The Counts Beige Mk1 [Archive] - Page 2 - Performance Nova Group

Count Vaux Alot

30-01-11, 09:38 AM

some brilliant fabrication skils there, nice work mate!
Cheers mate :d

That is a awesome repair, looks factory

I would love to have skills like that
That was the look i was going for, any one can bodge it and dont get me wrong it would be fine that way (in most cases lol) but it looks so much better done right.

Excellent job cheif, how many hours in that repair? Certainly worth it,
Thanks Bazil thats the best part of 5 hours work but as you say i think its worth it even if its on an area thats mostly unseen.

James I hate you at times lol that's a mint repair and I'm so gelious of your fab skills meh.
Keep up the good work and it's so nice to see pictures in a project thread.
Ernie anyone can do a reasonable job if they put their mind to it and take some time to think about it. Although i come from an engineering background ive never been taught bodywork or fabrication as such ive just picked bits up as i go.

I always like to see pics so i just take them as i go once i move on to something new or a different part of the job.

wow nice repair work,do you work on it most weekends,changing the servo and m/c must be worth it did you do it to your last nova
I get down there as much as i can, once ive got an idea in my head i just need to do it or i wind myself up thinking about it, kinda weird i know but thats me - im doing it now in fact as i cant wait to get back up there now :d

Great work on that repair James. Really nice to see some proper fab work going on. Nice idea with the 2 pieces of box section to make the v shape in the sheet metal.

Look forward to more updates.
Thanks Ben the two bits of box is the simple way so no fancy tools needed and i had the box lying around too so bonus.

:thumb:

Pistol Pete

30-01-11, 09:41 AM

Looks awesome. Time consuming, but so very worth it. Top job!!

Andy

30-01-11, 09:45 AM

fabulous work,thats how to do it properly

Benn

30-01-11, 10:37 AM

Fantastic fab work as always James.

bmw156

30-01-11, 10:58 AM

im speechless by that repair.
greatwork.

Mazz

30-01-11, 11:48 AM

Great work, i'm......not.......jealous.....

MK999

30-01-11, 12:12 PM

James I hate you at times lol that's a mint repair and I'm so gelious of your fab skills meh.
Keep up the good work and it's so nice to see pictures in a project thread.

As per this, was halfway through doing the same section before uni took off again and my solution involved a flat bit of sheet and a hammer lol

craig green

30-01-11, 12:45 PM

Great skills Count! I'm looking forward to more updates.

NOV4_SPORT

30-01-11, 01:26 PM

That repair looks really good, you have some really good metal work skills matey well done

iain

kevster

30-01-11, 02:10 PM

fabrication skils of a god !!! thats what i would say!!! craking build .

keep it up ,cant wait to see it done .

Cle

30-01-11, 02:15 PM

Nice repair :) will need to follow this build :thumb:

Rickyb

30-01-11, 02:48 PM

looking good fella.
at this rate it'l be finished by the middle of march lol.
rick

krobinson

30-01-11, 02:49 PM

Loving the fabrication work!

Count Vaux Alot

31-01-11, 11:24 AM

Thanks again chaps - more updates to come later :)

Count Vaux Alot

31-01-11, 09:38 PM

Progress from yesterday (i spent most of the day decorating so only got a couple of hours on the car)

Firstly i needed to tidy this up as i got a little carried away with the grinder when cutting the battery tray out

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige336.jpg

Welded it up

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige337.jpg

Then cleaned it off

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige338.jpg

Tacked the servo mounting in place

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige339.jpg

Leaving a small area behind the turret to fill

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige340.jpg

So after some careful measuring (there was a lot of measure and measure again) it was on with the technical drawing

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige341.jpg

Transferred the measurements to the metal (note its not exactly the same as the original shape eps the bulk head mounting area as im going to try some thing different here)

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige342.jpg

And cut it out

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige343.jpg

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige344.jpg

Then marked out what needed bending which way

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige345.jpg

Let the bending begin

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige346.jpg

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige347.jpg

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige348.jpg

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige349.jpg

Count Vaux Alot

31-01-11, 09:41 PM

Had to flip it over and turn it around to bend the right angles

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige351.jpg

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige352.jpg

Bent

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige353.jpg

Get in the hole!

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige355.jpg

Ah but its not so simple as that a there are other bends needed

Firstly some curvature added to follow the contort of the turret

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige358.jpg

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige359.jpg

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige356.jpg

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige357.jpg

Then the dip to follow the drain gutter down to the hole

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige360.jpg

Some general fettling to get the right shape

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige361.jpg

Nearly there

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige362.jpg

A few tacks

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige363.jpg

I began to start welding it in

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige365.jpg

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige366.jpg

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige367.jpg

Thats that for now cheers

Benn

31-01-11, 09:44 PM

Awesome panel making dude.

kevster

31-01-11, 09:49 PM

you know what , i really look forward to seeing what you have next in this thread ... can i ask how you cut the tin so neat !!!

top work fella

Count Vaux Alot

31-01-11, 09:55 PM

Awesome panel making dude.
Thanks bud

you know what , i really look forward to seeing what you have next in this thread ... can i ask how you cut the tin so neat !!!

top work fella
Cheers mate, sure you can ask what ever you want - I always use a grinder by hand with a thin disc :thumb:

kevster

31-01-11, 09:58 PM

you know what i never thought of that useing a diegrinder what a dick!!! lol
i always hack it off with tin snip's nomore im a changed man now :)

bazil

31-01-11, 10:49 PM

I always use a grinder by hand with a thin disc :thumb:
plasma dics? 1mm thick?

ive never read any of your previous wip threads but i feel i may have to now lol

Count Vaux Alot

31-01-11, 11:18 PM

plasma dics? 1mm thick?

ive never read any of your previous wip threads but i feel i may have to now lol
Yes mate exactly that - standard 4inch/100mm grinder using a 1mm disc and a steady hand.

http://i248.photobucket.com/albums/gg167/Count85/Beige/engbay006.jpg

Count Vaux Alot

01-02-11, 10:55 PM

I had a present delivered today which meant i needed to tidy up - Look at this sh!t hole mess lol

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige374.jpg

Getting better

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige375.jpg

Span the car round

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige376.jpg

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige377.jpg

Then flipped her over

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige378.jpg

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige379.jpg

Cleaner than i thought which is a result

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige380.jpg

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige381.jpg

The wedged it against the wall for the time being

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige382.jpg

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige383.jpg

Mmmm the free space

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige384.jpg

Then look who turned up......OH HIA im pleased to meet you

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige385.jpg

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige388.jpg

Count Vaux Alot

01-02-11, 10:56 PM

Its a rolling shell with a rotten front end, funked doors and bits of interior and its had lots of 'patching' but all the areas im interested in are sound

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige389.jpg

Get in there

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige391.jpg

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige392.jpg

More pics later

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige393.jpg

And i picked up some of these too

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige394.jpg

;) lol

Benn

01-02-11, 11:33 PM

Weapon!

bazil

01-02-11, 11:37 PM

I bet that loon won't like the intension of the cutting discs lol

Count Vaux Alot

02-02-11, 12:47 PM

Thanks Benn I think lol

Bazil - no it probably won't, it's on it's last legs lol

Edd

02-02-11, 12:55 PM

Count Vaux Alot

02-02-11, 01:25 PM

as i already said, you got skills, thought you sold turbos ? looks like your a pro fabricator lol

under side looks quite clean tbh, you stripping that back in time as well ?

........saloon arches then ? :)

Thanks Edd - I dont really sell turbos im the 'technical co ordinator' and that involves just about everything to do with turbos poissible. Developing, building, modifiying etc etc.
My main interests are cars, engineering, fabrication and panel work as a hobby really.

The underside is going to be stripped and painted - i cant decide whether to do it beige or in a contrast colour prob some sort of brown like hessian.

Yep im going to give the saloon arches a go, i think i can make them work which makes it a challenge too.

:thumb:

AdamK

02-02-11, 01:55 PM

Actually cant wait to see this done! amazing fabrication skills there mate plus rep

craig green

02-02-11, 06:31 PM

Looking at a saloon Nova I was following for a few miles today, where Golfs look good with the round arches is because the arch lip runs right to the base line of the body under the sill, Nova arches taper back in to the body shape a few inches up into the wing (1/4 panel), so the added width of the arch isnt constant all the way down.

Just my 2pence worth.

scott.parker

02-02-11, 07:25 PM

Your funcking mad, cant believe your back again with another one!

At first i thought ah just a quick restore, lol no way you get carried away way to easily...

Love what you done so far mate, ill be watching, keep it going, though not sure yet on this round arch idea..

Scott

Count Vaux Alot

02-02-11, 11:04 PM

On with the new arrival tonight

Window out

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige395.jpg

Interesting pair of seats on nova frames - anyone know what they are? they are for sale along with anything im not using.

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige396.jpg

Started here on the spot welds zip zip zip

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige397.jpg

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige398.jpg

Then down the B pillar

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige399.jpg

And along the sill

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige400.jpg

Then the door was in the way

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige401.jpg

Guess what happened next

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige402.jpg

yep cut it off

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige404.jpg

Its clean but it has been molested during some sort of theft attempt so i will try and save it.

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige403.jpg

At this point the drill ran out of battery (i really need a corded one) so i moved on the the head lights

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige405.jpg

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige406.jpg

Annoyingly its not too good here but i might try saving it

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige407.jpg

Slightly better here but not great

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige408.jpg

Count Vaux Alot

02-02-11, 11:05 PM

I removed all the wing bolts then moved inside the car for the two inside the wing and found this gem of a repair lol honestly ffs.

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige410.jpg

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige409.jpg

Messed around - gangsta low you get me yer!

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige411.jpg

Wing off and its clean as well - result

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige412.jpg

The splash guards crispy as fook though

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige413.jpg

And very bent - how do you bend that like that there?? Animals.

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige414.jpg

On the plus side it does have coil overs

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige415.jpg

Thats all for to night thanks for looking :thumb:

burgo

02-02-11, 11:10 PM

:( dont like you now james, poor saloon. it would be worth you getting the head lining out in one piece if its good

Novasport

02-02-11, 11:32 PM

They are Calibra seats

scott.parker

02-02-11, 11:35 PM

They are Calibra seats

Ahh yes! knew i had sat on some, lol they were on the manky Eco-tec calibra i test drove before i found my mk4 Astra..

Paul

02-02-11, 11:37 PM

Count Vaux Alot

02-02-11, 11:37 PM

:( dont like you now james, poor saloon. it would be worth you getting the head lining out in one piece if its good

I know i know its a shame but it honestly is fooked ready for scrap :(

Count Vaux Alot

02-02-11, 11:47 PM

Spot weld drill bits dont really work in corded drills, theyre too powerful and when you go through the first skin, you cant tell as easily when you hit the second skin.

On the cordless one's, they grab a bit, and you hear and feel the drill slightly slow down.

You need a spare battery back and a quick charger, thats what i do with mine and just constanlty swap them over...

I used a corded drill for ages until recently when i killed it, i didnt really have any trouble with it but the cordless is better just the battery's sh!t so im on the hunt for another.

Paul

02-02-11, 11:55 PM

I got a absoloute deal with Screw-Fix when I bought mine.

I got one of these (http://www.screwfix.com/search.do?fh_search=DeWalt&action=search&omitxmldecl=yes&fh_view=detail&fh_refview=search&fh_refpath=facet_91874409&fh_reffacet=_price_range&fh_oneslice=yes&fh_location=%2f%2fscrewfix%2fen_GB%2f%24s%3dDeWalt %2fcategories%3c%7bscrewfix_w1_power_tools%7d%2fca tegories%3c%7bscrewfix_w1_power_tools_w2_professio nal_cordless_drills%7d%2f_price_range%3d26pound3b5 0202d2026pound3b100&fh_eds=%c3%9f&ts=90583) and one of these (http://www.directbrandtools.com/Detail.asp?qsFullScr=Yes&qsProd=D21716K&qsCat=2&qsSubCat=8) for £50

Was a year ago or more, Manager special at my local one...

scott.parker

02-02-11, 11:58 PM

Paul you just hurt my eyes! Err De-Fault drills!!... No.........

Count Vaux Alot

03-02-11, 08:46 AM

srs1

03-02-11, 12:35 PM

Count Vaux Alot

03-02-11, 01:28 PM

just caught up reading this wip.

as ever, stunning skills and a true legend when coming to fabrication skills, just goes to show you can do anything when you put your mind to it.

please hurry up with the brake peddle mod, its what i need to do next lol.

Cheers dude - there is plenty more fab to come!

Heres a link to the first time i did the corsa B pedal mod should help you out for the time being

>>LINK<< (http://www.pngclub.com/forum/showthread.php?t=109412&page=16)

Count Vaux Alot

03-02-11, 01:41 PM

MK999

03-02-11, 02:28 PM

I had thought about flaring them a little but im undecided yet :confused:
lower and wider and you might just redeem yourself lol

Count Vaux Alot

03-02-11, 02:42 PM

You want that engine or not boyo lol

Trust me it will be low and wide dont you worry :thumb:

MK999

03-02-11, 02:47 PM

I meant the arches!

Out and to the floor! :d

http://www.dmmultimedia.com/escort_mk2/mk2_017ww.jpg

nova_niek

03-02-11, 07:21 PM

James, as said by many you have a display of some amazing fabricating skills going on here! :thumb:

I once had a go at repairing the front inner arch of my daily Citroën BX and didn't even get within 5% of what you did with the battery tray. In the end I gave up and bodged it using lots of fiberglass and resin. It's gotten the old lady through APK (Dutch MoT) twice already so the job was well worth the £10 it cost me. :)

Excellent well-documented thread btw. Have some +rep! Subscribed!

Niek

The Simps

03-02-11, 07:26 PM

Just had a catch up on this as not read it for a while. I see your still poncing around making fancy panels :p

Seriously tho, excellent work and keep going. Your challenge is to finish it before Mark gets his yellow one on the road.

MK999

03-02-11, 07:42 PM

Your challenge is to finish it before Mark gets his yellow one on the road.

Does it have to be taxed MOT'd and insured? TBH it'd be a bitch pushing it back up the drive anyway though.

Given my uni fundage has been cut by about 1600 (what I needed to finish it :roll:) I don't see it being a challenge!:( Specially if the derv keeps getting jealous and throwing its toys out the pram lol

Benn

03-02-11, 07:57 PM

You know the pins knock out and the door comes off yeah?

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige396.jpg

Oooo i need the black plastic bits you flip the seat forward with... Sell me them.

novacabrio

03-02-11, 11:45 PM

You want that engine or not boyo lol

Trust me it will be low and wide dont you worry :thumb:

:cry: my engine? lol

great work mate

Count Vaux Alot

04-02-11, 11:06 AM

:cry: my engine? lol

great work mate

No don't worry it's the 1.5 Td that's also sitting at my mum and dads lol

The Simps

04-02-11, 12:52 PM

Is your mum going to be home tomorrow morning James when myself & Mark call round ;)

Count Vaux Alot

04-02-11, 01:32 PM

Is your mum going to be home tomorrow morning James when myself & Mark call round ;)

Probably not but she may make special arrangements to be there if she knows you two hunks are going to be there.

Are either of you boys brave enough to mess with Mrs Hard??

lol lol

The Simps

04-02-11, 01:42 PM

I just spat my tea all over the keyboard! lol

MK999

04-02-11, 05:38 PM

I thought Simps was more interested in Mr Hard in general.

Count Vaux Alot

04-02-11, 11:37 PM

Slipped up the workshop again tonight for some more mincing

Rear window out

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige416.jpg

Both window and rubber out without any issues

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige418.jpg

Starting were i left off i continued with a little more spot weld removal

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige417.jpg

Then removed the rear wheel and bumper

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige419.jpg

Moved on to the sill and wire wheeled it off to reveal the spot welds

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige420.jpg

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige421.jpg

The drilled them out

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige422.jpg

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige423.jpg

Removed the boot lid

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige424.jpg

And drilled out the spot welds here

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige425.jpg

then drilled out the spots on the underside of the arch

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige428.jpg

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige429.jpg

Count Vaux Alot

04-02-11, 11:38 PM

Whilst wire wheeling i found some rust holes that will need repairing

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige430.jpg

Now all the spots are drilled out i could get the grinder out

Zip

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige431.jpg

Zip

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige432.jpg

wriggle wriggle and she's free and in one piece

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige433.jpg

:thumb::thumb:

novacabrio

04-02-11, 11:44 PM

Genius mate!

The Simps

05-02-11, 12:10 AM

Dam you have some patience! lol

Count Vaux Alot

05-02-11, 10:32 AM

/\ that's only half of it lol hopefully have the other side done by the end of the weekend!

L14MNP

05-02-11, 10:41 AM

Is your mum going to be home tomorrow morning James when myself & Mark call round ;)

Pics. lol

Nice work! The inner arches don't look too bad on that. Shame on you for killing it! lol

peester

05-02-11, 10:48 AM

educational stuff

ooh 5,000th post

Count Vaux Alot

05-02-11, 11:26 AM

Pics. lol

Nice work! The inner arches don't look too bad on that. Shame on you for killing it! lol

lol about shame for killing it it's a sh!tter I wanted a better one - there is too many bodge repairs around this one.

bmw156

05-02-11, 11:39 AM

what are your plans with the blue archs?

onto the beige?

twin40s

05-02-11, 12:12 PM

What drill and bit do you use for the spot welds pics and details please?
Had a mission with these on my project.
Vid of how to would be great.:)

Count Vaux Alot

05-02-11, 12:27 PM

what are your plans with the blue archs?

onto the beige?

Yep blue on the beige.

On another note I can't make my mind up as whether or not to tub the rear arches while I'm there? Opinions?

Count Vaux Alot

05-02-11, 12:27 PM

What drill and bit do you use for the spot welds pics and details please?
Had a mission with these on my project.
Vid of how to would be great.:)

I will see what I can do :thumb:

Pistol Pete

05-02-11, 12:58 PM

With regards to tubbing, as it will all be exposed, why not!!

Loving this WIP.

Mike

05-02-11, 01:17 PM

A medium wheel base nova?

Count Vaux Alot

05-02-11, 01:48 PM

A medium wheel base nova?

Keh?

L14MNP

05-02-11, 02:12 PM

What drill and bit do you use for the spot welds pics and details please?
Had a mission with these on my project.
Vid of how to would be great.:)

Hope you don't mind Count.

Use the flat spot weld drills, not the hollow hole saw type ones.

About 6 quid in Machine Mart iirc.

The reason to use the flat ones is that the other type can skip across the surface in my experience and always needs the use of a centre punch beforehand. With the flat jobs you don't even need to centre punch most of the time.

Not this type
http://t2.gstatic.com/images?q=tbn:ANd9GcQwjJ9S_JwJSuJvueipDt9_Sdr23ljoI 6-TO1gFjrXmc5zArF6I

This type
http://t2.gstatic.com/images?q=tbn:ANd9GcRCeN4O4k-DsXWM7iyW76dpluS0rBMrNLhCTBv7SXy-TB8mUul59g

Hope this helps.

Count Vaux Alot

05-02-11, 02:26 PM

Thanks Limpy

Iain

05-02-11, 02:59 PM

I've used the above type of drillbit from Screwfix and would agree with Liam's comments. When they come off without making a mess it's very satisfying! Nice work on the shell(s) Mr Count. I guess it depends how low you're planning on running it to decide whether it's worth tubbing?

scott.parker

05-02-11, 04:56 PM

Count Vaux Alot

05-02-11, 11:47 PM

IMO don't tub it as its more work, and tbf it seams your already getting carried away with things on what i thought was going to be more of a budget build so you could finish it quicker, no?

Good progress though, but if your planning on putting the hole sill rear quarter on the hatch then the loon window part will have to go no?

Scott

Im only as carried away as i intended in the first place - it would have had two quarters whether they were hatch or saloon, i also planned on rear turrets so that means cutting up the rear inner arch too so its another one of those while im there it would be rude not to situations. Im still undecided myself though.
I have no real time constraints although i would like it at billing. imo its better done the way i want as opposed to the quick way.

As for the saloon rear window the bottom part of the window is the same as the hatch i will explain more on this when im at the fitting stage.

Count Vaux Alot

05-02-11, 11:57 PM

Not a massive amount done today as i had limited time but its a head start on tomorrow.

I hung the removed quarter back on the car for ease of storage along with re fitting the rear wheel

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige434.jpg

Then it was back on the floor so i could turn it round

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige435.jpg

The next victim

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige436.jpg

Front wing off

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige437.jpg

Hinges dealt with

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige438.jpg

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige439.jpg

Rear window removed

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige440.jpg

And up in the air

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige441.jpg

Wiped down the spot welded areas to make them easier to see

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige442.jpg

the rubbed them down to emphasise them more so

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige443.jpg

One spot weld drill

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige445.jpg

Then got drilling

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige446.jpg

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige447.jpg

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige448.jpg

More tomorrow hopefully :d

Count Vaux Alot

05-02-11, 11:58 PM

Nice to meet you by the way Chris :thumb:

bazil

06-02-11, 12:00 AM

Mind the ones in the petrol cap area lol
quick work too

Count Vaux Alot

06-02-11, 12:26 AM

Mind the ones in the petrol cap area

Are there 6 of?

AlexW

06-02-11, 12:38 AM

As for the saloon rear window the bottom part of the window is the same as the hatch i will explain more on this when im at the fitting stage.

But a saloon rear window is Longer than a Hatch?

Progress is good as always.

Edd

06-02-11, 02:07 AM

And a different shape in the rear corner :confused:

scott.parker

06-02-11, 02:56 AM

And a different shape in the rear corner :confused:

Thats what i was basically getting at, so i guessed it needs cutting right off etc??

Scott

Ernie

06-02-11, 08:20 AM

I'm sure James has already thought of a way around it.

Benn

06-02-11, 09:45 AM

Can i ask. Why didn't you just buy saloon arch repair panels? Would have been no rust or anything that way...

bazil

06-02-11, 09:48 AM

Are there 6 of?

I can't quite remember but I know the info is I'm my guide in articles on one of the scaned pages from the thatcham book.

bmw156

06-02-11, 11:43 AM

And a different shape in the rear corner :confused:

i thought that,

hence why i asked.

and i cant see with out chopping alot how james is going to get the "saloon tail" to fit the normal hatch bum around the tail lights etc.

count, if your chopping it that much, why not just chop them out of the saloon...

L14MNP

06-02-11, 12:47 PM

I'm sure James has already thought of a way around it.

This. I am intrigued, but won't question the man. We all know what this guy is capable of. :thumb:

lol @ a guy called 'Count' asking about a number btw. (little things) lol

mowgli

06-02-11, 12:58 PM

This. I am intrigued, but won't question the man. We all know what this guy is capable of. :thumb:

lol @ a guy called 'Count' asking about a number btw. (little things) lol
http://t1.gstatic.com/images?q=tbn:ANd9GcT4AaeW_T8jYNrVn58R0NR3Z0LjkWW0P ifvOj-VbuuF0qqfEho5Mw?

L14MNP

06-02-11, 12:59 PM

:confused:

He asked how many spot welds were behind the filler cap.

The rest is surely self explanatory given the previous posts?

(Nice pic. I'm not sure it was worth an edit to add that mind - or did you just get my 'joke'?) lol

mowgli

06-02-11, 01:03 PM

did you not watch sesame st??? or did they only have byker grove??

it is also a mental image i get every time i see the counts project thread...

L14MNP

06-02-11, 01:06 PM

did you not watch sesame st??? or did they only have byker grove??

it is also a mental image i get every time i see the counts project thread...

Of course I did, I obviously know who 'The Count' is, hence the reference to numbers earlier. :roll: Von spotveld ah ah ah. etc

Byker Grove! GTF! lol

Sorry about this CVAL, I never intended this much pointless spam. My initial reply was valid. Blame mowgli! lol

frills

07-02-11, 05:56 PM

nice meeting on saturday aswell,r there no more updates thought you would have got the other side done too,if ever you need a hand just shout,takes 10 minutes to get to you

GSI-TOMMY

07-02-11, 06:38 PM

that looks alot like one of my old saloon, sold it to a lad in scotland
same calibra seats aswell
sorry to hijack the thread.:roll:
nice build!:thumb:

http://i950.photobucket.com/albums/ad345/gsi-tommy/novasaloon1.jpg?t=1297103698

GSI-TOMMY

07-02-11, 06:53 PM

http://i950.photobucket.com/albums/ad345/gsi-tommy/pvs2009135.jpg?t=1297104776
:thumb:

Nobby

07-02-11, 10:42 PM

Top Work Mate!

Count Vaux Alot

07-02-11, 11:07 PM

Right chaps update time.....but im going to clear a few things up first

But a saloon rear window is Longer than a Hatch?
A saloons window is shorter than a hatch window only by a nats c0ck

Pics of a saloon window in a hatch recess

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige449.jpg

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige451.jpg

Its also taller and the angle of the dangle is different ask my man Pythagoras

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige450.jpg

And a different shape in the rear corner :confused:

Length is the issue in the bottom corner, Its the angle from the bottom cornet to the top thats the main difference.

I'm sure James has already thought of a way around it.

Yes i have and its a simple one

Can i ask. Why didn't you just buy saloon arch repair panels? Would have been no rust or anything that way...

Simple because i didnt want to completely butchered the arch to remove all of the hatch flair (although there will be butchery of sorts) as below - this guy had a go at it but the car got burned out before it finished - you even commented on the way he had done it lol

http://i248.photobucket.com/albums/gg167/Count85/Beige/Photo0325.jpg

http://i248.photobucket.com/albums/gg167/Count85/Beige/Photo0388.jpg

It looks like Frankenstein's monster

http://i248.photobucket.com/albums/gg167/Count85/Beige/Photo0407.jpg

Less cutting meaning less welding meaning less distortion meaning less seams to hide meaning less filling etc

He even lead filled it to try and hide the seams

http://i248.photobucket.com/albums/gg167/Count85/Beige/Photo0416.jpg

http://i248.photobucket.com/albums/gg167/Count85/Beige/Photo0417.jpg

Looks good here though - Imagen the beige, low stance plow etc etc

http://i248.photobucket.com/albums/gg167/Count85/Beige/Photo0405.jpg

I shouldnt have to use as much lead/filler

http://i248.photobucket.com/albums/gg167/Count85/Beige/Photo0424.jpg

Anyway

i thought that,

hence why i asked.

and i cant see with out chopping alot how james is going to get the "saloon tail" to fit the normal hatch bum around the tail lights etc.

count, if your chopping it that much, why not just chop them out of the saloon...

Why take short cuts when they are usually the long way in the end - as i dont know 100% how this is going to work until i do it i want as much of the saloon 3/4 that i can get so im not left needing more of it.

Yes there will be some chopping but i want to hide as much of the seams and welding under the window and door rubbers and as before less cutting, welding etc etc.

This. I am intrigued, but won't question the man. We all know what this guy is capable of. :thumb:

lol @ a guy called 'Count' asking about a number btw. (little things) lol
Thanks for having some faith....i think.

Wrong Count btw

Count Vaux Alot

07-02-11, 11:08 PM

The right count

http://t1.gstatic.com/images?q=tbn:ANd9GcT4AaeW_T8jYNrVn58R0NR3Z0LjkWW0P ifvOj-VbuuF0qqfEho5Mw?

Ah i like - guess who has a new avatar

nice meeting on saturday aswell,r there no more updates thought you would have got the other side done too,if ever you need a hand just shout,takes 10 minutes to get to you

Yep indeed there are updates - see further down the page :) thanks for the offer too mate i may have to take you up on that one day :d

that looks alot like one of my old saloon, sold it to a lad in scotland
same calibra seats aswell
sorry to hijack the thread.:roll:
nice build!:thumb:

Yep bud it was your old saloon although it looked a lot better when you had it. Its fooked now

Count Vaux Alot

07-02-11, 11:09 PM

Right on with the update

Arch spots removed

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige454.jpg

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige455.jpg

Then cleaned off sill

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige456.jpg

There they are the little c u n t s

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige457.jpg

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige460.jpg

Filler cap - Limpy

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige461.jpg

Grinder out

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige458.jpg

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige459.jpg

BANG and the 1/4's gone

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige462.jpg

Then i borrowed another chunk

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige463.jpg

Look at this bodgery

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige464.jpg

Chrispy

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige465.jpg

Found a pound though - result

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige467.jpg

Seats out - if anyone wants any of the bits off her be quick as its going in the big metal bin soon.

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige468.jpg

Collected the new daily

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige470.jpg

Count Vaux Alot

07-02-11, 11:11 PM

Got the saloon back on the floor and out of the workshop

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige471.jpg

Seats for sale nice and cheap

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige472.jpg

Mmm nice clean up leaving some space

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige473.jpg

So i layed these out to ponder over them

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige474.jpg

I then set about the saloon outside stripping it of anything i thought might be useful

front sus, anti roll bar and 236 vented calipers and discs off along with the rear axle.

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige475.jpg

With the free space i was then able to go from this

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige479.jpg

To this

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige480.jpg

Some one rammed something in the past - tesco car park special??

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige481.jpg

Although the arches are fooked its quite clean on the under side pleasingly

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige482.jpg

Thats all for tonight :thumb: thanks for looking

mowgli

07-02-11, 11:12 PM

re chopping all the metal out.. it is always way better to start with a large piece of metal & then trim it to fit.

that underside is amazing don't they use road salt in your part of the world??

maddogdaz666

07-02-11, 11:18 PM

nice work. are the Coilovers for sale?

Count Vaux Alot

07-02-11, 11:25 PM

I will basically follow this as a rough guide as the areas of the 1/4 that the weld will run across are flat so should be easier line up and to sand back

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige000.jpg

Count Vaux Alot

07-02-11, 11:27 PM

re chopping all the metal out.. it is always way better to start with a large piece of metal & then trim it to fit.

that underside is amazing don't they use road salt in your part of the world??
Exactly hence my removal of as much as possible

The underside is good its just a shame the rest isnt the same!

nice work. are the Coilovers for sale?

Thanks. yes they are along with the lowering springs and shock from the rear :)

maddogdaz666

07-02-11, 11:32 PM

pm headin ur way

Connor

08-02-11, 12:18 AM

Top work Mr Count, although i love the nova square arches,
im really keen on the saloon/round arches on the 3 door, look really smart on it. Cant wait to see this all painted up now :thumb:

Count Vaux Alot

08-02-11, 10:18 AM

Cheers Connor I'm getting there slowly lol

Count Vaux Alot

08-02-11, 07:56 PM

Im still undecided whether to use the vaux wheels or go for something a bit more hard core?

moffat

08-02-11, 08:09 PM

good work fella. be nice to see something different. i reckon hardcore wheels

AdamK

08-02-11, 08:10 PM

Agree with above be nice to see something different as said before good work mate keep it up

Connor

08-02-11, 08:15 PM

Go for something similar to the ones you had on the brown 'loon
think it will suit it perfectly

peester

08-02-11, 08:20 PM

euro-esque hardcore wheels or rally-slag hardcore wheels?

burgo

08-02-11, 08:23 PM

that other one looks awesome so yours will no doubt look even better

Count Vaux Alot

08-02-11, 09:14 PM

euro-esque hardcore wheels or rally-slag hardcore wheels?

Prob not too euro esque but more classic like my brown saloon - ive been looking at all sorts from 13-17 but i suspect it will be 15's or 16's that win. I would love some split rims but they are ££££ which puts me off a little.

Cheers Burgo i hope it will turn out nice.

Southie

08-02-11, 09:51 PM

Nice that this is still on going but feel your only at 50% effort, you need warmer conditions lol

Keep going James, god you welding skills are good so hope this all works out. :)

Count Vaux Alot

08-02-11, 09:58 PM

50% effort! lol what do i need to do to gain another 50%?

scott.parker

08-02-11, 10:07 PM

Well i must admit i expected to see about 12 pics!

lol funny how we don't care unless there is pics, its all about visuals on here..

Scott

Count Vaux Alot

08-02-11, 10:10 PM

Well i must admit i expected to see about 12 pics!

lol funny how we don't care unless there is pics, its all about visuals on here..

Scott

Theres like 30 pics a page back lol

Southie

08-02-11, 10:25 PM

50% effort! lol what do i need to do to gain another 50%?
Your a visual man so I'd prefer less typing and more photos, your actions in your cause do speak louder than word (well type) ;)
Scott I'll share the wavelength love lol

Count Vaux Alot

08-02-11, 10:50 PM

Well I will try my best with the pics tomorrow when I get back to work on the beige one.

The Simps

08-02-11, 11:01 PM

slacker

L14MNP

08-02-11, 11:07 PM

I guessed the right Count lol. The one you now have an avatar of!

Interesting craic with the arches. I look forward to seeing you make it look a piece of p!ss to fit. lol I am a square arch fan too, it's a unique feature that sets Nova's apart from all of the Fiestas/Polos etc etc. Not that hatches with round arches don't look good mind - I guess I just love all Nova's? lol lol

frills

08-02-11, 11:10 PM

i get the impression theres a fair amount of pressure on you,and expectations are high.im sure warmer days will inspire a fair amount of us keep up the good work:cool:

Southie

08-02-11, 11:45 PM

i get the impression theres a fair amount of pressure on you,and expectations are high.im sure warmer days will inspire a fair amount of us keep up the good work:cool:
Frills = Bolllocks you've read something that means feck all lol

Count Vaux Alot

09-02-11, 08:38 AM

Frills you learn to ignor the gibes from this bunch or raging homo's esp simps. lol

Edd

09-02-11, 11:00 AM

Benn

09-02-11, 07:27 PM

Ah ha now i remember the round arch going in that other Nova.

I was wondering if you'd go along the swadge line (where the sticker is)

I wish i could have mine like this... I'd be able to do it all in a night.

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige480.jpg

ben doodar

09-02-11, 07:54 PM

Yh it would certainly make life easier benn. Think I'm going to make something similar. I think the saloon arches will look cool.

Good work mate.

Benn

09-02-11, 10:07 PM

James,

Cage? http://www.pngclub.com/forum/showthread.php?t=164173

Count Vaux Alot

09-02-11, 10:54 PM

looks like you got a good plan for fitting the quarters

still not sure on the arches tho lol sorry, the thing i think will look a little out of place is where the saloon arch meets the sill it tapers in abit, maybe flare it out a little ? just a idea and opinion, ignore it if you like lol

Every ones entitled to an opinion Edd good or bad - i will see what the arches need when they are on the car.

Ah ha now i remember the round arch going in that other Nova.

I was wondering if you'd go along the swadge line (where the sticker is)

I wish i could have mine like this... I'd be able to do it all in a night.

Yer mate its so so much easier to have the car on its side. I will fit the 1/4 along the window seam from the b pillar for as far as i can and then drop to the swadge line and along and down to keep the hatch rear lights.

Yh it would certainly make life easier benn. Think I'm going to make something similar. I think the saloon arches will look cool.

Good work mate.

Cheers mate :thumb:

James,

Cage? http://www.pngclub.com/forum/showthread.php?t=164173

I've got one dude just forgot to mention it as its currently in storage. Its a saftey devices full 6point for a car with a dash - its spanishes old one iirc was part of the deal on my mk1 astra estate with Nath.

Count Vaux Alot

09-02-11, 10:56 PM

Cracked on tonight

Got the car back on the floor

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige492.jpg

Then set to work on the battery tray again to finish it off

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige493.jpg

Mmmm some new toys!

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige494.jpg

Started with this

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige495.jpg

Then laid some welds down

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige496.jpg

Most of the welding complete - its a pain the ar$e to weld as the material is quite thin but got there in the end.

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige497.jpg

Then put some puddles in

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige498.jpg

And began the clean up

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige500.jpg

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige501.jpg

Then gave it some acid etch primer to protect it a little

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige502.jpg

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige503.jpg

Looks ok IMO

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige504.jpg

Ok on the underside too

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige505.jpg

More next time :thumb:

novacabrio

09-02-11, 11:01 PM

that it? more pictures next time or STFU

MK999

09-02-11, 11:03 PM

Oh, a variety of hammers! Which one's best for phillips head screws? :)

Count Vaux Alot

09-02-11, 11:06 PM

that it? more pictures next time or STFU

:wisewood:

:roll: lol

Benn

09-02-11, 11:25 PM

Good work on the cage and ooo same tapping hammer set i have..

nova_niek

10-02-11, 08:46 PM

Mmmm some new toys!

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige494.jpg

Mmmm lovely new tools get me all wound up and stuff. Yum yum :thumb::thumb::thumb:

biggerderek7

10-02-11, 08:57 PM

nice

AlexW

10-02-11, 09:03 PM

I presume you have noticed the cut on the up-right bit? lol Get it welded up before it leaks lol.

Count Vaux Alot

10-02-11, 10:56 PM

Evening all didn't get a great deal done tonight, the activities began with these

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige506.jpg

I removed the tie bars and bolted them to the front panel, then welded some supports in to keep them in position.
I have a new slam panel and front panel skin on order as they have rusted out.I plan on making the most of the lower panel out of box section to make it easier to fab up rad and inter cooler mounts exactly were i want them.

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige507.jpg

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige508.jpg

A couple of cross braces were also added to keep everything square

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige509.jpg

Leaving me with this

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige510.jpg

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige511.jpg

Once i was happy with the bracing i moved on to another game of hunt the spot weld. JOY!

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige512.jpg

zip

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige513.jpg

Then out with this lot, i have new coming

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige514.jpg

Leaving this

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige515.jpg

More rust and more spot welds

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige516.jpg

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige517.jpg

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige518.jpg

Most of the c r a p removed - N/S doesnt look too bad

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige519.jpg

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige521.jpg

Count Vaux Alot

10-02-11, 10:56 PM

O/S is worse but not the end of the world.

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige520.jpg

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige522.jpg

Hopefully should get a good run at it over the weekend :thumb:

Count Vaux Alot

10-02-11, 10:58 PM

I presume you have noticed the cut on the up-right bit? lol Get it welded up before it leaks lol.

Yes you were correct in your presumption, the whole area isn't finished yet. ;)

Southie

10-02-11, 11:42 PM

More goodness with the battery tray, looks very well.
How much time did you spend on that then?

Pictures, I like ;)

Mboasty

11-02-11, 01:00 AM

subscribed:) , from what ive looked through so far, this looks right up my street, im gonna read through the rest asap

Mboasty

11-02-11, 01:00 AM

subscribed:) , from what ive looked through so far, this looks right up my street, im gonna read through the rest asap

Connor

11-02-11, 02:55 AM

Awesome work as per Mr Count ;)

The Simps

11-02-11, 12:39 PM

I really dont know where you find the time to work on the car nearly every day mate. Its hard enough just finding time in a weekend! Now, crack on...

Benn

11-02-11, 01:13 PM

I really dont know where you find the time to work on the car nearly every day mate. Its hard enough just finding time in a weekend! Now, crack on...
Depends what you do with your free time really...

The Simps

11-02-11, 04:07 PM

Free time? Whats that??!

Count Vaux Alot

11-02-11, 04:42 PM

Free time? Whats that??!

He's talking about the time you would usually spend waking yourself off that's considered as 'free time' to most of us. lol

The Simps

11-02-11, 04:52 PM

That reminds me I need to order some more lube!

mk1nova_rich

11-02-11, 08:21 PM

coming along nicely :)

Count Vaux Alot

11-02-11, 11:15 PM

No real progress on the car tonight as i've been on a parts collection mission but i did find some time today after work to do a little.

I put the lump of saloon wing mounting panel i borrowed in the paint stripper over night to see if it was savable - here it is after a degrease and a hot wash.

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige523.jpg

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige524.jpg

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige525.jpg

At this point i thought ffs thats too crispy but i carried on regardless. At least the spot welds are easy to see when they arnt covered in paint and underseal.

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige526.jpg

zip

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige527.jpg

And in to bits - the section on the left i wish to save.

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige529.jpg

Fortunately its the better bit - ish

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige530.jpg

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige531.jpg

Now to the hand shot blaster - coarse stainless shot first then fine glass to finish

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige532.jpg

Count Vaux Alot

11-02-11, 11:15 PM

After the first going over with the stainless shot

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige534.jpg

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige535.jpg

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige536.jpg

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige537.jpg

then after the fine glass shot

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige538.jpg

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige540.jpg

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige541.jpg

And a quick acid etch prime to finish it off

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige542.jpg

Im unsure as to whether i will use it yet as you can get new but we will see.

The Simps

12-02-11, 12:00 AM

Its nice to have options!

Benn

12-02-11, 08:11 AM

Is yours really that rotten too need that bit? Thought it was the headlamp panel where yours had rotted..

Count Vaux Alot

12-02-11, 10:15 AM

Benn.....

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige517.jpg

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige520.jpg

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige522.jpg

The Simps

12-02-11, 01:24 PM

Just an idea - can you not remove the inner wing piece in full just running the slam/headlamp surround like corsas do? Can then maybe make a corsa wing liner fit? Would be lighter too!

Benn

12-02-11, 01:41 PM

Or knock up a bit of metal to go in there, shape isn't too hard. The wing bit is tiny and the headlamp bit is only a straight shaped bit.. Or buy a headlamp panel (you can buy them in ones.

Edd

12-02-11, 01:48 PM

Carry on with repairing the original one IMO and fit a new slam/front panel

No doubt you will do a top job on it

The Simps

14-02-11, 12:12 AM

Boooo! No sunday nite update :(

MK999

14-02-11, 12:15 AM

Boooo! No sunday nite update :(

Want me to go on yours see when the last progress update was? lol

Edd

14-02-11, 12:22 AM

I was looking forward to a update as well :(

Count Vaux Alot

14-02-11, 12:51 AM

By the time I got in and made dinner ( the missis was on lates) there wasn't enough time and I couldn't be ars ed there's a good 130 pics to come lol

Watched a film instead. It was good!

Edd

14-02-11, 01:02 AM

Get them uploaded NOW ! !!!! ! lol

Count Vaux Alot

14-02-11, 11:11 PM

Right gayers here you got - hope you have a spare 10mins you wanted pics lol

Ok started here with Friday nights winnings

New panels

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige606.jpg

And 16x6 steels in 4stud figment from a corsa D @ £12 each thanks very much! There are some on a v dub forum atm that the guy wants £480!! given thats with tyres but still :eek: im sure i will find a use for them.

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige607.jpg

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige608.jpg

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige609.jpg

on sat - front of the car up in the air

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige543.jpg

Roll over frame off

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige544.jpg

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige545.jpg

With that out the way i set at the front panel

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige546.jpg

Plasma cutter makes light work or awkward cuts

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige547.jpg

What could your nova be hiding from you?

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige548.jpg

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige549.jpg

So now im left with this

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige550.jpg

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige551.jpg

Count Vaux Alot

14-02-11, 11:13 PM

Started tidying the area removing more spot welds

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige553.jpg

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige554.jpg

Then decided my first support was in the way so added another one so i could take the first out

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige555.jpg

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige556.jpg

Much better

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige557.jpg

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige558.jpg

Another quick sand off

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige559.jpg

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige560.jpg

Started to remove these spot welds as i was going to reuse/save the area below the main chassis leg before i decided to cut it all off

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige561.jpg

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige563.jpg

And the other side

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige564.jpg

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige565.jpg

This leads me on to the new cross member

Im going to use some 50x50 box combined with these to replicate the same shape as the original cross member for clearance in front of were the turbo will hang.

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige566.jpg

They will go here

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige567.jpg

behind the 50x50 box

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige569.jpg

Count Vaux Alot

14-02-11, 11:14 PM

The only problem was they were 75mm tall and i needed them to be 50mm tall to match the box so

Plasma out again

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige571.jpg

Nice neat cut and so much less faf and mess that grinding

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige572.jpg

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige573.jpg

Chamfered the edges ready for some penetration

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige575.jpg

clamped

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige576.jpg

Tacked

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige577.jpg

And on to the next before the weld

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige578.jpg

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige579.jpg

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige580.jpg

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige581.jpg

Cleaned and chamfered this side too

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige583.jpg

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige584.jpg

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige585.jpg

Tacked

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige586.jpg

Count Vaux Alot

14-02-11, 11:14 PM

Welded

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige588.jpg

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige589.jpg

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige590.jpg

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige591.jpg

Took most of the weld back with a grinding disc

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige593.jpg

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige594.jpg

Like this

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige595.jpg

Then fully cleaned with a sanding disc

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige596.jpg

Hard to tell its been welded

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige597.jpg

And a quick prime

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige599.jpg

So they go here like so

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige600.jpg

Count Vaux Alot

14-02-11, 11:21 PM

Then the ends will be chopper at an angle were the line is

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige601.jpg

To replicate this shape

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige602.jpg

Finally the remains of Saturday

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige605.jpg

More to follow but i uploaded sundays pics in jumbo size like a :tard:

Count Vaux Alot

15-02-11, 12:11 AM

This leads me to sunday

Roll over frame brackets off and out of the way

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige614.jpg

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige613.jpg

Removed what was left of the original front panel skin

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige615.jpg

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige616.jpg

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige617.jpg

Moving to the bay its a self for a clean and de clutter

Filthy

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige618.jpg

Had these brackets off as they looked untidy and arn't needed any more

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige619.jpg

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige620.jpg

A good wipe down with thinners - much better

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige621.jpg

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige622.jpg

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige623.jpg

Nitro mors paint stripper out - best way to shift paint imo

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige624.jpg

Applied to all the seams to be stitch welded

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige625.jpg

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige626.jpg

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige627.jpg

Count Vaux Alot

15-02-11, 12:14 AM

While that was maturing i set my focus on removing the last of the original headlight surrounds

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige628.jpg

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige629.jpg

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige630.jpg

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige631.jpg

A quick brush off with a hand wire brush then a blow off with an airline left me with this

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige632.jpg

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige633.jpg

A few bits of crisp and rust along the seams but nothing too serious

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige634.jpg

Then to the wire wheel on the grinder to get right in there

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige635.jpg

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige636.jpg

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige637.jpg

Once i was happy with the seams in the bay there i moved back down here

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige638.jpg

To cut this area off the bottom

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige639.jpg

plasma chomp

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige640.jpg

Count Vaux Alot

15-02-11, 12:15 AM

And neatened it up with the grinder

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige641.jpg

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige642.jpg

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige643.jpg

Further cutting to get the exact shape with out cutting to much off

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige644.jpg

Then off with that crusty bit of metal under the leg

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige645.jpg

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige646.jpg

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige647.jpg

Cleaned up

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige648.jpg

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige650.jpg

On to some more cutting - triangle to be removed

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige651.jpg

cut cut

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige652.jpg

like magic

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige653.jpg

cleaned up

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige654.jpg

Count Vaux Alot

15-02-11, 12:16 AM

And in position to give you a clearer idea of where im going with this

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige655.jpg

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige656.jpg

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige657.jpg

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige659.jpg

time to box the ends in

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige664.jpg

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige665.jpg

Weldy

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige666.jpg

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige667.jpg

Cleaned off

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige668.jpg

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige669.jpg

Next

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige670.jpg

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige671.jpg

What a pair!

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige672.jpg

In place

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige673.jpg

Count Vaux Alot

15-02-11, 12:17 AM

The to will obviously be welded together

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige674.jpg

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige675.jpg

Happy with them for the moment i moved on to making up some strengthening plates to support the new cross member

Paper template

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige660.jpg

Transferred the measurements to 2mm plate

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige661.jpg

And cut it out with the grinder (1mm disc again)

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige662.jpg

Tried for fit

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige663.jpg

Thats it for now thank fook!

Edd

15-02-11, 12:45 AM

What a awesome update !!!

Loving this WIP :)

Southie

15-02-11, 05:36 AM

:eek: Now THATS an update, some man hours going into now but my god it's going to be worth it. Glad you got the camera out because it's making it into one hell of a project and for me who, cannot weld, and is no mechanic gets a feel of how to go about doing this sort of thing, if I had a garage.

I feel a little guilty though telling you to get plenty of pictures up now though, if you'd not taken them all it would be nearly finished lol

Out of interest were the Corsa steelies bought from Vauxhall then?

Favourite project at the moment :thumb:

The Simps

15-02-11, 10:48 AM

Looks like a good update James but a big chunk of the pictures in the middle are showing as moved or deleted :(

L14MNP

15-02-11, 10:58 AM

Count Vaux Alot

15-02-11, 10:59 AM

Looks like a good update James but a big chunk of the pictures in the middle are showing as moved or deleted :(

FFS!!!! They were fine earlier, I spent so long sorting that lot out if I could smash photobucket I would!

I will try and sort it when I get in from Wk.

Count Vaux Alot

15-02-11, 11:02 AM

Stunning stuff mate. Your fabrication leaves me awe struck every time you do something!

Pics are the same for me too. :( I was hoping it's maybe because you said you uploaded some too large, so you're just having a shuffle about?

It was Sundays set that were too large now the rest are funked it's so annoying - I can't workout what's happened as the first few are fine! :mad:

L14MNP

15-02-11, 11:04 AM

Photobucket likes to do that from time to time! I know the feeling. You upload them and all should be well, but (the big) computer says no!

Hopefully it will sort itself out.

Mieran

15-02-11, 11:13 AM

Glad I was here last night and saw all the pics, good progress.

And if I had your skills I would make a double wishbone system or similar, tie bar setup is ghey lol

davidfox280585

15-02-11, 11:17 AM

some serious fabrication skills you have james and good work
+rep for a1 work

AdamK

15-02-11, 11:32 AM

Didnt get to see some of the pictures stupid photobucket:(

as said many times before brilliant work and im glad its not another slow ass one like mine:roll: :p

have some more rep

Edit must spread the rep before i can give it to you again -_-

L14MNP

15-02-11, 11:38 AM

Glad I was here last night and saw all the pics, good progress.

I seen them last night too! :p lol

General Lee

15-02-11, 02:18 PM

It's really enjoyable to watch your update's James. In a way will be a shame when you have finished. But awsome to see at the same time. Really motivates me looking at your thread to get my own A*** in gear.

The estate is going great sorted out a few niggles on it too.

BTW it's Nath

MattBrown

15-02-11, 03:27 PM

Looks good james.

Where were the steelies from?

Breakers?

Or dealer delivery wheels?

Connor

15-02-11, 03:53 PM

Awesome update Count, shame not all the pictures are there but meh,
This car is going to be epic once its finished.
Oh and what an absolute steel on those wheels. Sorry for the lame humour there lol

Count Vaux Alot

15-02-11, 04:15 PM

Apparently the steels my only be 15's as I may have measured them wrongly but it doesn't really matter either way. £12 each for new steels is still good IMO.

MK999

15-02-11, 04:18 PM

Apparently the steels my only be 15's as I may have measured them wrongly but it doesn't really matter either way. £12 each for new steels is still good IMO.

They look a lot like these to me (which were a bargain at a pound each!):

http://cgi.ebay.co.uk/4-X-STEEL-WHEELS-6J-X-16-INCH-4-BOLT-VAUXHALL-CORSA-D-/260734556004

Plus yours measure at around 16.5 inches across the centre I'd reckon, 6-8mm for the tyre to bead onto on each side sounds about right

edit: http://www.vauxhall-accessories.com/Meriva-B-16-Steel-Wheel-Cover%20?category_id=441 seems they come on meriva's too.

Count Vaux Alot

15-02-11, 04:24 PM

So WTF are they lol I'm confused!

MK999

15-02-11, 04:25 PM

Take a set of 4 15" tyres to a tyre place and find out lol

If you walk in and they go :tard: :tard: :tard: :tard:, they're 16's :)

I'll have a tenner on 16 myself

bazil

15-02-11, 04:35 PM

corsa d steel wheel link (http://cgi.ebay.de/Stahlfelge-Opel-Corsa-D-6x16-ET40-4-Loch-Sonderpreis-/370482977663?pt=Auto_Felgen&hash=item5642819b7f)

nova_stee

15-02-11, 04:53 PM

what a amsome project your a true crafts man pal and your skills are a credit to you.

scott.parker

15-02-11, 05:22 PM

lol Gutted about the PB fail as i was just getting comfy for my pic fix!
Hope that gets sorted dude, and them wheels are a bargain mate!

Good update even with the pic fail.

Scott

mowgli

15-02-11, 05:43 PM

count, in case i got it wrong, this pic explains it.

http://t1.gstatic.com/images?q=tbn:ANd9GcSXLUscRP7yV4jO89SDNudaVGUZhXZIc pMy6D0UiCTXWvW_BPE7wA&t=1

Count Vaux Alot

15-02-11, 06:06 PM

Pics fixed i funking hope! :wall:

Benn

15-02-11, 06:21 PM

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige566.jpg

Ooooooooooooooo that looks like the kinda stuff i need to drop my tie bar mounts down... Gen me up on some off cuts dude.

Now being that you've removed bits from the chassis leg, wont the box sess your putting in be higher.. So you'll lose space where the rad will be and the tie bars will be much higher up no?

Rickyb

15-02-11, 07:54 PM

ive read every page on this i must say this is an awsome project i cant wait to see it done.

MK999

15-02-11, 07:56 PM

Is the cross member mod absolutely required when bolting a turbo to the small block, or just a good thing to do to decrease the heat soak etc?

Count Vaux Alot

15-02-11, 08:14 PM

Ooooooooooooooo that looks like the kinda stuff i need to drop my tie bar mounts down... Gen me up on some off cuts dude.

Now being that you've removed bits from the chassis leg, wont the box sess your putting in be higher.. So you'll lose space where the rad will be and the tie bars will be much higher up no?
What size off cuts do you require?

The box section is roughly the same height as the original cross member and ive fixed the tie bar drop links in position so they havent moved from standard.

The pic shows very roughly were the box section now sits

http://i248.photobucket.com/albums/gg167/Count85/Beige/boxsectioncrossmember.jpg

Count Vaux Alot

15-02-11, 08:18 PM

Is the cross member mod absolutely required when bolting a turbo to the small block, or just a good thing to do to decrease the heat soak etc?

No its not 'absolutely required' at all but as mine was rotten and i was going to replace it makes sense to replace it with something like this. The box section should hake it easier to mount the rad and inter cooler was well as adding some strength - esp compared to the original.

MK999

15-02-11, 08:19 PM

Count Vaux Alot

15-02-11, 08:33 PM

Nice one :) Just realised that sounded a bit like I was bashing the idea, which wasn't what I meant, just wondered if the positions of the turbo etc made it required! As you say it most likely adds some strength compared to the original too.

I didnt read it like you were bashing it mate, the shape is quite important though as you can see here if i had just gone straight across between the tie bar mounts it would be very close to the turbo and exhaust.

http://i248.photobucket.com/albums/gg167/Count85/Track%20day%20nova/1600turbo010.jpg

http://i248.photobucket.com/albums/gg167/Count85/Track%20day%20nova/1600turbo007.jpg

I intend to fit a ball bearing turbo and tubalar manifold in the future (assuming this all works as it should) so the more space the merrier. :d

MK999

15-02-11, 08:37 PM

yeah if you're gonna be modding it you may as well go for as much space as possible really, without sacrificing strength of course.

gazz

15-02-11, 08:52 PM

Great build going on here, CVA.
be great to see finished result..
+rep:thumb:

TonySR

15-02-11, 09:11 PM

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige608.jpg

mk1nova_rich

15-02-11, 09:12 PM

awesome work here James, I've probably said it before but I'd love the time, facilities and skills that you have. Seriously good work going on mate, keep it up :d have some rep too lol

I'll have to owe you :(

TonySR

15-02-11, 09:12 PM

/\ Where the bolt holes are, it should say 6J x 16 if there 16s?...

scott.parker

15-02-11, 09:21 PM

Ah now i see what you been upto..

Your one skilled man, wish i had somewhere to work let alone some skill like yours lol

Keep at it mate it's flying along now.

Scott

Benn

15-02-11, 09:27 PM

What size off cuts do you require?

The box section is roughly the same height as the original cross member and ive fixed the tie bar drop links in position so they havent moved from standard.

The pic shows very roughly were the box section now sits

http://i248.photobucket.com/albums/gg167/Count85/Beige/boxsectioncrossmember.jpg

150mm long x 80mm wide x 30 thick rough though... Thick ones so i can bolt thru them.. Thinking captive nut for the top(front facing hole)

And ah ok, thought it was up higher on to where the stop weld marks where...

Southie

15-02-11, 09:38 PM

James a mate of mine has just bought some of those steelies from Vauxhall for his Nova, I'll ask him what he asked for, his are 15,s btw.

Edit: His are from a 05 tigra and he got a fifth from a W reg Astra D from the scrappers ;)

novacabrio

15-02-11, 11:23 PM

If im not mistaken then they could be 16s. No Corsa came with 16 inch steels on from the factory. But I think you may find them as a spare. Is it not stamped on them?

Southie

15-02-11, 11:32 PM

I'll measure the ones my mate got to compare then, he's got 15" tyres so I'll measure the rim as you've done James ;)

The Simps

16-02-11, 09:24 AM

I'll go measure my rim too just for reference.......

Count Vaux Alot

16-02-11, 10:34 AM

I'll go measure my rim too just for reference.......

Don't loose your tape measure this time!

scott.parker

16-02-11, 06:13 PM

IIRC though all wheels "look" to be 1" bigger across the face, as the outer edge is further across then where the tyre sits, Mowgli's diagram pretty much shows this.

Scott

Mazz

16-02-11, 06:34 PM

Stunning work, some sexy welding :)

Have you considered doing this for a living?

mowgli

16-02-11, 09:22 PM

Stunning work, some sexy welding :)

Have you considered doing this for a living?

it would stop being fun..

Count Vaux Alot

16-02-11, 11:09 PM

UPDATE! only a small one though.....

Had a couple of hours on the car to night, i started by cleaning off the edges of the bits to make up the front lower cross member so i had a nice clean surface for weldage

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige676.jpg

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige677.jpg

Clamped them in place to keep everything were it should be

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige678.jpg

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige679.jpg

Applied a few tacks of weld

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige680.jpg

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige681.jpg

Giving me this

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige682.jpg

Then the first run of weld

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige684.jpg

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige685.jpg

Both sides welded

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige686.jpg

Cleaned off a bit

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige687.jpg

And ran a grinding disc through the centre of the weld on the top facing surface to V it out a little so i could run a cap weld over the to so it will smooth out flat.

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige688.jpg

Caped

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige689.jpg

V'ed the other top facing surface

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige691.jpg

And capped

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige693.jpg

Count Vaux Alot

16-02-11, 11:09 PM

Smoothed

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige695.jpg

Primed

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige696.jpg

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige697.jpg

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige698.jpg

And tried it for visualisation

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige699.jpg

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige700.jpg

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige701.jpg

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige702.jpg

I'm happy with that :d

Thats it for tonight thanks for looking.

Benn

16-02-11, 11:29 PM

Beautiful.

Southie

16-02-11, 11:33 PM

Yet more good welding, the welds are that liquidy I'm sure you the guy from Terminator 2 lol

http://www.chrisandphilpresent.co.uk/wp-content/uploads/2011/01/terminator2.jpg

The Simps

17-02-11, 12:42 AM

Great attention as always Jimmy boy! Where'd you get the idea to run the 2nd bead?

Andy

17-02-11, 12:56 AM

Its known as a Root and cap weld,used when doing thick metalwork
Top stuff mate,that is brilliant engineering work

bazil

17-02-11, 04:52 AM

Makes me want to go and play with my welder lol, very high quality work.

out of interest, what welder do you have and what gas?

( I have an old beat up sealy 180 TURBO lol and use air products cougar gas )

ben doodar

17-02-11, 02:53 PM

superb skills there mate, that new cross member looks ace. im loving how you have ground the welds down and made it look like 1 piece. im really looking forward to more updates on this, its definatly one of my favourite builds at the minute.

Adam

17-02-11, 04:26 PM

Nice work as always. Very impressive weldage!

Count Vaux Alot

17-02-11, 04:59 PM

Beautiful.

Thanks mate :d

Yet more good welding, the welds are that liquidy I'm sure you the guy from Terminator 2 lol

Thanks Southie I like that pic!

Great attention as always Jimmy boy! Where'd you get the idea to run the 2nd bead?
Indeed Andy's right its called root weld and cap weld - a technique regually used when welding thicker material and/or with larger gaps to fill.

Its known as a Root and cap weld,used when doing thick metalwork
Top stuff mate,that is brilliant engineering work
Cheers Bud

Makes me want to go and play with my welder lol, very high quality work.

out of interest, what welder do you have and what gas?

( I have an old beat up sealy 180 TURBO lol and use air products cougar gas )
I love welding and fab work - my welders a migatronic, the green one in all the pics its only a 180 amp too but its a proper job with a euro torch etc - i use this one as it runs off a 13amp plug so you can use it anywere. However i would like a more powerful one to make welding the thick stuff easier.

superb skills there mate, that new cross member looks ace. im loving how you have ground the welds down and made it look like 1 piece. im really looking forward to more updates on this, its definatly one of my favourite builds at the minute.
I'm happy with how the cross member has turned out and im looking forward to cracking on with the rest of the problem.

Nice work as always. Very impressive weldage!
Thanks Adam :thumb:

gazz

17-02-11, 05:48 PM

Top work bud..
Welding is spot on.. Gather your using argon mix?

Count Vaux Alot

17-02-11, 06:35 PM

Yes mate it's boc's Argo shield mix nothing special.

Count Vaux Alot

17-02-11, 10:28 PM

Evening all! A little more progress this evening

Started here

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige703.jpg

Ran some weld down the seam

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige704.jpg

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige705.jpg

Cleaned and blended this end off nice and smooth

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige706.jpg

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige707.jpg

A little more work (read as grindy, weldy, grindy, weldy etc) on both side to get it spot on

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige708.jpg

Began blending and smoothing every thing in to one

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige709.jpg

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige710.jpg

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige711.jpg

Then moved on to a finer sanding disc (40 grit to 60 grit)

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige712.jpg

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige713.jpg

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige714.jpg

Shot some primer on it and left it to dry off

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige715.jpg

http://i248.photobucket.com/albums/gg167/Count85/Beige/Beige716.jpg

Thats that basically sorted now next will be fitting it to the car.

MK999

17-02-11, 10:31 PM

I can see you doing filler-less bodywork repair, although flatting back metal with 1200 might be fun lol

scott.parker

17-02-11, 10:34 PM

lol love it 40-60 grit! thats well harsh in my line of work!

But i also like how similar it is to working with wood, just a bit of common sense to make it look good etc, and the main reason i love to see pics form people like you and Oli H is that i, or anyone els can learn some basic rules for basic fools!... lol

Nice update keep um coming.

Scott

Count Vaux Alot

17-02-11, 10:52 PM

It will come up much better when i give it a go over with a DA sander.

BRoadGhost

17-02-11, 10:55 PM

This is what it's all about. I can see myself doing such a conversion to mine in the not too distant...

You've crafted that baby like a fcuking sculpture ~ seems a shame to mow down children with it now

Count Vaux Alot

18-02-11, 10:43 AM

Adam

18-02-11, 12:23 PM

That crossmember is pretty impressive.
Much nicer than the usual "bar" welded between the chassis legs.

yellow_seh

20-02-11, 11:22 AM

Connor

20-02-11, 01:54 PM

That crossmember is a piece of art.
Top work, updates on this project are hard to keep up with lol :thumb:

Count Vaux Alot

20-02-11, 06:35 PM

That crossmember is a piece of art.
Top work, updates on this project are hard to keep up with lol :thumb:

Thanks! You won't struggle to keep up with the updates this weekend as there arnt any unfortunately as I've been at the DIY all weekend. :(

Stripped the tiles from the kitchen floor which was a bad enough job ( dont get me wrong i dont mind a bit of graft) until it came to removing the fecking tile adesive what a sh!t job that is. My heart goes out to any timers out there.

Sorry to disappoint for all who thought there were some pretty pics to look at.