2.photobucket.com/albums/y15/joff-turbo-nova/meriva0001.jpg

http://i2.photobucket.com/albums/y15/joff-turbo-nova/meriva0002.jpg

http://i2.photobucket.com/albums/y15/joff-turbo-nova/meriva0004.jpg

http://i2.photobucket.com/albums/y15/joff-turbo-nova/meriva0003.jpg


Will finish off sometime this week and then get on with the waxoyling of the box sections at the back and
around the petrol tank.

Also had a thought today - it may get a bit confusing in our house when we are talking about the meriva ,
now we have two. The colour of the new gold one is Lancelot, so that's its new name, my wife has decided
to call her meriva Guinevere (oh women lol )

Joff

[NOV4_SPORT]

looking good joff matey, well done.

iain

[joff-turbo-nova]

Bit more done today....

Gave the arches another coat of hammerite and finished off where I had run out last week and cleaned up the rear brakes and hubs .....

http://i2.photobucket.com/albums/y15/joff-turbo-nova/meriva04.jpg

http://i2.photobucket.com/albums/y15/joff-turbo-nova/meriva05.jpg

Also pick up today the zafira alloys which have been resprayed the usual colour :thumb: . Also put some
new shape Vauxhall logo's on the centre caps.....

http://i2.photobucket.com/albums/y15/joff-turbo-nova/meriva02.jpg

http://i2.photobucket.com/albums/y15/joff-turbo-nova/meriva03.jpg

http://i2.photobucket.com/albums/y15/joff-turbo-nova/meriva01.jpg

Waxoyl and underseal tomorrow. Also trail fitted one of the focal speakers in the rear door , it will need an
MDF spacer which I will sort tomorrow.

Joff

[Spudly]

Liking the names of them Joff thats quite amusing, shame the wheels are five stud, i cant come and borrow them for my astra lol

[joff-turbo-nova]

More work....

Have done all the waxoyling at the back and put back in all the arch liners and rear bumper......

http://i2.photobucket.com/albums/y15/joff-turbo-nova/meriva010.jpg

Also fitted on the rear the new wheels with the centre caps , the light was a bit iffy , they look better than the pics show :d

http://i2.photobucket.com/albums/y15/joff-turbo-nova/meriva011.jpg

http://i2.photobucket.com/albums/y15/joff-turbo-nova/meriva012.jpg

http://i2.photobucket.com/albums/y15/joff-turbo-nova/meriva013.jpg

http://i2.photobucket.com/albums/y15/joff-turbo-nova/meriva014.jpg

Looks a bit higher at the back than it is as its sitting on a slope and the suspension hasn't settled from being jacked up.

Just need to fit the side skirts and the rear spoiler, install the speakers and waxoyl the doors and tailgate and its done!

Joff

[Spudly]

Ummm, she is looking awfully high there Joff, is that just due to the fact the car has just been jacked up without being moved to allow it to settle, and that its on the 90 degree slope you call a drive lol

[joff-turbo-nova]

Ummm, she is looking awfully high there Joff, is that just due to the fact the car has just been jacked up without being moved to allow it to settle, and that its on the 90 degree slope you call a drive lol

See edit !:thumb:

[blue_peg_16v]

needs eibacks me thinks

[Spudly]

See edit !:thumb:




Sneaky :p

[joff-turbo-nova]

Had time tonight to put the rear Lester spoiler on. It takes a bit of courage to drill holes in a brand new tailgate :confused:

http://i2.photobucket.com/albums/y15/joff-turbo-nova/meriva016.jpg

http://i2.photobucket.com/albums/y15/joff-turbo-nova/meriva017.jpg

Sideskirts are next...

Joff

[scott.parker]

Lovely looking car mate, never really thought about them, but there alright looking with irmy kit..

And i would of thought 50 profile would of helped reduce the arch gap?

Scott

[7ova]

looking good!

[joff-turbo-nova]

Update....


One sideskirt attached with sikaflex and lots of things holding it in place lol lol lol

http://i2.photobucket.com/albums/y15/joff-turbo-nova/Meriva17.jpg

http://i2.photobucket.com/albums/y15/joff-turbo-nova/Meriva18.jpg

Joff

[John]

Nice work Joff! Will look well with the kit on :)

[joff-turbo-nova]

On the final straight now .....


Got the other skirts on .....

http://i2.photobucket.com/albums/y15/joff-turbo-nova/Meriva030.jpg

And then sorted some MDF rings for the Focal speakers and got one of them wired in once I had blasted inside the door with waxoyl....

http://i2.photobucket.com/albums/y15/joff-turbo-nova/Meriva031.jpg

Next job is to get the speakers and waxoyl into the other 3 doors and waxoyl the tailgate and we're done!

Joff

[joff-turbo-nova]

Well my ebay bargain of the year arrived today .

I got lucky with a mis typed auction on ebay for a Irmscher backbox - start price £0.99 - 1 bid - mine - winning price - £0.99 :eek: :eek: :eek: :eek:

I sorted a courier for £7 and two days later it arrived - yay !!

It was a bit scabby and scruffy so got to work with the wire brush and sandpaper.

Then a couple of coats of VHT black paint and some Autosol on the chrome work and it was looking like new !

http://i2.photobucket.com/albums/y15/joff-turbo-nova/Exhaust1.jpg

I left it to dry till late this evening , then removed the old box and fitted this one - went on a treat with no messing !


http://i2.photobucket.com/albums/y15/joff-turbo-nova/Exhaust3.jpg

http://i2.photobucket.com/albums/y15/joff-turbo-nova/Exhaust2.jpg

Finishes off the rear end nicely !

I have an exam on Monday so will crack on with finishing the meriva once thats out the way!

Joff

[Mike]

Jammy git! Irmscher rear boxs for new age GMs fetch really good money!

[Spudly]

Irmscher boxes for any age GM's fetch good monies, Joff, i tip my hat to thee good sir, thats a bargain and a half:thumb:

[Andy]

what a guy!

[joff-turbo-nova]

Irmscher boxes for any age GM's fetch good monies, Joff, i tip my hat to thee good sir, thats a bargain and a half:thumb:

Yeah , the guy listed it as an Irmischer back box - here's the auction link...

http://cgi.ebay.co.uk/ws/eBayISAPI.dll?ViewItem&item=220788417763&ssPageName=STRK:MEWAX:IT

Joff

[joff-turbo-nova]

There's a brand new one on the bay .... £160 !

http://cgi.ebay.co.uk/VAUXHALL-MERIVA-IRMSCHER-EXHAUST-i3708001-/220791661998?_trksid=p4340.m506&_trkparms=algo%3DNGRI%26its%3DI%26itu%3DUA%26otn%3 D8%26pmod%3D220788417763%26ps%3D63%26clkid%3D39435 1868888745689

[Andy]

Yeah , the guy listed it as an Irmischer back box - here's the auction link...

http://cgi.ebay.co.uk/ws/eBayISAPI.dll?ViewItem&item=220788417763&ssPageName=STRK:MEWAX:IT

Joff
everyone on ebay calls them that though lol
Irmisher irmischer or airmisher ive even seen,i arent kidding!

[Spudly]

Oh well, finally illiterate numpties are starting to come unstuck, if they could spell, or even looked harder into the items history/genre before advertising it for sale then they wouldnt gave failed as hard as they did lol


Of course we wouldnt have such a currently happy Joff on the flipside!

[joff-turbo-nova]

Just a quick update on this.

Clarion Stereo installed , focal speakers installed (on offside)

http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_8827.jpg

http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_8830.jpg



I have rear electric windows to install, however due to the penny pinchers at Vauxhall, I have a poverty spec body loom and will need to splice in some extra wire along the sills to accommodate the extra wires. I plan to do this when the weather gets a little warmer as its rather nippy in the garage at the moment !



I also have some Vectra GSI seats I am going to get retrimmed along with the door cards and rear seats in something nicer than the OE seats. They are OK but offer little support when you get a shift on going round corners!



The big event however will be an engine transplant ....



Some of you will be aware that at the end of 2011 broke for spares a 2002 Astra Coupe Turbo. This was all stripped off and the bare shell went to the scrap yard a few weeks ago.

http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_8772.jpg



I originally sourced it from a chap in Birmingham (see roadtrip thread - LINK - Road Trip (http://www.pngclub.com/forum/showthread.php?176821-My-Road-Trip)) and drove it back to East Yorkshire without problems. The engine ran sweetly and didn’t seem to puff smoke or anything.

http://i2.photobucket.com/albums/y15/joff-turbo-nova/Nokia0809004.jpg

The big plan is to pull the 1.4 twinport engine out at some point in early 2013 and reinstall the Z20LET engine . Being a fan of six speed traction, I have also sourced an M32 six speed gearbox to mate up to the engine (which has caused a few headaches in its own right!)

http://i2.photobucket.com/albums/y15/joff-turbo-nova/Engineout001_800x600.jpg

http://i2.photobucket.com/albums/y15/joff-turbo-nova/Engineout002_800x600.jpg

http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_8831.jpg

http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_8832.jpg


As the Meriva is basically very similar to a Corsa C at the front end, then a Z20LET conversion should be fairly straightforward-ish ! I am aware of only one other Z20LET meriva which is a Stienmetz one in Germany LINK -Merifast (http://www.steinmetz.de/printable/productsenglish/conceptcars/merifast/index.html) , this conversion seems to be very rare in the UK !

http://www.tuningnews.net/gallery/steinmetz-merifast/03.jpg

The main hurdles to overcome are the wiring (which I am fairly comfortable about) and the drivetrain which I still need to solve .

My jobs I need to do in the next 12 months are :-

Rebuild the block

new seals, piston rings, gaskets and an oil pump and check the bores (may need a light hone). I will put in head studs from SteveBoySlim (Mig) to aid further headwork in the future. I will also be putting in under piston oil squirters to aid reliability.

Rebuild the head

new seals and gaskets , clean out the lifters and clean and reseat the valves


Replace the turbo

the Z20LET turbo had a fair bit of play in the shaft , I don’t think it was the original turbo (car had done 102k) but needs changing – I have been able to secure an excellent deal with Evans Halshaw in Newport care of the VXROnline forum for a replacement Z20LEH turbo at no extra charge so billy bonus on that one.

Intercooler

Source a nice intercooler as the standard Z20LET one is rubbish and sits in the wrong place for the Meriva front end.

Gearbox

I have sourced already an M32 gearbox from the Midlands (which went missing in transit for 10 days !) – this apparently a low mileage VXR item , however after reading up about them, they seem to have some serious bearing issues inside, so will be sourcing a rebuild kit to replace all the bearings and seals. This gearbox has also thrown up some other issues :-


Clutch & flywheel – I need to change to a VXR dual mass as the standard Z20LET has different splines

Driveshafts – the Z20LET inner CV joints don’t fit into an M32 box , so I need to source some VXR shafts, however the outer CV’s won’t fit the Meriva drive flanges (none of flanges across the range fit) . I am looking into the Meriva VXR stuff but its dealer only spares and dealer prices and second hand breakers for Meriva VXR are like gold plated teeth from hens sitting on poo from a horse that rocks !


I am investigating whether Astra H SRI turbo CV’s fit as the have the correct teeth numbers on both inside and outside to mate to 1.7 Cdti flanges, however the do not have any ABS rings on them . The CV’s may need machining to accommodate this . Alternatively I have a contact on Corsa-C.co.uk who is looking into bespoke driveshafts that will accept Cavalier/Calibra Turbo CV’s .

So I have lots to do and a while to sort it all out. More pictures to follow when things arrive and bits get pulled apart !


Joff

[Connor]

Cant wait for progress on this, will be watching this one, also got a few mates that would love this project so i'll have to show them aswell lol

[Connor]

If you need wiring diagrams or info for the z20let let us know, as i have them all off autodata

[blue_peg_16v]

Thought the seats would be in by now Joff your slacking lol

Nice to see something a little different.

[mowgli]

re the clutch, is it worth investigating the vectra diesel clutch plates?

[Ben]

tbh i would try everything to avoid choosing to put a dual mass on anything!

[joff-turbo-nova]

If you need wiring diagrams or info for the z20let let us know, as i have them all off autodata

I think I have this covered as I have pulled all the pin connections from TIS for both the Astra and Meriva , I just need to work out which pins need to go where.

On Corsa-C forum it's as though this is REALLY secret information. It's quite straightforward really. There's about 40 pins you need to look at and not all of them need moving.

Joff

[Ben]

i once looked right into it and the 1.0l corsa has the same ecu as the z20 not sure what you need to do re the programming or what the mervia one is like. but all in all its not half as bad as people make out.

[joff-turbo-nova]

This box was waiting for me when I got home last night which had come from Evans Halshaw in Newport ....

http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_8837.jpg

Out came a top gasket and seal set ....

http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_8839.jpg

Next were these bubble wrap blue things.....

http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_8840.jpg

Turns out to be a set of Meriva VXR caliper carriers so I can fit the 308mm brakes from the Astra (the discs and pads were brand new!)....

http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_8841.jpg

Next up was a new turbo fitting kit....

http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_8843.jpg

And finally one Z20LEH (Astra VXR) turbo brand spanking new .....

http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_8844.jpg


I also ordered off ebay a valve clamp as well so I can get the valves in and out of the head when I pull it off the block .....

http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_8833.jpg

I'm sure more stuff will come soon - Christmas all over again !

Joff

[blue_peg_16v]

Ooooh box of wondrous goodness

[Vlietje]

Jummie jummie!! Me likes!

[pie]

looks nice that buddy

[Connor]

On Corsa-C forum it's as though this is REALLY secret information. It's quite straightforward really. There's about 40 pins you need to look at and not all of them need moving.
Joff

Yea i noticed how secretive they are about the information, yet its actually a rather simple conversion imo.
Yea it should be all relatively straight, judging by how tidy your nova conversion is, this one will be a cracker :thumb:

[joff-turbo-nova]

Update..

I sourced a 5k miles alternator from an Astra VXR. What I didn't know is that the pulley has a different depth than the Z20LET one. The brackets sit the alternator 1/2 inch further in to accommodate this.

http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_8846.jpg

I therefore picked up today the correct brackets so it should all fit on the Z20LET block.

http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_8845.jpg

Its also a higher rated one than the Z20LET at 120A...

http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_8847.jpg

I got a Cdti airbox a few weeks ago - brand new from Autovaux. Its a shame I didn't measure up properly before ordering as its far to big to fit in the space behind the meriva headlight (its going up for sale soon!)....

http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_8848.jpg

I therefore bought this off ebay last week, a Pipercross filter which I will hook up to an induction hose which should be effective at keeping the heat out of the induction tract.....

http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_8849.jpg

http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_8850.jpg

And talking of the induction tract I sourced a flow meter to turbo kit last month ....

http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_8852.jpg

And also a Courtenay kit for the top hat and a metal side pipe .....

http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_8851.jpg

I've also had word that I may have access to some Meriva VXR shafts and CV's so watch this space!

Lastly, these arrived today from a firm in the West Midlands ... a nice set of Timken bearings for an M32 box. Will do a "how to" on changing these bearings when I get round to working on the box.

http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_8853.jpg

Enjoy!

Joff

[Balley]

Fook me you have spent some pound notes there. This should be a very impressive build.

Dan

[joff-turbo-nova]

Fook me you have spent some pound notes there. This should be a very impressive build.

Dan

Redundancies are meant to be spent on something useful !!! Started a new job on the 9th Jan . Got my redundancy payout on the 20th !

I actually started accumulating this stuff back in 2011 when I decided to Z20LET the meriva so it hasn't been loads spent all at once, well apart from the bearings and vauxhall order!

[Graeme]

Cracking work pal wouldn't mind a zlet in a c myself, looking forward to seeing it go in

[Ben]

That's what I love about joff's build threads, details, pictures Goodluck Joff!

[Tom-Tank]

Should be a good conversion when done, PM me if you need wiring diagrams as i have them all here

[joff-turbo-nova]

I got hold of a "balancer shaft deletion kit" last weekend , which is basically a girdle and oil pick up pipe from a Vectra or Astra X20XEV engine.

These were pretty caked in muck so I set too with the gunk and RTF and soon had them cleaned up.

http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_8867.jpg

There seems two schools of thought about getting rid of the balancer shafts mainly to do with engine harmonics. The Z20LEH engine doesn't have them as they run dual mass flywheels which does a similar job.

Therefore as I will running a dual mass I thought it would be better to get rid of the balancer shafts, which weigh a hefty amount (about 9 kg I thing) and they do sap a little of the engine power!

I also trail fitted the Z20LEH alternator on the revised brackets and it all seems to sit fine . I didn't order the straight flat bracket at the back by mistake , but lengthened the bolt holes at each end and everything seems to sit where it should.

http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_8866.jpg

Joff

[joff-turbo-nova]

Update...

Another box rolled up today ....

http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_8895.jpg

It contained a nice shiney intercooler........

http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_8896.jpg

And a dual mass flywheel, clutch and cover plate from a 15k VXR engine .....

http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_8897.jpg

There is a little bit of surface rust where it has got slightly wet, but nothing a bit of sanding won't fix !

http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_8898.jpg

Joff

[NOV4_SPORT]

Looking good as always joff, keep up the good work.

[Rick Draper]

Out of interest why do you feel there is the need for balancer shafts or a dual mass flywheel on a engine thats merely a evolution of a 20XE? Did it do anyones 20XE any harm not having them?

[Ben]

Tbh I think your mental fitting a secondhand dm and clutch.

[Ben]

On another note have got to change the starter to the matched Vxr item?

[mowgli]

Out of interest why do you feel there is the need for balancer shafts or a dual mass flywheel on a engine thats merely a evolution of a 20XE? Did it do anyones 20XE any harm not having them?

marketing people drive these decisions... dmf is so that little not very strong people can use a clutch on a big torquey engine without any great effort, and also there is a big push for refinement these days, and what us nova people put up with isn't necessarily what everyone else will...

[Ben]

marketing people drive these decisions... dmf is so that little not very strong people can use a clutch on a big torquey engine without any great effort, and also there is a big push for refinement these days, and what us nova people put up with isn't necessarily what everyone else will...

Ricks hardly nova person, did he ever drive his?

[mowgli]

joff, i wouldn't bother sanding the fly/clutch down, just store it in the dry till you fit it, i have a funny feeling the first couple of test runs will finish any rust off...

[joff-turbo-nova]

Tbh I think your mental fitting a secondhand dm and clutch.

Been doing a bit more reading up on DMF's . The concept is a good idea and as long as the reliability is there I can't see it being any different to having to change a clutch every so often. On the modern Vauxhalls its a gearbox off job to change the clutch anyway so doing the flywheel at the same time is no biggie.

However I may invest in a brand new DMF, as I already have another coverplate and friction plate which has done less than 5k . I can get a LUK one for £200 brand new from the bay.

Joff

[joff-turbo-nova]

Out of interest why do you feel there is the need for balancer shafts or a dual mass flywheel on a engine thats merely a evolution of a 20XE? Did it do anyones 20XE any harm not having them?

Balancer shafts I am deleting. The DMF is being used as this is the only OE flywheel that the Z20LEH clutch will fit as I am running an M32. The splines on the M32 differ to the F23 and the diameter of the clutch plate differs as well (228mm v 240mm)

You can get solid flywheels and sprung friction plates, however I can't justify spending nearly a grand on an aftermarket performance solid flywheel and sprung clutch assembly at this time.

Joff

[Ben]

The concept is a good idea and as long as the reliability is there I can't see it being any different to having to change a clutch every so often.

this is the problem in theory it works, tourqe on the other hand destroys the theory, they are unreliable and problematic. you pretty much need a new dmf evry clutch change and a new starter at the same time.

[Spudly]

If you end up getting a new LUK DMF, Joff, I would check into the compatibility with your current clutch, a friend had loads of issues with fitting an LUK clutch in his golf gttdi, it turned out they're engineered to only be compatible with each other so if you run one, you have to buy the other as nothing else will physically fit, yes I know it's not a golf before anyone else says anything, but there may be similar issues here!

[Rick Draper]

Balancer shafts I am deleting. The DMF is being used as this is the only OE flywheel that the Z20LEH clutch will fit as I am running an M32. The splines on the M32 differ to the F23 and the diameter of the clutch plate differs as well (228mm v 240mm)

You can get solid flywheels and sprung friction plates, however I can't justify spending nearly a grand on an aftermarket performance solid flywheel and sprung clutch assembly at this time.

Joff

TBH I had no idea it would be nigh on a grand to do away with the DMF and unable to combine parts off other vauxhalls to do away with it.

Unlike said know it all above who claims to know everything my nova ever did and how far I ever drove it...

[joff-turbo-nova]

Update,

Upgraded the brakes today and have also done a "How to" on brake caliper refurbishment, here is the main text and pics to save you swapping threads :-

Right first off - I started with a set of cruddy 308mm Astra G calipers. Fortunately the calipers had brand new pads and the vehicle had brand new discs so it was just the condition of the calipers that concerned me.

http://i2.photobucket.com/albums/y15/joff-turbo-nova/Brakes001.jpg

http://i2.photobucket.com/albums/y15/joff-turbo-nova/Brakes002.jpg

So I stripped down the calipers to the various components and gave them a wish with a flapper disc in my grinder, and also a going over with a wire wheel attachment in my drill . I then soaked them in my tub of vinegar for a few days to clean them up a bit and this was the results :-

http://i2.photobucket.com/albums/y15/joff-turbo-nova/Brakes003.jpg

http://i2.photobucket.com/albums/y15/joff-turbo-nova/Brakes004.jpg

http://i2.photobucket.com/albums/y15/joff-turbo-nova/Brakes005.jpg

If you have access to media blasting equipment (I don't) then you may get even better results!

I then used some silver smooth Hammerite and gave the components a couple of even coats.

http://i2.photobucket.com/albums/y15/joff-turbo-nova/Brakes008.jpg

http://i2.photobucket.com/albums/y15/joff-turbo-nova/Brakes007.jpg

http://i2.photobucket.com/albums/y15/joff-turbo-nova/Brakes006.jpg

I then purchased a rebuild kit of Ebay for about £22 which I thought was good value - the parts from Vauxhall are about four times this !

http://i2.photobucket.com/albums/y15/joff-turbo-nova/Brakes009.jpg

http://i2.photobucket.com/albums/y15/joff-turbo-nova/Brakes010.jpg

I then set about rebuilding the calipers. The slider bolts live in two rubber housing at each side of the piston, these just need pressing through. There is a rubber seal within the piston housing about 1/4 from the top, this needs replacing and then the piston dust seal needs putting on.


http://i2.photobucket.com/albums/y15/joff-turbo-nova/Brakes011.jpg

http://i2.photobucket.com/albums/y15/joff-turbo-nova/Brakes012.jpg


Next job is jack the car up and put the axle stands underneath for safety.

http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_8798.jpg

And start removing the standard 280mm brake cailpers and discs ...

http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_8799.jpg

First job is to clamp the brake hose so you do not lose all the brake fluid out ...

http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_8804.jpg



Continued below ..

[joff-turbo-nova]

Then undo the two retaining bolts with a E18 torx socket...

http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_8803.jpg


And remove the calliper. The disc can now be removed, if it has one fitted remove the bolt with an allen key/allen key socket .

Once off you should be left with something like this …

http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_8805.jpg

This flange is only 2 years old and is already rusty. Vauxhall do not coat these with anything from the factory so the discs tend to rust to the flanges and become solid.

I cleaned mine up and put a thin coat of copper grease on the face to eliminate future problems should I need to remove the disc in the future …

http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_8806.jpg

Next up is put the new 308mm disc on and bolt up the centre bolt with an allen key again. Then put the calliper carrier in place. At this point I found that the Astra G calliper carriers are the wrong shape and will not fit up against the hub. The solution for a corsa C / Meriva hub is a set of calliper carriers off a Meriva VXR which I sourced new for £48 each ….

http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_8908.jpg

The put the pads in , using a thin layer of copper grease on the backs of the pads to stop brake squeal …

http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_8909.jpg

And then put the calliper onto the carrier and tighten up the slider bolts onto the carrier ….

http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_8910.jpg

Reattach the brake hose and bleed the brakes with either a pressure bleed system , or an assistant pumping the pedal.

http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_8912.jpg


Put the wheels back on. And here is proof 308mm discs fit under 16” Vauxhall alloys ….

http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_8914.jpg


Full "How To" is here :- How To - brake calliper refurbishment (http://www.pngclub.com/forum/showthread.php?183116-*HOW-TO*-Refurbish-brake-calipers-308mm-brakes-on-a-Meriva-Corsa-C)


Joff

[mowgli]

joff, i'm glad that some proper caliper refurbishing is being shown, all too often people simply chuck stuff away, seemingly unaware that a repair kit can be used for a fraction of the cost of 'exchange' parts

keep up the good work

[joff-turbo-nova]

Quick update from this morning :-

Got my engine stand out - never actually had need for it till now ....

http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_8925.jpg


No instructions , but hey instructions are for wimps ......

http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_8926.jpg

Engine rolled out ready for the crane .....

http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_8927.jpg

Needed to get the flywheel off before I mounted it to the engine stand. Made a little flywheel jam from a bit of spare steel plate. Not exactly pretty but did the job .....

http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_8928.jpg


Then got the engine mounted on the stand ready for some stripping action .....

http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_8930.jpg

Joff

[shed-on-wheels]

well i have been waiting for another one of your build im going to be keeping an eye on this i cant wait bud

[joff-turbo-nova]

Started stripping the head last night .....

http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_8931.jpg


Its been used and abused this engine and its somewhat caked up. This is the top breather.......

http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_8932.jpg

And this is into the exhaust ports .....

http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_8933.jpg



I wonder what's lurking inside !!!! It runs without any clattering or undue noise so I suspect its just rather tired and coked up inside.

Joff

[Edd]

Looks like my zlet after 45k lol

[NOV4_SPORT]

Looking good buddy, the brakes look a tight fight, but its good you can still fit them under the 16"'s thou, keep up the good progress

[joff-turbo-nova]

A bit more stripping done tonight ....

http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_8934.jpg

http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_8935.jpg

The cams look in good condition , I was getting a bit worried when I saw the state of the breather yesterday !!!

http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_8936.jpg

Joff

[Vlietje]

Some good progress Joff! Keep it up mate!

[16v-kev]

herm i have thought of doing this with the wifes meriva i will be keeping an eye on the one top job so far !

[joff-turbo-nova]

More bits arrived in the post today....

Paint for the block....

http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_8938.jpg

Restrictor bolt for the oil line to the turbo.....

http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_8943.jpg

New thermostat, which is an 82 degrees cool one ....

http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_8939.jpg

http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_8940.jpg

Got the old thermostat housing out and changed out the old ....

http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_8937.jpg


For the new ....

http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_8946.jpg

Also got a brand new GM Bosch airflow meter for £41 off the bay last week - less than an aftermarket cheap one .....

http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_8947.jpg

Busy on the nova over the next few days pulling the turbo off so nothing much will happen on this for a while.

Cheers

Joff

[scott.parker]

Joff quick Q, is the oil restricter bolt mod applicable on the Z16LEX turbo setup?

[joff-turbo-nova]

Short answer is - yes.

Long Answer - taken from the corsa-d forum :-

"----------------------------------------------------------------------

the oil restrictor mod

--------------------------------------------------------------------------------

ok,thought i may as well put this up in here now,as i'm getting battered by pm's about it and its getting a bit repetative now.

this is a very simple engineering solution to several vxr turbo problems.

loads of people have problems with oil leaks,oil smells,smoke on idle.to which the standard response is "take it back the dealers" then there are people who have had 4 or 5 turbos under warranty and still get the same issues.then you get the "these turbos are crap" or "they are made of chocolate" statements.

well,you're wrong.its not the turbo's,its the car thats the problem and heres why.

vxrs have under piston cooling jets,and so have a higher pressure oil pump to accomodate them.this means they have oil pressure in excess of 100 psi (over 6 bar) when the oil is cool.even the old zlets have oil pressure of near 90psi.yes i have measured this pressure at the turbo.super.

the problem is,turbos are only supposed to run with between 2-4 bar (30-60)psi oil pressure.ball bearing turbos are supposed to have less than 2 bar (30psi).which means you are feeding the turbo's with way more oil pressure than they need and the seals are struggling to cope with it.thats why they seem to leak easily.not so much of a problem with the stock exhaust system,as the back pressure in it helps the oil seals.but when you fit a large bore exhaust and reduce the back pressure,it makes it even easier for the oil to get out of the exhaust side seal with its lower pressure.bingo.blue smoke on idle.

now for the interesting bit.

when you take your car to the dealers for turbo related issues.TIS has a standard procedure.check for leaks.if its the drain,fit the thicker z19dt drain gasket and clamp on the drain tube.if the problem still exists,swap the turbo.

NOWHERE does it say,check for excessive oil pressure.so,if you have had 3 or 4 turbos under warranty with the same fault,its not the turbo thats the problem.

also,if you have a rebuild by the likes of turbo dynamics,universal turbo's etc.they statically test the oil seals for leaks at guess what pressure.60psi (4 bar) MAX.so,its fine on the bench,then it can leak on the car with the extra pressure the car generates.this is where you then get into the back and forth of "its not the turbo mate,its your car or your exhaust doesnt have enough back pressure"

WRONG!!!!!

turbos dont like ANY back pressure,quoting a turbo guru "the best exhaust for a turbo is no exhaust".ever seen a turbo hayabusa or drag bike with more than 6 inches of exhaust?.dont think they have any back pressure do you?.

this is where the oil restrictor mod comes into it.

after many hours of work,testing and machining by me,this caps the max oil pressure the turbo see's to approx 40psi.this is more than enough to lubricate it yet doesnt overpower the seals.which means,you dont get any issues with running big bore exhaust.no smoke on idle with oil forcing its way past the seals.minimal risk of leaks (standard vaux drain isnt the best anyway) and oily smells when driven hard.

it WONT help with cracked manifolds (excessively high exhaust gas temps from too much boost) or burned out bearings (severe shaft overspeed down to too much boost).

the other plus,is you get more oil pressure where you need it,in the engine.a turbo oil feed line is essentially a haemorage from the engine.by controlling it,you control your oil pressure better.

theres loads of guff knocking about on various forums about these as pointless mods.they work.FACT!.

there are loads of people now running these with no further issues,some members on here have them aswell,some of whom have had turbo issues which have now gone without changing the turbo.i have cured some super smoky turbos with these without having the turbo rebuilt and there are several track cars running these with no issues.

they will also fit,corsa's,meriva's and vectra's too.

now for a bit of a warning,with the amount of stuff/ideas that gets copied (more so on here),i have applied for a patent for these babies,so there is now a patent pending."

See link here - CLICK -CORSA-D forum (http://www.ukcorsa-d.com/forum/showthread.php?27497-Oil-restrictor-bolt&)

Joff

[joff-turbo-nova]

More boxes arrived today ....

Some nice gauges care of a chap on VXRonline - not cheap ones , but look really nice...

http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_8955.jpg

Went for boost, oil pressue and oil temp.

This how they look installed in a bespoke astra dash, I'm putting my in a 3 gauge pillar pod....

http://i2.photobucket.com/albums/y15/joff-turbo-nova/gauges.jpg

Lots and lots of nice new hoses from Roose ....

http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_8958.jpg

And finally an Astra VXR gearstick which works with the M32 gearshift pattern....

http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_8956.jpg

http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_8957.jpg

May get a play with the engine on Saturday ....

Joff

[krobinson]

Cool. The I fitted the oil restrictor bolt to Terri-Ann's Astra GSI after it was smoking a little. Hasn't been any smoke at all since :-)

[blue_peg_16v]

Joff do they do the bolt for the c20let if so were do I get one

[joff-turbo-nova]

Joff do they do the bolt for the c20let if so were do I get one

Link is a bit further up the page , it's the same bolt as the Z20LET - all you do is unscrew out of the C20LET turbo the threaded sleeve and then put the bolt through the banjo with a copper washer on each side of the banjo and bolt back into the turbo.

My bolts have a 9mm allen key hole. I currently don't have a 9mm allen key or socket ! Guess whats on the shopping list !

Joff

[blue_peg_16v]

just found on ebay 1 on its way for when the turbo is rebuilt cheers joff

[joff-turbo-nova]

Been a busy day today, took a trip down to the VBOA parts day to meet up with a couple of chaps who did me some excellent deals.

First off was my ebay purchase from last week .... a full Meriva VXR interior :thumb::thumb::thumb:

http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_8970.jpg

http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_8969.jpg

http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_8979.jpg


Next up was a variety of driveshafts (Meriva VXR ones included) , cv's flanges, gearbox mounts and a set of coilovers for both a corsa C and Astra G from my newest best friend Paschal from Migweb.

http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_8971.jpg

http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_8972.jpg


Just about managed to get everything in the car. I then went for a wander round the VBOA stuff, not really that much stuff that I was interested in , and nothing that I needed.

Just bought a couple of funnels for the garage lollollollollollollol

Cheers

Joff

[Vlietje]

Some nice parts Joff! Love the interior!! Can't beat Recaro's!! :thumb::thumb:

[joff-turbo-nova]

You can't underestimate how rare these interiors are, I think there have only been about 5-6 Meriva VXR's that have been broken for spares !

It's strange, the rear electric windows I sourced came from the same vehicle but via two different people !

Its a small world!

Joff

[joff-turbo-nova]

Had chance for a quick session this morning before the rain set in ....

Got the tools out ready for getting the front seat out .....

http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_8981.jpg

Sods law one of the torx bolts decided to round off , which was handy . Out with the MIG welder and a 13mm nut sorted it out ....

http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_8983.jpg

Needed to sort the wiring out under the seat and swap over the pre tensioners and then bolted the VXR seat in.....

http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_8984.jpg

The clouds started gathering so I quickly fitted the switches for the heat pads and put two 15A fuses in slots 38 and 39 and tested the heating....

http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_8985.jpg


Toastie ar$e was the result !

Need some better weather for the other side and the rears!

Joff

[Connor]

What engines come standard in the meriva vxr's?

[John]

What engines come standard in the meriva vxr's?

z16let same as corsa vxr :)

[Connor]

Ahh sound, cheers john.

[joff-turbo-nova]

Right,

Been using the VXR seat for a week and have felt the door side base bolster to be very uncomfortable.

Having a prod through the leather it feels as though the sponge has worn through to the metal support bar with bums getting in and out.

Enquired at Vauxhall for a replacement base and they are a special order from recaro. Best price I could get was £160 + VAT + delivery :eek::eek::eek::eek:

So I took the opportunity to pull it apart this morning and undertook some DIY surgery....

Seat out in my lounge ready to pull apart ...

http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_9004.jpg

Back separated from the base quite easily with about 4 bolts removed ...

http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_9005.jpg

You can see here the damage to the sponge ......

http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_9006.jpg

I obtained some supplies from that very handy shop Boyes !!

http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_9007.jpg

First job was to reinforce underneath in the groove where the bar sits with two layers of calico....

http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_9008.jpg

I then trimmed away the loose foam leaving a large hole....

http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_9009.jpg

I put in a layer of foam for support and then another layer on top (sitting next to the glue pot) which would give more shape to the area ....

http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_9010.jpg

I then reinforced the area on the top with more calico ....

http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_9011.jpg

Then covered the whole bolster in wadding to help tension the leather cover....

http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_9014.jpg

I also reinforced the underside of the leather where it had worn slightly .....

http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_9017.jpg

Foam back on base ....

http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_9018.jpg

Cont/....

[joff-turbo-nova]

Cover back on and rear reattached .....

http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_9019.jpg

Still a slight crease in the leather , but a whole lot more comfy !

http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_9020.jpg

These also arrived which I picked up on Astra Owners Club forum at a good price ...

http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_9015.jpg

I'll fit the passenger seat tomorrow.

Cheers

Joff

[Andy]

Nice job on the seats,gotta do that on my 205 gti's seat at some point in the same place.
No wonder your rounding bolts off using windy guns! lol
Ruffer!! lol

[joff-turbo-nova]

Nice job on the seats,gotta do that on my 205 gti's seat at some point in the same place.
No wonder your rounding bolts off using windy guns! lol
Ruffer!! lol

I actually rounded that rear bolt off using my ratchet !! The windy gun was a last resort and buzzed them out no problem!

You'd think it would be the other way round !!

Joff

[Andy]

Indeed,i'll let you off then and retract "ruffer" lol

[Royston]

Good old Boyes, branches throughout the north east:d

Great progress!!

[Ben]

That's shocking to wear at that age, was the donor galactic mileage?

[Nobby]

Just read your thread start to finish mate, really good to see someone modifiying a new car like most do to "older" cars, hmmm actually got me looking at merivas on ebay! Top work mate. + rep

[joff-turbo-nova]

That's shocking to wear at that age, was the donor galactic mileage?

Not sure as this is the 3rd Meriva these seats have been in - they originally came out of an Arden Blue Meriva VXR last year which was broken due to damage. My rear electric windows came from the same original vehicle strangely enough!

I would guess it was around 60-70k , but this is a common problem on the VXR bolsters apparently.

Joff

[burgo]

awesome work on that seat joff

[mowgli]

joff you are yet again proving to be a genius... but just how old is that evo stik?? it looks older than half the people on here.. lol lol

any more spare air bags yet???

[Ben]

lol Joff want some 19" VXR wheels for it?

[joff-turbo-nova]

lol Joff want some 19" VXR wheels for it?

Free of charge - YES please lollollollollol

Seriously though I am on the hunt for some 17" Astra GSI snowflakes which I think would look better than the 16" ones I have on!

Joff

[Spudly]

Awesome work as always Joff, will be good to watch this one taking shape/help when needed too :d

[joff-turbo-nova]

Had time for a quick mince this morning before I got hijacked into the back garden with the wife lol

Out with the old passenger seat......

http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_9037.jpg

A swap of the pretensioners.....

http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_9039.jpg

In with the new.....

http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_9047.jpg

Nicked the covers out of the nova for now to keep the leather from wearing on day to day use....

http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_9048.jpg

Need to tackle the rears and the door cards as well!

Also had to repair my wifes meriva with a cracked door yesterday - see here :-

Project Keeping the Mrs happy - click (http://www.migweb.co.uk/forums/projects-restorations/425183-project-keep-mrs-happy-2.html#post4606386)

Cheers

Joff

[Nova_Tek]

Great work Joff. Love those seats and the work you did on them. Nice looking dials too (where from and how much? :) )

That custom astra centre dash looks very nice.

[Spudly]

Jeees that door on Paula's car looks really bad, its only a few years old, how the hell:eek:



Didnt look too pretty afterwards but who cares if its fixed and in a place where it wont be seen, good work fine sir :thumb:

[Stuart]

Dd you drill stop the cracks before welding up? If not they will come back :s

[mowgli]

spud, as for how, my money is on child abuse, as in the child who opens that door abuses it, ramming it against the stop

[joff-turbo-nova]

Dd you drill stop the cracks before welding up? If not they will come back :s

Drilled and migwelded over !

Joff

[John]

Shouldn't that have been covered under warranty Joff?

[joff-turbo-nova]

Great work Joff. Love those seats and the work you did on them. Nice looking dials too (where from and how much? :) )

That custom astra centre dash looks very nice.


Not too sure whether you are on about these gauges ...

http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_8955.jpg

Or the standard dials ....

http://i2.photobucket.com/albums/y15/joff-turbo-nova/clocks.jpg


The centre console is standard as well !

Joff

[joff-turbo-nova]

Shouldn't that have been covered under warranty Joff?

No, that's on the OTHER meriva in the family (the wife;s) - its a 53 plate with eighty odd thou on the clock - can't see Vauxhall holding their hands up to that one even if its due to the thickness of the door metal (quite thin!!)

Joff

[Nova_Tek]

On about the boost gauges :)

[joff-turbo-nova]

On about the boost gauges :)

Have a look at the thread on VXROnline : http://www.vxronline.co.uk/forum/showthread.php?161945-Gauge-Convertions-Pillar-Pods-and-Gauges

Joff

[Nova_Tek]

Cheers for that Joff. They look very similar to these ones

http://rspec.co.uk/performance-gauges/stepper-motor-peak-series/52mm-smoked-stepper-motor-peak-turbo-boost-gauge-psi

[Mike]

Free of charge - YES please lollollollollol

Seriously though I am on the hunt for some 17" Astra GSI snowflakes which I think would look better than the 16" ones I have on!

Joff

Ive got some 17" Astra Coupe Turbo 5 spokes with tyres coming up for sale soon if your interest Joff?

[joff-turbo-nova]

Ive got some 17" Astra Coupe Turbo 5 spokes with tyres coming up for sale soon if your interest Joff?

Thanks Mike, I sold a set last year from the Coupe I broke, the design doesn't really do it for me - cheers for the offer anyway !

Joff

[joff-turbo-nova]

Had a good tidy up in the garage today.

One of these arrived this morning ....

http://i2.photobucket.com/albums/y15/joff-turbo-nova/6f2ecc0957428beacbba_large_14.jpg

So I chopped it up as you do .....

http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_9053.jpg

And mocked up the pillar trim like so.......

http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_9054.jpg

There's a fair bit of fibreglass and fettling that will be required , but you get the general idea !

http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_9057.jpg

http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_9058.jpg

I got some adhesive and flock off Prey on here so will get the flocker machine out once I'm happy with the shape!

Joff

[Ben]

Joff would it not have been cheaper to buy a Vxr? lol

[joff-turbo-nova]

Joff would it not have been cheaper to buy a Vxr? lol


Where's the fun in that ?? lollollollollollol

[Spudly]

Where's the fun in that ?? lollollollollollol




Exactly, i think for the most part the fun for you is in the build and the tinkering isnt it Joff, (hopes Paula doesnt read this) but keeps you away from the wife/house/garden work lol

[joff-turbo-nova]

The wife has just been looking at these pictures as she was wondering what I have been up to in the garage this morning....

She says, and I quote "you've done the three pod pillar gauge thing before.... can't you think of anything new to do????"

http://i2.photobucket.com/albums/y15/joff-turbo-nova/pod1a.jpg

Errr, no.

Joff

[joff-turbo-nova]

Been in and out of the garage today.

Got the first pod fibreglassed in....

http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_9059.jpg

http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_9060.jpg

Then smoothed off with some filler and a guide coat put on, still a few holes to sort...

http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_9065.jpg

Then got the second pod secured on ......

http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_9066.jpg

And tried in position to see how they fit....

http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_9068.jpg

Need to get the third pod on and check for clearance against the top of the dash as it may be a bit tight .

Joff

[Connor]

Nice work on the pods Joff :thumb: Much better than the off the shelf crappy jobs :)

[joff-turbo-nova]

Quick update...

Second pod now smoothed in , third pod in place....

http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_9072.jpg

http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_9071.jpg

Joff

[Benn]

Lots more room to fit them then on the Nova. Nice.

[joff-turbo-nova]

Quick update...

All three pods are now smoothed in and have been sprayed grey ready for the flocking session at the weekend.

http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_9081.jpg

http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_9080.jpg



Joff

[7ova]

nice work!

i like your workshop set up,
all the tools have there own place
stu

[joff-turbo-nova]

I had a nice package roll up today.....

http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_9082.jpg

I opened them up to find these fine specimens......

http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_9083.jpg


The general condition is poor as you can see, however they were priced accordingly and I was aware of this when I purchased them .....

http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_9084.jpg

http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_9085.jpg

http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_9086.jpg


I need to get hold of my contact who can get them acid dipped for me ! I'm not going down the media blasting route as it roughs the surface of the alloy too much !

Joff

[joff-turbo-nova]

Bit of a weekend end update .....

Got the flocking machine out of storage, one new battery and we were ready for action...

http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_9091.jpg

First up was the offside trim.....

http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_9087.jpg

Then the nearside.....

http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_9092.jpg

Here's a close up of one of the pods and one of the screw covers, has worked quite well really - its been about 5 years since I did a bit of flocking !

http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_9090.jpg

http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_9088.jpg

Then after curing over night I got the nearside trim fitted....

http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_9094.jpg

And then wired in and fitted the gauges and got the trim clipped in.....

http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_9095.jpg

Seem to work all OK , but I have not run any of the gauge loom from the sensors yet ....

http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_9101.jpg

I quite chuffed at the results really !

http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_9096.jpg

http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_9105.jpg

http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_9106.jpg




Enjoy

Joff

[Benn]

They look great, very nice gauges too.

[Vlietje]

Factory finish! Looks flocking good! lol

[Old man Jimbo]

That's a fooking good effort!

Is that a DIY kit or "a proper job"?

[joff-turbo-nova]

That's a fooking good effort!

Is that a DIY kit or "a proper job"?

Professional adhesive and flock, semi pro applicator - DIY user lollollol

It's not some of the cheap kits you get from Frost. This process uses professional graded flock with a two part substrate (adhesive which has a adhesive and hardener you mix together like araldite!) . Its applied with an electrostatic charge to make the flock hairs imbed into the adhesive end on to give a hairy flock effect.

The Electrostatic applicator I sourced from the US about 7 years ago. You can't purchase this type of applicator in this country .


Joff

[Old man Jimbo]

Professional adhesive and flock, semi pro applicator - DIY user lollollol

It's not some of the cheap kits you get from Frost. This process uses professional graded flock with a two part substrate (adhesive which has a adhesive and hardener you mix together like araldite!) . Its applied with an electrostatic charge to make the flock hairs imbed into the adhesive end on to give a hairy flock effect.

The Electrostatic applicator I sourced from the US about 7 years ago. You can't purchase this type of applicator in this country .


Joff

*Dreams shattered of doing the do with a £30 kit*

Thought it was a good looking job! lol

[The Simps]

Thats a job well done and to be proud of mate. As said, gauges look like smart ones too!

[Prey]

looking good - and pods are very factory/stealth.

[joff-turbo-nova]

Quick update....

Been busy with other non car projects over the last few weeks however.....

A nice delivery from Vauxhall .....

Bottom end seals, piston rings, rod shell bearings and a new oil pump ....

http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_9142.jpg

http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_9141.jpg

http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_9140.jpg

Also got some super strength aircraft paintstripper to have a go at the alloys as I am having difficulty finding somewhere local to get the dipped. So I did a bit of a quick test...

http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_9152.jpg

So take one cruddy alloy ....

http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_9147.jpg

After 10 minutes ...

http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_9150.jpg

After 30 mins ....

http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_9151.jpg

So looks like this stuff will work - just need to get the tyres off the alloys at the weekend.

Joff

[burgo]

fooking hell they are well curbed

[joff-turbo-nova]

fooking hell they are well curbed

Yes, I bought them of a chap called Mr S. Wonder.

lollollollol

Joff

[burgo]

oh well should only take 20 mins to buzz back. also superglue is your friend for wheel refurbs ;)

[joff-turbo-nova]

also superglue is your friend for wheel refurbs ;)

Spill the beans...

[Spudly]

I think he means to fill in the gaps in the wheel with superglue, it will then go rock hard once set and be easy to sand into shape, then cover with paint, more pikey than touching up a black car with a permanent marker (and yes as a valeter i have done that before lol)

[burgo]

pretty much sort of like spud said. you obviously buzz as much damage out as possible but when you come to some that is that deep you are going to alter the shape of the wheel grinding it out you use superglue to fill it. much much stronger than filler obviously. just so you know its how all year old vauxhalls are done ;) yes wheel refurbing is now my job

[joff-turbo-nova]

A couple more bits arrived today.

Steveboyslim has kindly sent me a stud conversion kit with ARP nuts and GM washers . Nice !

http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_9154.jpg

Joff

[joff-turbo-nova]

It's been a while since any updates , mainly down to having a severe back problem, which seems to be recovering OK (touching lots of wood now!) and the need to rebuild the Z18XE in the wife's merv (see my other thread).

My ECU is currently off being remapped and tweaked so it will run the cooling fan OK - many thanks to Warren from the Corsa-C site for his assistance, especially on the wiring front.

Also secured a nice steering wheel from a mk5 Astra VXR .....

http://i2.photobucket.com/albums/y15/joff-turbo-nova/Z18XE076.jpg

http://i2.photobucket.com/albums/y15/joff-turbo-nova/Z18XE077.jpg

Any before anyone comments that the electrics won't work, fear not, its been modded to work on a Astra mk4 (G) which runs the same controls as the Merv so fingers cross all should be good !

Joff

[Benn]

I like green apples myself. But the steering wheel is very nice. Why would the ECU not run the fans?

[joff-turbo-nova]

I like green apples myself. But the steering wheel is very nice. Why would the ECU not run the fans?

The Astra G's run a separate cooling ECU situated under the wing next to the washer bottle. The engine ECU talks to the cooling ECU which then tells the fans to do things.

It's overly complicated as the cooling ECU's seem to fail a fair bit - mainly due to water ingress due to the positioning under the wing next to the spray from the wheels!

Joff

[joff-turbo-nova]

Update .....

Picked up the Astra GSI alloys from the bodyshop today and got the tyres fitted...

http://i2.photobucket.com/albums/y15/joff-turbo-nova/tent001.jpg

Then gave one a clean and polish - they look quite nice .....

http://i2.photobucket.com/albums/y15/joff-turbo-nova/Alloys001.jpg

Also had the rocker cover done the same colour whilst they had the spray gun out ....

http://i2.photobucket.com/albums/y15/joff-turbo-nova/Alloys002.jpg

This also arrived today, the new flooring for the garage, just awaiting the adhesive and I'll be getting rid of the manky oily tiles!

http://i2.photobucket.com/albums/y15/joff-turbo-nova/Alloys003-1.jpg

Joff

[mowgli]

is that rubber matting?

[joff-turbo-nova]

is that rubber matting?

Yes it is . I couldn't really afford , or justify the thicker tiles as they came out at about £1500 for the space I wanted to cover. The rubber flooring is a) better than bare concrete and b) considerably better than the old kitchen flooring tiles that have been down since about 2001 and have soaked up oil, grease and whatever else I have spilt on the floor in the last 11 years!

Joff

[joff-turbo-nova]

Time to get the flooring sorted. It's 3mm Barley Plate style rubber flooring. Its been used in a garage before for about 3 months so is nearly new. I have 5 rolls, 2 5m long and 3 4m long. The 5m rolls have been used before, the 4m rolls are brand new.

First job was to remove the old tiles.....

http://i2.photobucket.com/albums/y15/joff-turbo-nova/Flooring001.jpg


Then sweep and hoover the floor so there was minimal dust.....

http://i2.photobucket.com/albums/y15/joff-turbo-nova/Flooring002.jpg

I then laid the flooring and secured it down with Soudaflex 40FC which is used to bond rubber to concrete. Just looks like tiger seal to be honest!

http://i2.photobucket.com/albums/y15/joff-turbo-nova/Flooring003.jpg


I then laid the second longest roll, making sure the joint had plenty of adhesive to keep it tight and together...

http://i2.photobucket.com/albums/y15/joff-turbo-nova/Flooring005.jpg

It just needs a clean with some white spirit it will come up like new...

http://i2.photobucket.com/albums/y15/joff-turbo-nova/Flooring004.jpg

Will need to sort the other half in the morning

Joff

[joff-turbo-nova]

Got the other side of the garage sorted yesterday before watching an excellent Grand Prix .....

http://i2.photobucket.com/albums/y15/joff-turbo-nova/Flooring006a.jpg

http://i2.photobucket.com/albums/y15/joff-turbo-nova/Flooring007.jpg

I then put everything back to its original positions with sufficient room for the Nova in the middle...

http://i2.photobucket.com/albums/y15/joff-turbo-nova/Flooring009.jpg

http://i2.photobucket.com/albums/y15/joff-turbo-nova/Flooring010.jpg

And my fleet of Vauxhall's on the drive....

http://i2.photobucket.com/albums/y15/joff-turbo-nova/Flooring008a.jpg

Time to get Z20LET stripping next week

Joff

[scott.parker]

That's dam nice size garage dude!
Lol your neighbours must think oh he's doing something again!

[blue_peg_16v]

Nice what happened to the nova caravan?

[joff-turbo-nova]

Nice what happened to the nova caravan?

It's on hold at the moment - its hiding at the top of the drive next to the house under a grey cover.

I will get on with the trailer once I have finished the Z20LET project sometime next year.


Joff

[joff-turbo-nova]

Right,

On with stripping the LET engine down ....

First job, whip out the cams ....

http://i2.photobucket.com/albums/y15/joff-turbo-nova/Engine013.jpg

Then remove all the pulleys and cam covers, it looks like the exhaust camshaft seal has been leaking at some point...

http://i2.photobucket.com/albums/y15/joff-turbo-nova/Engine001.jpg

Next was the removal of the head - as you will note the valves and tops of the pistons, although have some carbon deposits are generally OK.

http://i2.photobucket.com/albums/y15/joff-turbo-nova/Engine002.jpg

http://i2.photobucket.com/albums/y15/joff-turbo-nova/Engine003.jpg

Had a look at the bores, you can still see the original factory hone marks so all is good here ....


http://i2.photobucket.com/albums/y15/joff-turbo-nova/Engine004.jpg

I then removed the millions of bolts off the sump. Had me a but stumped at first as I undid all the big bolts holding the main sump to the block and it was still solid - I then undid all the smaller bolts on the secondary sump to find some bolts on the inside that needed removing, so all sorted in the end ....

http://i2.photobucket.com/albums/y15/joff-turbo-nova/Engine005.jpg

It was rather messy on the inside ....

http://i2.photobucket.com/albums/y15/joff-turbo-nova/Engine007.jpg

It was then time to get shot of the balancer shafts as I am going to be running a dual mass flywheel which will remove the need for these, they weight a tonne !

http://i2.photobucket.com/albums/y15/joff-turbo-nova/Engine006.jpg

http://i2.photobucket.com/albums/y15/joff-turbo-nova/Engine009.jpg

It was then piston removal time.....

http://i2.photobucket.com/albums/y15/joff-turbo-nova/Engine008.jpg

They all seem to be in good order with no wear to the skirts, just generally gunged up carbon deposits...

http://i2.photobucket.com/albums/y15/joff-turbo-nova/Engine012.jpg

The shells have some signs of wear , but nothing too major given the fact it had covered 103k miles...

http://i2.photobucket.com/albums/y15/joff-turbo-nova/Engine010.jpg

And this was my bin with all the discarded engine bits .....

http://i2.photobucket.com/albums/y15/joff-turbo-nova/Engine011.jpg

Crank removal tomorrow and I will then start cleaning down the block . I need to drill and tap the 4 oil holes which supplied the oil feed to the balancer shafts and then put in some grub screws to seal them up. Also need to hone the bores out ready for the new rings.

Joff

[joff-turbo-nova]

Update...

Didn't get to the engine block today as got sidetracked into other jobs, however I did get the Astra GSI rims polished up and fitted and they look spot on ....

http://i2.photobucket.com/albums/y15/joff-turbo-nova/Wheels2.jpg

http://i2.photobucket.com/albums/y15/joff-turbo-nova/Wheels001-1.jpg

http://i2.photobucket.com/albums/y15/joff-turbo-nova/Wheels004.jpg

http://i2.photobucket.com/albums/y15/joff-turbo-nova/Wheels005.jpg


Just need to sort some Griffin badges for the centre caps and they are done.

Also got No1 piston cleaned up ready for new rings and bearings - here's No1 and No2 for comparison ....

http://i2.photobucket.com/albums/y15/joff-turbo-nova/Pistons001.jpg

http://i2.photobucket.com/albums/y15/joff-turbo-nova/Pistons002.jpg

Cleaned the old wheels up ready for selling - if anyone wants to buy them, PM me for details...

http://i2.photobucket.com/albums/y15/joff-turbo-nova/Wheels006.jpg

Joff

[Nick J]

Nice work on the flooring joff...... Think I'd quite like some of that! If you have time get yourself to our Scarborough meet for a catch up etc.

Nick.

[Graeme]

Excellent work joff, do you know any where breaking a 1.3 cdti one if thereby any chance?

[Spudly]

Fantastic work as always Joff, i would keep the old shoes off the merv as winter boots tbf, you has enough space to keep them in the corner lol



Btw, you didnt fuzz out the reg on the nova in one of the pics up there ^^ :p

[Benn]

Love the flooring, wheels look nice too. Needs 308s now (if it isn't have them)

[joff-turbo-nova]

Love the flooring, wheels look nice too. Needs 308s now (if it isn't have them)

Already done, see page 13 !!!

Joff

[joff-turbo-nova]

Bit more of an update.....

Got on with cleaning the pistons and found this damage on the crown of piston no3 - looks like a bit of spark plug has been bashed around on the top of it. Not too sure how this has happened as the cylinder head and bores all seem to be fine without any damage ....

http://i2.photobucket.com/albums/y15/joff-turbo-nova/Z20LET122.jpg

On the hunt for a replacement piston now !

Then got on with taking the crank out - I needed to blank off the oil ways on the no2 and no3 crank caps as I will no longer be running the balancer shafts. I have had a few requests on how to do it , so here goes ....

Take the cap off, and obtain a 6.8mm drill bit. Drill out the two existing holes , I chose a depth of 10mm, in order that the grub screw would sit just below the cap surface, and not interfere with the girdle that bolts on top of the caps. I also used my pillar drill to get a nice vertical drill...

http://i2.photobucket.com/albums/y15/joff-turbo-nova/Z20LET123.jpg

Then get a M8 x 1.25 tap and thread the holes down to 10mm .

http://i2.photobucket.com/albums/y15/joff-turbo-nova/Z20LET124.jpg

http://i2.photobucket.com/albums/y15/joff-turbo-nova/Z20LET125.jpg

Then get the M8 grub screws and make sure they fit...

http://i2.photobucket.com/albums/y15/joff-turbo-nova/Z20LET126.jpg

Then put some loctite on the threads and screw them in tight - oilway now blocked off...

http://i2.photobucket.com/albums/y15/joff-turbo-nova/Z20LET127.jpg

Then got on with honing the bores out - all seem to be in good order, including no3 which had the damage to the piston crown ....

http://i2.photobucket.com/albums/y15/joff-turbo-nova/Z20LET130.jpg

I then cleaned the block off....

http://i2.photobucket.com/albums/y15/joff-turbo-nova/Z20LET129.jpg

http://i2.photobucket.com/albums/y15/joff-turbo-nova/Z20LET128.jpg

And gave it a first coat of engine enamel paint....

http://i2.photobucket.com/albums/y15/joff-turbo-nova/Z20LET131.jpg

Needs another coat mid week and then I can start rebuilding next weekend.

Enjoy !

Joff

[joff-turbo-nova]

Quick update...

Decided that I would fit oil squirters on the Z20LET block on Monday , so needed to round all the parts up that were required. (die grinder burr, 5.8mm drill bit and some 1.7 tdi oil jets)

Sourced a new burr for the die grinder ....

http://i2.photobucket.com/albums/y15/joff-turbo-nova/Z20LET137.jpg

And then got busy prepping the block - sealed up the hoses so swarf didn't scatter too far and put grease in some of the holes .....

http://i2.photobucket.com/albums/y15/joff-turbo-nova/Z20LET134.jpg

Drilled the first hole and got the die grinder to cut a channel between the two holes ....

http://i2.photobucket.com/albums/y15/joff-turbo-nova/Z20LET135.jpg

Then started on the second ....

http://i2.photobucket.com/albums/y15/joff-turbo-nova/Z20LET136.jpg

Then once all the holes and grooves were drilled I took out the main grub screw out of the oil gallery and cleaned up the block inside and out with a good few cans of carb cleaner, lots of rags and my air line. Then inserted the oil squirters with some thread lock. Quite a tight fit (which is good) .....

http://i2.photobucket.com/albums/y15/joff-turbo-nova/Z20LET138.jpg

These seem to be in about the right place - point towards the front of the block and towards the middle of the piston ....

http://i2.photobucket.com/albums/y15/joff-turbo-nova/Z20LET139.jpg

http://i2.photobucket.com/albums/y15/joff-turbo-nova/Z20LET140.jpg

Next up I need to get the crank refitted and then start on replacing the pistons with the new rings. Just awaiting a replacement piston for the jiggered number 3 piston which should be here next week.

Cheers

Joff

[joff-turbo-nova]

Update...

Crank back in with new shells.....

http://i2.photobucket.com/albums/y15/joff-turbo-nova/Z20LET141.jpg

Used the wrong socket to nip up the bolts and jiggered one of the heads when I first tried to torque it up , I used an E14 and they are E12's !!

http://i2.photobucket.com/albums/y15/joff-turbo-nova/Z20LET040.jpg

Handily Vauxhall only supply them in 10's so I replaced the whole lot!

Managed to source some ARP's for the rods this week ....

http://i2.photobucket.com/albums/y15/joff-turbo-nova/Z20LET142.jpg

So with my replacement no3 piston sourced I put new rings in the pistons and put them into the block...

http://i2.photobucket.com/albums/y15/joff-turbo-nova/Z20LET143.jpg

http://i2.photobucket.com/albums/y15/joff-turbo-nova/Z20LET144.jpg

Then sorted the girdle, baffle plate and oil pick up with the new oil pump ....

http://i2.photobucket.com/albums/y15/joff-turbo-nova/Z20LET145.jpg

http://i2.photobucket.com/albums/y15/joff-turbo-nova/Z20LET146.jpg

The new oil pumps come without the oil cooler feeder pipe attachement and the attachment is held on with this handy sized nut ....

http://i2.photobucket.com/albums/y15/joff-turbo-nova/Z20LET147.jpg


So got busy with the welder and steel bar and made this with a nut on the top....


http://i2.photobucket.com/albums/y15/joff-turbo-nova/Z20LET148.jpg

Wizzed off the oil cooler attachement and refitted it to the new pump...

http://i2.photobucket.com/albums/y15/joff-turbo-nova/Z20LET149.jpg

Then put the lower sump on....

http://i2.photobucket.com/albums/y15/joff-turbo-nova/Z20LET150.jpg

And then the upper , not forgetting to bolt in the sump level sensor and plug....

http://i2.photobucket.com/albums/y15/joff-turbo-nova/Z20LET151.jpg

Whilst tidying up I found some carbon wrap film I used last year on some parts I sold on ebay - the spark plug cover had a small crack , so after repairing this with some fibreglass filler I decided a wrapped plug cover was in order....

http://i2.photobucket.com/albums/y15/joff-turbo-nova/Z20LET152.jpg

http://i2.photobucket.com/albums/y15/joff-turbo-nova/Z20LET153.jpg

Next up is stripping the cylinder head and cleaning it all up .

Joff

[Benn]

Good work.

[16v Nova Kev]

Tidy bit of engine work there.

[NOV4_SPORT]

Awesome work as always Joff !!

Iain

[Balley]

Plug cover looks spot on!

[Mike]

Good stuff as always Joff :)

[burgo]

I know who I'm going to be visiting when it comes to rebuilding my zlet

[joff-turbo-nova]

Hi all,

Quick update , not much done over Christmas, however after looking at the dash , the VXR carbon effect trim panel that goes across the dash seems to clash a bit with the silver centre console.

As my new VXR steering wheel has piano black inserts I thought I would make the centre console piano black as well .

I sourced a replacement control panel to begin with....

http://i2.photobucket.com/albums/y15/joff-turbo-nova/dash1-1.jpg

Then rubbed it down removing all the symbols and numbers, then sprayed with primer and GM Sapphire black ...

http://i2.photobucket.com/albums/y15/joff-turbo-nova/Piano1_zpsa672f9aa.jpg

I originally tried to source some vynal stickers to replace the symbols and numbers, however due to the very small size this was not an option.

Next choice was some decals, which worked sort of but due to the transparent nature you could hardly see them,

http://i2.photobucket.com/albums/y15/joff-turbo-nova/Piano3_zps2e09314b.jpg


so have gone with the third option .....

http://i2.photobucket.com/albums/y15/joff-turbo-nova/Piano2_zps0369b202.jpg

Just blank (and laquered)..... and I will have to remember where all the settings are !!

Joff

[NOV4_SPORT]

Awesome work Joff matey, Iam loving the detail in the little decal kit for the dials, it's a pity it didn't really work out to well, Iam sure it will be easy enough to remember what the settings or positions the dials are at mate

[joff-turbo-nova]

Awesome work Joff matey, Iam loving the detail in the little decal kit for the dials, it's a pity it didn't really work out to well, Iam sure it will be easy enough to remember what the settings or positions the dials are at mate

Heat is easy, top hot, cold bottom, middle is fan speed from zero to 4 and the direction knob I only use either on windscreen or dash vents and the three buttons still have their signs on them - job sorted !

Joff

[Spudly]

Brilliant work as always good sir, happy new ear (deliberate mis-spelling there lol) to you Paula and Patrick :thumb:

[joff-turbo-nova]

Brilliant work as always good sir, happy new ear (deliberate mis-spelling there lol) to you Paula and Patrick :thumb:

And to you and your tribe - by the way know anyone who can program central locking remotes apart from the stealers?

Joff

[Spudly]

And to you and your tribe - by the way know anyone who can program central locking remotes apart from the stealers?

Joff




No unfortunately, i want to source a second key for mine, i know you can get them from the bay, but they still need coding :cry:

[Benn]

Oh i thought the lettering would light up?

[nova ian]

Shame the decal idea didn't work Joff. We gave it a go though, was worth a try hey!

[joff-turbo-nova]

Happy New Year to everyone !!

In a moment of "this sounds like a good idea" I put an offer in on an OPC bumper (same as the VXR one) on ebay.de - they only go and accept the offer - so I now have a used but in reasonable condition bumper on its way from Germany ....

http://i2.photobucket.com/albums/y15/joff-turbo-nova/OPCBumper1.jpg

http://i2.photobucket.com/albums/y15/joff-turbo-nova/OPCBumper2.jpg

http://i2.photobucket.com/albums/y15/joff-turbo-nova/OPCBumper3.jpg

http://i2.photobucket.com/albums/y15/joff-turbo-nova/OPCBumper4.jpg

Its got a slight scuff on the nearside lower part but that's about it - the others I have seen seem to have large cracks on the corners just under the headlamps.

Also has the inserts cut out for headlamp washers !

I spoke to Vauxhall and put an order in for some grills and chrome surrounds and the headlamp washer jet housings which should be here next week sometime as some of the parts are coming from Europe as well !

Need to decide on the fog lamps themselves, do I go for standard fogs.....

http://i2.photobucket.com/albums/y15/joff-turbo-nova/OPCfog1.jpg

With CREE LED's

http://i2.photobucket.com/albums/y15/joff-turbo-nova/OPCfog2.jpg


Or full on DRL's with 18 LEDS...

http://i2.photobucket.com/albums/y15/joff-turbo-nova/OPCfog3.jpg


Thoughts and comments appreciated !

Joff

[Benn]

Liking the bumper and i'd got with the bottom 18led lamps...

[Jeff16v]

Joff, could you not put the stickers over the original heater controls then paint the whole lot, then peel the stickers off?

[joff-turbo-nova]

Joff, could you not put the stickers over the original heater controls then paint the whole lot, then peel the stickers off?

I had considered this, however due to the really fiddly design of some of the pictures (especially the ones with the heated screen sign) and the number of layers needed (2 primer, 2 colour and 2 lacquer) it just wasn't going to work.

If someone has access to a specialist vinyl cutter which can do ultra fine work I would be happy to discuss this further.

Joff

[scorge01]

Very nice project really like the attention to detail

[joff-turbo-nova]

Quick update...

This arrived in the post recently.....

http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_1215.jpg

If you can see through the rust its an Astra Whiteline rear ARB which also fits a Meriva!

http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_1217.jpg

Just need to get the angle grinder with a flapper disc and clean it all up and repaint it before fitting.

Also fitted the head stud kit from SteveBoySlim along with a standard GM head gasket...

http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_1212.jpg

Then started on the cylinder head, 8 inlet valves taken out and 8 exhaust valves to come out .

http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_1213.jpg

http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_1214.jpg

The exhaust valves were quite coked up , but they will clean up nicely in the drill.

Then had to tackle 2 snapped off exhaust studs in the head. I perfected this method when rebuilding the wife's Z18XE engine , so one snapped off thread ...

http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_1218.jpg

You put a washer over the hole to protect the head, with the mig welder buzz some weld onto the end of the stud and enough to get to the level of the washer , then put a nut on the washer and buzz inside the nut.

At this point it will be glowing red hot, let it cool slightly.....

http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_1219.jpg

Then just wind out the stud which should come out very easily - both mine did .....

http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_1220.jpg

I then started cleaning up the face of the cylinder head and noticed that cylinder 3 had sustained damage from the debris which had damaged the crown of piston 3 ....

http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_1222.jpg

However once cleaned and slightly sanded flat it looks a whole lot better ....

http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_1230.jpg

The exhaust ports were quite coked as well....

http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_1221.jpg

so out with the dremel for a clean up with a sanding wheel .....

http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_1224.jpg

Two ports done, six to go ! I will also give the inlets a quick wizz smooth as well. The valves need lapping in especially the exhaust ones.

Cheers

Joff

[Lee H]

Those marks on the head and pistons are from detonation by the looks of it. Seen it on quite a few pistons now in various cars (always turbo ones).

[joff-turbo-nova]

Quick update....

A few parts have arrived this week ....

Bitten the bullet and got a brand new LUK DMF flywheel which should see me good for quite a while ....

http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_1246.jpg
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_1245.jpg

Also got some standard VXR fogs ......

http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_1233.jpg

And to go in them I have a full set of HID kits, H7R, H1 and H11 for the fogs....

http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_1249.jpg

Along with the side light bulbs in CREE leds ....

http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_1252.jpg

I was surprised at how small the ballasts are now , the ones on my Vectra and Corsa were quite chunky....

http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_1250.jpg

And hopefully with the reflectors in the Meriva headlights and the shields on the H7R's these shouldn't dazzle other road users ....

http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_1251.jpg

Also got stocked up on jubliee clips , hose joiners, slicone vacuum hose and cable ties ....

http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_1248.jpg

Also arrived this week from Austria was an Opel fog light unit to convert to twin fogs, as I noticed the meriva only has the one fog on the drivers side...

http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_1232.jpg

http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_1231.jpg

I have been busy cleaning up some of the exhaust valves from this....

http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_1235-1.jpg

To this.....

http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_1237.jpg

Also cleaned and dremelled the cylinder head to remove the casting marks ....

http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_1242.jpg

More work to be done over the weekend.

Joff

[Spudly]

Oooohh, Joff, where did you source the cree 501's from, i could do with some of those when i come to fit my new rear lights on the nova and faff my wiring about!



Your parts collection looks cool, and all of the HID's have slimline ballasts these days, theyre supposed to last longer as they dont get as hot as the bigger ones do, i have them in my astra:thumb:

[joff-turbo-nova]

Oooohh, Joff, where did you source the cree 501's from, i could do with some of those when i come to fit my new rear lights on the nova and faff my wiring about!


Try here ......

Cree 501 LEDS (http://www.ebay.co.uk/itm/221128604162?ssPageName=STRK:MEWNX:IT&_trksid=p3984.m1439.l2649)

Joff